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Service

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Fox 2005 ➤ , Golf 1992 ➤ , Golf 1998 ➤ ,

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Jetta 2011 ➤ , LT 1997 ➤ ,
Lupo 1999 ➤ , Lupo 3L 1999 ➤ ,
Multivan 2004 ➤ , Multivan 2010 ➤ ,
New Beetle 1999 ➤ ,
New Beetle Cabrio 2003 ➤ ,
Passat 1994 ➤ , Passat 1997 ➤ ,
Passat 2006 ➤ , Passat 2011 ➤ ,
Passat 2015 ➤ ,
Passat (NMS - US) 2012 ➤ ,
Passat CC 2009 ➤ ,
Passat Variant 1997 ➤ ,
Passat Variant 2011 ➤ ,

Service Department. Technical Information


Service

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Air conditioning system with refrigerant R134a
Edition 10.2014

Service Department. Technical Information


Service
List of Workshop Manual Repair GroupsList of
Workshop Manual Repair GroupsList of Workshop
Manual Repair Groups

Repair Group swage


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Technical information should always be available to the foremen and mechanics,


because their careful and constant adherence to the instructions is essential to
ensure vehicle road-worthiness and safety. In addition, the normal basic safety
precautions for working on motor vehicles must, as a matter of course, be
observed.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2014 Volkswagen AG, Wolfsburg D4B8027068B


Service

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All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2014 Volkswagen AG, Wolfsburg D4B8027068B


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Basics of air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Characteristics of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ks
1.7 Refrigerant machine oil . . . s.w.a.ge.n.A.G.. .Vo. l. .w.a.g.en. A. G. d. o.e.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.8 Comfort . . . . . . . . . . d. b.y .V . . . . . . . . . . . . . . . . . . . . . . . o.t g. u.a. . . . . . . . . . . . . . . . . . . . . . . . .
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1.9 How air conditioning horisworks . . . . . . . . . . . . . . . . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . . . . . . . . 9
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1.10 General safety ss a.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . . . 10
1.11 Safety precautions for when working on vehicles with air conditioning and when handling

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refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.12 Basics for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2.1 Refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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ole,

2.2 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

spec
urposes, in part or in wh

2.3 Evacuation and charging valves for quick-release couplings of air conditioner service station

t to the co
on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Switch and sender in refrigerant circuit and related connections . . . . . . . . . . . . . . . . . . . . 27
2.5 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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2.6 Pressures and temperatures in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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2.8 Refrigerant circuit with restrictor and reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.9 Test and measurement work that can be performed using a pressure gauge . . . . . . . . . . 36

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2.10 Air conditioner service and recycling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37


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2.11 Notes to repairs on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38


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3 Statutory texts and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


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3.1 Statutes and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


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3.2 Recycling and refuse law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44


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3.3 Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them
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(retrofitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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3.4 Maintaining records on refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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46
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4.1 Important repair notes on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


4.2 Retrofitting refrigerant circuit from R12 refrigerant to R134a refrigerant . . . . . . . . . . . . . . 46
5 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Important notes for working with the air conditioner service station . . . . . . . . . . . . . . . . . . 48
5.2 Connecting air conditioner service station for measuring and checking . . . . . . . . . . . . . . 48
5.3 Draining refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . . . . . 49
5.4 Evacuating refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . . . 50
5.5 Charging refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . . . 51
5.6 Bringing air conditioning system into service after charging . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7 Charging container in air conditioner service station with refrigerant . . . . . . . . . . . . . . . . . . 53
5.8 Draining air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Detecting leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Leak detection in refrigerant circuit using compressed air or nitrogen . . . . . . . . . . . . . . . . 56
6.2 Searching for leaks in refrigerant circuits using leak detector V.A.G 1796 . . . . . . . . . . . . 58
6.3 Detecting leaks in refrigerant circuit using leak detecting system VAS 6196 or leak detecting
system VAS 6201 or a later model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Clearing refrigerant circuit of contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Blowing through refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . 65

