Get Technical data -> 3 Repair notes Guide for Volkswagen Touran 4 Door Second Generation (2015-2022)

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Repair notes

⇒ “3.1 Rules for cleanliness”, page 8

⇒ “3.2 Refrigerant circuit seals”, page 8

⇒ “3.3 Refrigerant and refrigerant oil”, page 9

⇒ “3.4 Handling pressurised tanks/containers”, page 11

⇒ “3.5 Handling refrigerants”, page 12

3.1

Rules for cleanliness

Even small amounts of contamination/soiling can lead to defects.

Therefore, observe the following rules for cleanliness when work‐

ing on the air conditioning system:

♦ Seal open pipes and connections immediately with clean

plugs, for example from the engine bung set - VAS 6122- .

♦ Place removed parts on a clean surface. Cover with lint-free

cloths only.

♦ If repair work cannot be performed immediately, carefully cov‐

er or seal components.

♦ Install only clean parts; do not remove new parts from pack‐

aging until immediately before installing. Do not use parts that

have been stored outside their packaging (e.g. in tool boxes).

♦ Do not work with compressed air when the system is open.

♦ Protect disconnected electrical connections from dirt and wa‐

ter and only reconnect in dry condition.

3.2

Refrigerant circuit seals

♦ Renew seals after removal.

♦ Moisten seals with refrigerant oil before installing.

♦ Ensure proper seating of seals on the pipe or in the groove.

♦ Work in a completely clean environment. Even the smallest

contaminants, e.g. a hair, can cause leaks.

♦ Install only seals resistant to refrigerant R134a/R1234yf and

respective refrigerant oil ⇒ Electronic parts catalogue (ET‐

KA) .

The dimensions -a- and -b- depend on the fitting location of the

seal ⇒ Electronic parts catalogue (ETKA) .

Rep. gr.00 - Technical data

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

3.3

Refrigerant and refrigerant oil

⇒ “3.3.1 Important repair instructions for refrigerant and refriger‐

ant oil”, page 9

⇒ “3.3.2 Refrigerant oil”, page 9

3.3.1

Important repair instructions for refriger‐

ant and refrigerant oil

•

An air conditioner designed for R1234yf refrigerant must never

be charged with R134a refrigerant.

An air conditioner designed for R134a refrigerant must never

be charged with R1234yf refrigerant.

The refrigerant oils especially developed for refrigerant circuits

with R1234yf and R134a refrigerant may not be used in a re‐

frigerant circuit charged with a different refrigerant unless the

relevant permissions have been granted ⇒ Electronic parts

catalogue and ⇒ Heating, air conditioning system; Rep. gr.

00 ; Technical data; refrigerant oil .

•

Air conditioner service stations which come in contact with re‐

frigerant may only be used for the target refrigerant.

A label -A- is attached in the engine compartment to the lock

carrier or the plenum chamber to provide information on the

refrigerant used.

•

Different refrigerants must never be mixed.

Depending on the type and production period, it may also in‐

dicate the GWP for the refrigerant used.

•

To ensure that only R1234yf refrigerant with a certain purity

level is drawn into the air conditioner service station (R1234yf),

a gas analysis must be performed before the refrigerant circuit

is emptied

⇒ “2.3 Performing gas analysis of refrigerant”, page 134 .

Note

If, during the gas analysis, it is found that the R1234yf refrigerant

is contaminated with a different gas, it must be extracted from the

refrigerant circuit and analysed, processed or disposed of as gas

of unknown composition in accordance with the legal require‐

ments ⇒ VW / Audi ServiceNet ,

⇒ “2.3 Performing gas analysis of refrigerant”, page 134 and

⇒ “6.2.17 Returning contaminated R1234yf refrigerant for analy‐

sis, processing or disposal”, page 25 .

3.3.2

Refrigerant oil

CAUTION

Risk of chemical burns from atomised refrigerant oil. Eyes and

other parts of the body could be injured.

– Wear protective gloves.

– Wear protective goggles.

– Never inhale atomised refrigerant oil.

♦ Refrigerant oil mixes with the refrigerant (about 10 to 40%,

depending on compressor type and amount of refrigerant) and

circulates constantly in the system, lubricating the moving

parts.