Contents i
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

7.2 Purging (cleaning) refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . 67


8 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.2 Smells from heater and air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9 Connecting air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.1 For vehicles that have connections on both low-pressure and high-pressure sides of
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
10 Checking pressures on vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.1 Checking pressures in refrigerant circuit (using air conditioner service station) . . . . . . . . 127
10.2 Checking systems with a restrictor and collector (with internally regulated air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.3 Checking systems with an expansion valve and reservoir (with internally regulated air
conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.4 Checking systems with an expansion valve and reservoir (without regulated air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating
valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . . . . . . . . . 143
10.6 Checking systems with an expansion valve, receiver and air conditioner compressor
regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 148
10.7 With expansion valve, receiver and electrical air conditioner compressor . . . . . . . . . . . . . . 158
11 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
11.1 In the event of leaking or damaged components (apart from the air conditioner compressor,
receiver or reservoir) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
11.2 Renewing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
11.3 Renewing receiver or reservoir, and restrictor . . . . .. V. o.lk.s.w.ag. e. . . . . . . . . . . . . . . . . . . . . . . 163
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12 Testing equipment and tools . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o.e.s .no.t .g . . . . . . . . . . . . . . 165
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12.1 List of test equipment, tools and materials ise
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ii Contents
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

00 – Technical data
1 General notes on air conditioning
systems
(VRL007231; Edition 10.2014)

1.1 Introduction
This repair manual is intended to provide technicians and fitters
with the basic knowledge required for performing trained work on
these systems.

Note

♦ Successful completion of a training course such as AB160 or


ST160 Air conditioning systems including "technical informa‐
tion" is required.
♦ This repair manual is a part of the training material.

It should also be available to the responsible supervisory


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Non-authorised tools or materials (e.g. leak inhibitor additive)


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1.2 Additional information


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♦ Technical Service Handbook with measures for rectifying lat‐


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est malfunctions.
♦ Workshop manual for service work specific to model ⇒ Heat‐
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ing, air conditioning; Rep. gr. 87 .


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♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐


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♦ Self-study programme No. 208 is no longer up-to-date in some


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each time the refrigerant circuit is opened”. The following con‐


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♦ Video programs for staff training.
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♦ Catalogue of special tools / workshop testing.
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♦ Service Organisation Volume 1 Additional equipment.
♦ Workshop manual for air conditioning system with R12 refrig‐
erant (for vehicles that were manufactured up to model year
1993). This workshop manual is only available as a hard copy.

1. General notes on air conditioning systems 1


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

1.3 Basics of air conditioning


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The four known
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B - Heat dissipation

1.3.2 Heat always flows from warmer to colder


material
Every material consists of a mass of moving molecules. The fast
moving molecules of a warmer material loose part of their energy
to slower molecules possessing less heat. This slows down the
molecules of the warmer material and accelerates those with less
heat. This continues until the molecules in both materials are
moving at the same speed. They have the same temperature, and
no further exchange of heat occurs.

1.3.3 Pressure and boiling point


The boiling points given in the table below are always based on
an atmospheric pressure of 1 bar. If the pressure on a liquid is
changed, its boiling point changes also.
It is well known that, for example, the lower the pressure, the lower
the temperature at which water boils.
The vapour pressure curves for water and for refrigerant R134a
show that at constant pressure and falling temperature the vapour
becomes liquid (in the condenser), and that when pressure drops,
the refrigerant changes from liquid into the vapour state (evapo‐
rator).

2 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
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.
1.4 Vapour pressure table for refrigerant
t rig
gh ht
pyri by
Vo
o
R134a
c by lksw
cted agen
Prote AG.

The vapour pressure table for each refrigerant is published in the


literature for refrigeration engineers. This table shows the vapour
pressure exerted on the liquid column in the container for a given
temperature of the container.
Since a characteristic vapour pressure table is known for every
refrigerant, one can determine what refrigerant is present by
measuring pressure and temperature.

Note

Absolute pressure means that 0 bar corresponds to an absolute


vacuum. The normal ambient pressure (positive pressure) corre‐
sponds to 1 bar absolute pressure. On most pressure gauges, a
reading of 0 bar corresponds to an absolute pressure of one bar
(which is confirmed by the existence of a -1 bar marking beneath
the 0 scale marking).

Temperature in °C Pressure in bar (positive pres‐


sure) R134a
-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00
-5 1.43
0 1.92

1. General notes on air conditioning systems 3


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Temperature in °C Pressure in bar (positive pres‐


sure) R134a
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6.70
35 7.83 agen
AG. Volkswagen AG d
oes
lksw not
40 9.10 d by
Vo gu
ara
ise nte
45 10.54 tho r eo
au ra
50 12.11
ss c

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nl

55 13.83

pt
du

an
itte

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60 15.72
erm

ab
ility
65 17.79
ot p

wit
, is n

70 20.05

h re
hole

75 22.52

spec
es, in part or in w

80 25.21

t to the co
85 28.14
90 31.34

rrectness of i
1.5 Refrigerant R134a
l purpos

Air conditioners in vehicles use the evaporation and condensation

nform
ercia

process. The system contains a liquid with a low boiling point,


called the refrigerant.
m

at
om

io
The refrigerant used is tetrafluoroethane R134a, which boils at

n
c

in t
or

-26.5°C with vapour pressure of 1 bar.

his
ate

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1.5.1 Physical data of refrigerant R134a


p

cum
for

en
ng

t.
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Chemical formula CH2F–CF3 or CF3–CH2F t. Cop py
rig
gh
Chemical designation Tetrafluoroethane
ht
pyri by
Vo
o
by c lksw
Boiling point at 1 bar -26.5℃ Prote
cted AG.
agen

Freezing point -101.6℃


Critical temperature 100.6℃
Critical pressure 40.56 bar (technical) pressure
equates to 39.5 bar (standard)
pressure

1.5.2 Critical point


Critical point (critical temperature and critical pressure) means the
point above which there is no longer a surface of separation be‐
tween liquid and gas.
Above its critical point, a substance is always gaseous.
At temperatures below the critical point, all types of refrigerant
contained within a pressure tank exhibit a liquid phase and a gas
phase, so that there is a gas cushion above the liquid.
As long as there is gas in the pressure vessel alongside the liquid,
the pressure depends directly on the ambient temperature
⇒ page 3 .

4 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

Different types of refrigerants must not be mixed with each other.


Only refrigerants specified for the respective air conditioning sys‐
tem may be used.

1.5.3 Environmental aspects of refrigerant


AG. Volkswagen AG d
R134a Volksw
agen oes
not
y gu
db ara
♦ R134a is a fluorocarbon and contains no chlorine.
or
ise nte
h eo
ut ra
♦ R134a has a shorter atmospheric persistence
ss
a than refrigerant c
R12.

ce
le
un

pt
an
d
♦ R134a does not damage the ozone layer, the potential to re‐
itte

y li
duce the amount of ozone is zero.
rm

ab
pe

ility
ot

♦ The Global Warming Potential (GWP) of R134a lies by ap‐

wit
, is n

prox. 1430 (the GWP for carbon dioxide lies by 1).

h re
hole

spec
♦ The contribution of R134a to the greenhouse effect is less by
es, in part or in w

a factor of 10 than that of refrigerant R12.

t to the co
1.6 Characteristics of refrigerant R134a

rrectness of i
l purpos

1.6.1 Trade names and designations


Refrigerant R134a is currently available under the following trade

nform
ercia

designations:
m

a
com

ti
♦ H-FKW 134a

on in
r
te o

thi
♦ SUVA 134a

s
iva

do
r

♦ KLEA 134a
rp

cum
fo

en
ng

t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
♦ Other trade designations may be used in other countries.
cted agen
Prote AG.

♦ Among the large selection of various refrigerants, only this one


may be used for vehicles. The designations Frigen or Freon
are trade names. They apply also to refrigerants which must
not be used in vehicles.

1.6.2 Colour
Like water, the refrigerant is colourless both in the vapour state
and the liquid state. Gases are invisible. Only the boundary layer
between gas and liquid is visible. (Fluid level in indicator tube of
charging cylinder for bubbles in sight glass.) Liquid refrigerant
R134a may appear coloured (milky) in a sight glass. This cloudi‐
ness is caused by partially dissolved refrigerant oil and does not
indicate a fault.