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

♦ Special synthetic refrigerant machine oils such as polyalky‐

lene glycol (PAG) oil with certain additives adapted to the

refrigerant oil are used in conjunction with R1234yf air condi‐

tioning systems. This is necessary because e.g. mineral oil

does not mix with R1234yf and, should the additives be miss‐

ing, undesired reactions with the refrigerant or components of

the refrigerant circuit could occur. In addition, the components

of the R1234yf air conditioning system could be attacked if the

mixture circulated within the refrigerant circuit under pressure

and at high temperatures, or the lubricant film in the air con‐

ditioner compressor broke down. The use of non-approved

oils can lead to failure of the air conditioning system. There‐

fore, use only approved refrigerant oils ⇒ Electronic parts

catalogue .

♦ Type of oil for R1234yf refrigerant in motor vehicles: PAG oil

with specific additives adapted to R1234yf refrigerant (polyal‐

kylene glycol with certain additives).

♦ The most important properties are high solubility with refriger‐

ant, good lubricating quality, absence of acid and low water

content. For this reason, only very specific oils may be used.

List of approved refrigerant oils and capacities ⇒ Electronic

parts catalogue and ⇒ Heating, air conditioning system; Rep.

gr. 00 ; Technical data (vehicle-specific workshop manual).

♦ The PAG oils suitable for refrigerant R1234yf are heavily hy‐

groscopic and cannot always be mixed with other oils. There‐

fore, only use approved refrigerant oils.

♦ Moisture and acids promote ageing of refrigerant oil, causing

it to become dark, viscous and aggressive towards metals.

Containers for refrigerant oil should therefore be kept closed

to prevent the ingress of moisture. When containers are

opened, they should be closed again immediately.

♦ Due to its chemical properties, refrigerant oil must not be dis‐

posed of together with engine oil or gear oil. Refrigerant oil is

to be disposed of as waste oil of unknown origin (observe local

regulations) ⇒ VW / Audi ServiceNet .

♦ For refrigerant circuits with R1234yf refrigerant circuit, only

approved oils may be used for this refrigerant and the air con‐

ditioner compressor installed in the system ⇒ Electronic parts

catalogue and ⇒ Heating, air conditioning system; Rep. gr.

00 ; Technical data .

♦ Refrigerant oil that was developed for R134a refrigerant is not

suitable for refrigerant circuits with R1234yf refrigerant (as it

is missing specific additives). Therefore, ensure that the cor‐

rect type is used ⇒ Electronic parts catalogue and ⇒ Heating,

air conditioning system; Rep. gr. 00 ; Technical data; Refrig‐

erant oil .

♦ Refrigerant oil that was developed for R1234yf refrigerant

could also be suitable for use in refrigerant circuits with R134a

refrigerant. Observe notes ⇒ Electronic parts catalogue and

⇒ Heating, air conditioning system; Rep. gr. 00 ; Technical

data (vehicle-specific workshop manual).

Note

♦ The cylinder in which the refrigerant oil is supplied has a label

from which the expiry date of the refrigerant oil can be gleaned.

♦ This expiry date is not critical if the cylinder is sealed tight.

♦ Refrigerant oil from a tightly sealed cylinder can also be used

after the expiry date specified on the cylinder.

Rep. gr.00 - Technical data

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Note

♦ Do not store refrigerant oils open to the atmosphere as they

are very hygroscopic (they readily absorb water).

♦ Always keep the refrigerant oil container and the refrigerant

circuit sealed.

♦ Do not use ester oils (POE oils) as these are currently only

compatible with larger systems under different operating con‐

ditions (not suitable for motor vehicle air conditioning sys‐

tems).

3.4

Handling pressurised tanks/containers

Keep containers tightly sealed in a well ventilated, cool location.

Refrigerant is heavier than air. Should gas escape from a system,

it collects at ground level in particular.

Protect against heat and direct sunlight, do not keep in areas with

temperatures higher than 50°C.

Do not keep in or near cellars or other low lying areas.

Only keep in areas with an adequate flow of air.

Keep containers away from sources of ignition.

Smoking is forbidden in areas in which R1234yf refrigerant is

kept. Also take measures to prevent electrostatic discharge.

Secure containers to prevent them falling over.

Secure upright cylinders to stop them falling over and cylinders

lying flat to stop them rolling away.

Containers must never be thrown.