1.6.3 Vapour pressure


In an enclosed container that is not completely full, refrigerant
evaporates as vapour at the surface in a quantity sufficient to form
an equilibrium between vapour and liquid. This equilibrium de‐
velops under pressure and is often called vapour pressure. The
vapour pressure is temperature-dependant ⇒ page 3 .

1. General notes on air conditioning systems 5


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

1.6.4 Physical properties of R134a


Because the vapour pressure curves of R134a and other refrig‐
erants are in part very similar, unique identification on the basis
of pressure alone is not possible.
The air conditioner compressor used for R134a is lubricated with
special synthetic refrigerator oils, such as PAG oils (polyalkylene
glycol oils).

1.6.5 Effects on metal


In its pure state, refrigerant R134a is chemically stable and does
not attack iron or aluminium.
However, impurities such as chlorine compounds in the refriger‐
ant do attack certain metals and plastics. This can lead to block‐
ages, leaks and deposits on the air conditioner compressor
piston.

1.6.6 Critical temperature and critical pres‐


sure
Up to a gas pressure of 39.5 bar positive pressure (corresponding
to a temperature of 101°C) the refrigerant R134a remains chem‐
ically stable; however, above this temperature the refrigerant
decomposes (see Combustibility).

1.6.7 Water content


Only very small amounts of water are soluble in liquid refrigerant.
On the other hand, refrigerant vapour and water vapour mix in
any proportion. wage
n AG. Volkswagen AG do
es ks not
Vol gu
Any water present in the refrigerant circuit will be carried d b along as
y ara
se nte
droplets. The dryer, dryer bag or dryer cartridge inththe ori receiver or eo
reservoir are capable of holding approx. 7 grams s au of water before ra
c
they are full and cannot absorb any more water. s
If there is further
ce
e
nl

water in the circuit, it will flow to the expansion valve jet or to the
pt
du

an
restrictor and becomes ice.
itte

y li
erm

The air conditioning system will stop cooling. ab


ility
ot p

wit
, is n

Water destroys the air conditioner because at high pressures and h re


temperatures it combines with other impurities to form acids.
hole

spec
es, in part or in w

1.6.8 Combustibility
t to the co

Refrigerant is non-flammable. On the contrary, it has a fire-inhib‐


iting or fire-extinguishing effect. Refrigerant decomposes when
rrectness of i

exposed to flames or incandescent surfaces. UV light can also


decompose refrigerants (UV is emitted by electric arc welding).
l purpos

Products of this decomposition are poisonous and must not be


inhaled. However, these chemicals irritate the mucous mem‐
nform
ercia

branes, giving adequate warning of their presence.


m

at

1.6.9 Charge factor


om

ion
c

in t
or

There must be space both for liquid and vapour in a container. As


his
ate

the temperature rises, the liquid expands. The space occupied by


do
priv

the vapour becomes smaller. Eventually, there will only be liquid


um
for

in the container. After that time, even a small increase in temper‐


en
ng

t.
yi
ature will result in a very large increase in pressure, since the
Co
Cop py
liquid is seeking to expand further but there is no space for it to
t. rig
gh ht
yri
do so. The resulting forces are sufficient to burst the container. p by
co Vo
lksw
To prevent containers from being overcharged, regulations gov‐
by
cted agen
Prote
erning the storage of compressed gases specify how many kilo‐
AG.

grams may be charged into a container for every litre of container


volume. This charge factor multiplied by the internal volume gives
the permissible charge quantity. The charge factor for the refrig‐
erants used in cars is 1.15 kg/l.

6 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

1.6.10 Detecting leaks


External damage can cause leaks in the refrigerant circuit. Be‐
cause a small leak will involve only small quantities of refrigerant,
leaks should be checked for using an electronic leak detector or
by introducing a leak detection additive to the refrigerant circuit.
Electronic leak detectors can detect leakage rates of less than 5
grams loss of refrigerant per year. The leak detector should be
specific to the composition of the particular refrigerant in use. For
example, a leak detector for R12 refrigerant is not appropriate for
R134a refrigerant because R134a refrigerant has no chlorine
atoms to which the lead detector responds.)

1.7 Refrigerant machine oil


Refrigerant machine oil is miscible (approx. 20%–40% depending
on the type of air conditioner compressor and the quantity of re‐
frigerant) in the refrigerant. It circulates continuously in the circuit
and lubricates the moving parts.
Special synthetic refrigerant machine oils such as polyalkylene
glycol (PAG) oil are used in conjunction with R134a air condition‐
ing systems. This is necessary because ordinary mineral oils are
immiscible in R134a. In addition the materials of the R134a air
conditioning system could be attacked if the mixture circulated
within the refrigerant circuit under pressure and at high tempera‐
tures, or the lubricant film in the air conditioner compressor broke
down. The use of unapproved oils can lead to the failure of the air
conditioning system, so only approved oils must be used.
⇒ Parts catalogue AG. Volkswagen AG d
agen oes
olksw not
y V gu
Type of oil for R134a in cars: d b PAG ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. General notes on air conditioning systems 7


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Amarok 2011aut ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010
ho e o ➤ , CC
ra 2012 ➤ , ...
Air conditioning
ss system with refrigerant R134a - Edition 10.2014 c

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

♦ Do not store refrigerant machine oils open to the atmosphere

h re
since they are very hygroscopic (they readily absorb water).
hole

spec
es, in part or in w

♦ Always keep oil containers tightly sealed.

t to the co
♦ Do not reuse used refrigerant machine oil.
♦ Disposing of used oil: Volkswagen InfoNet; Operation; Man‐

rrectness of i
uals and dealership documentation; Service handbook;
l purpos

15. Environmental Protection; Follow link “Environmental pro‐


tection in the dealership and in the workshop” in "General
notes"; 4. Waste disposal; 6. Disposal channels; g. Disposal

nf
ercia

of used oil; Refrigerant oils

orm
m

atio
♦ Used refrigerant machine oils from systems with halogenated
om

n in
hydrocarbons (at least one hydrogen atom has been replaced
or c

thi
by e.g the halogens fluorine, chlorine, bromine or iodine) must
te

sd
a

be disposed of as waste requiring particular care. It is imper‐


iv

o
r
rp

cu
missible to mix such oils with other oils or materials. Proper
o

m
f

en
storage and disposal must be performed according to guide‐
ng

t.
yi Co
lines in the country where the work is being performed. Ob‐ Cop py
serve, for example in the Federal Republic of Germany, the
t. rig
gh ht
yri by
climate protective regulation concerning chemicals; closed cop Vo
by lksw
substance cycle waste management and ensuring environ‐ cted agen
Prote AG.
mentally compatible waste disposal (in other countries other
statutes and regulations may apply)
♦ Reference sources for technical rules and safety at work / ac‐
cident prevention for the Federal Republic of Germany
♦ Sources in other countries may be obtained from the respon‐
sible authorities
♦ Ester-based oils are suitable only for larger systems (not for
air conditioning systems in cars).

1.7.1 Properties of refrigerant oils


The most important properties are high solubility in refrigerants,
good lubrication characteristics, freedom from acid and very low
water content. For this reason, only certain oils may be used. A
list of approved refrigerant oils and quantities can be found in the
vehicle-specific workshop manuals in ⇒ Rep. gr. 00 or ⇒ Rep.
gr. 87 .
The PAG oils suitable for refrigerant R134a are strongly hygro‐
scopic and are immiscible with other oils. Therefore, opened
containers should be closed again immediately to protect them
from moisture. Refrigerant oils age under the influence of mois‐
ture and acids; they become dark, viscous and aggressive to‐
wards metals.

Note

♦ For refrigerant circuits with refrigerant R134a, use only the oil
approved for the air conditioner compressor. See ⇒ Rep. gr.
00 or ⇒ Rep. gr. 87 in the repair manual for the specific ve‐
hicle.
♦ Disposing of used oil: Volkswagen InfoNet; Operation; Man‐
uals and dealership documentation; Service handbook;
15. Environmental Protection; Follow link “Environmental pro‐
tection in the dealership and in the workshop” in "General
notes"; 4. Waste disposal; 6. Disposal channels; g. Disposal
of used oil; Refrigerant oils

8 Rep. gr.00 - Technical data


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Air conditioning system with refrigerant R134a - Edition 10.2014