If they should fall, the containers may become severely deformed

and break open. The refrigerant evaporates immediately, liberat‐

ing considerable force. Flying fragments of cylinders can cause

severe injuries.

To protect cylinder valves, cylinders are only to be transported

with a protective cap screwed on.

Valves may break off if cylinders are not properly transported.

Do not place near radiators!

High temperatures can occur near radiators. High temperatures

are also associated with high pressures and the maximum per‐

missible tank pressure may be exceeded.

Do not heat up above 50°C

To mitigate any risk, the pressure vessel regulations stipulate that

tanks/containers must not be heated up above 50°C.

Do not expose to uncontrolled heat

Do not heat with a naked flame under any circumstances. The

local overheating that will result can change the structure of the

container's materials, thereby reducing the safe maximum pres‐

sure limit of the container. There is also a danger of the refrigerant

decomposing due to localised overheating.

Seal empty tanks/containers

Empty refrigerant tanks/containers must always be closed to pre‐

vent the ingress of moisture. Moisture causes steel tanks/con‐

tainers to rust. Rust weakens the tank/container walls. In addition,

3. Repair notes

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

rust particles which ingress into refrigeration systems from tanks/

containers cause malfunctions.

3.5

Handling refrigerants

Note

♦ Refrigerant has no perceptible odour and usually remains un‐

noticed.

♦ Refrigerant gas is heavier than air. It collects in low lying areas,

such as inspection pits, cellars and troughs or hollows, where

it displaces the ambient air along with the oxygen. Spending

time in areas starved of oxygen can be fatal.

♦ If liquid refrigerant escapes e.g. from a leak, it vaporises at an

ambient pressure of about 1 bar at approx. -29.4°C. If refrig‐

erant vaporises on the skin, the result will be frost bite or freeze

burns. Sensitive body parts, such as the cornea and mucous

membranes, are especially at risk. Larger freeze burns could

lead to loss of life.

♦ Refrigerant gas is inflammable: electrostatic discharge, sparks

from striking tools, hot surfaces and naked flames could ignite

a mixture of R1234yf refrigerant and ambient air. However,

refrigerant only burns if supported by a flame, or if it is in the

vicinity of a hot surface. It extinguishes when it is no longer

supported e.g. by a flame.

♦ Refrigerant decomposes when exposed to a flame or in con‐

tact with a hot surface. Danger of poisoning on inhaling poi‐

sonous decomposed products. A pungent odour indicates that

the products of decomposition are already present. Breathing

in these substances must be avoided in all circumstances, or

the bronchial tubes, lungs and other organs could be injured.

♦ The specific risks of refrigerant, material data etc. can be

gleaned from the safety data sheets. Safety data sheets about

refrigerant, refrigerant oil etc. can be found on the ⇒ VW

ServiceNet .

•

Do not weld, braze or soft-solder any parts of the charged air

conditioning system. This also applies to welding and solder‐

ing work on the vehicle when the danger exists that parts of

the air conditioning system may heat up. When spray painting

is carried out, temperatures of objects in the drying booth or

the preheating zone must not exceed 80°C.

Reason:

Heating causes great excess pressure to develop in the system,

which can cause the pressure release valve of the system to

open.

Remedy:

– Empty refrigerant circuit with air conditioner service station

⇒ page 129 .

Note

Do not repair damaged or leaking parts of the air conditioner by

welding or soldering. These must be renewed.

Refrigerant containers (e.g. charging cylinders of air conditioner

service station ) must never be subjected to excessive heat or

exposed to direct sunlight.

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

Reason:

Refrigerant expands as it heats up.

Remedy:

– When charging and storing compressed gas containers (re‐

turnable cylinders, recycling cylinders etc.), observe the ap‐

plicable regulations, technical rules and legislation.

– Containers must never be completely filled with liquid refrig‐

erant. Without sufficient expansion space (gas cushion), the

container will burst should the temperature rise with devastat‐

ing consequences ⇒ “6.2 Physical properties”, page 19 .

Under no circumstances may refri_lg_kerant be charged into systems

or vessels containing air.

Remedy:

– Evacuate systems and containers before charging with refrig‐

erant ⇒ page 129 .

3. Repair notes

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Technical data -> 3 Repair notes for Your Volkswagen Touran 4 Door Second Generation (2015-2022)

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