1.8 Comfort
A basic requirement for concentrated and safe driving is the feel‐
ing of comfort in the passenger compartment. Especially when it
is hot and humid, comfort can be attained only through the use of
air conditioning. Of course, open windows, an open sunroof or
increased air ventilation can contribute to comfort, but they all
have certain disadvantages within the vehicle interior, such as
additional noise, draughts, exhaust gases, unfiltered entry of pol‐
len (unpleasant for allergy sufferers).
A well regulated air conditioning system in conjunction with a well
thought-out heating and ventilation system can create a feeling
of well-being and comfort by regulating the interior temperature,
humidity and rate of air change, regardless of the external con‐
ditions. This must be available whether the vehicle is moving or
not.
Other important advantages of air conditioning are
♦ The cleansing of the air directed into the passenger compart‐
ment. (Dust and pollen, for example, are washed out by the
moist fins of the evaporator and carried off with the conden‐
sation water.)
♦ Temperatures in a mid-range car (for example, after a short
period of driving, ambient n temperature
AG. Volkswagen30°C
AG do in the shade and
the vehicle in direct
lks wage
sunlight). es n
Vo ot g
by ua
ed ra
thoris With air conditioning Without air condi‐
nte
eo
au system tioning system ra
c
ss
Head region 23℃ 42℃
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e
nl

pt
du

an

Chest region 24℃ 40℃


itte

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erm

ab

Footwell 30℃ 35℃


ility
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wit
, is n

1.8.1 Environmental aspects


h re
hole

spec

Since about 1992, the air conditioning systems of newly manu‐


es, in part or in w

t to the co

factured cars have been successively changed to refrigerant


R134a. This refrigerant contains no chlorine and thus does not
damage the ozone layer.
rrectness of i

Up until about 1992, air conditioning systems were charged with


refrigerant R12. Due to its chlorine atoms, this CFC has a high
l purpos

potential for destroying ozone and, in addition, a potential for in‐


creasing the greenhouse effect.
nform
ercia

There are programs for exchanging old air conditioning systems


m

at

containing the ozone-damaging refrigerant R12.


om

ion
c

in t

⇒ Repair manual for air conditioning systems with refrigerant


or

his
e

R12 . This workshop manual is only available as a hard copy.


at

do
priv

To protect the environment, no refrigerant should be released into


um
for

en
g

the atmosphere ⇒ page 39 (statutory texts and instructions).


n

t.
yi Co
Cop py
1.9 How air conditioning works
t. rig
gh ht
pyri by
Vo
co lksw
by
The temperature in the passenger compartment depends on the cted agen
Prote AG.
amount of heat radiated through the windows and conducted by
the metal parts of the body. In order to maintain comfortable tem‐
peratures for the occupants on very warm days, part of the
available heat must be pumped away.
Since heat spreads towards cooler bodies, a unit that can create
low temperatures is fitted in the vehicle interior. Refrigerant is
constantly being evaporated in it. The latent heat of evaporation
is taken from the air passing through the evaporator.
The refrigerant carries the heat with it as it is pumped away by the
air conditioner compressor. The work performed by the air con‐

1. General notes on air conditioning systems 9


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Air conditioning system with refrigerant R134a - Edition 10.2014

ditioner compressor on the refrigerant increases its heat content


and its temperature. Its temperature is now considerably higher
than that of the ambient air.
The hot refrigerant flows with its heat content to the condenser.
There the refrigerant looses its heat through the condenser to the
surrounding air due to the temperature gradient between the re‐
frigerant and the surrounding air.
Thus, the refrigerant is a means of heat transport. Because it will
be needed again, it returns to the evaporator.
All air conditioning systems basically depend on the circulation of
refrigerant. However, there are differences in the construction of
the system.

1.10 General safety


♦ In accordance with VBG 20, the Federation of Employers Li‐
ability Insurance Associations.
♦ Observe instructions specific to the workplace; ⇒ Volkswagen
ServiceNet; Handbooks; Service handbook; Environmental
protection . Refrigerant from air conditioning systems / refrig‐
erant oils - to be displayed at refrigerant designated working
area.

1.10.1 Product characteristics


Refrigerants used in car air conditioning systems belong to the
new generation of refrigerants, the chlorine-free, partially-fluori‐
dated hydrocarbons (H-CFC, R134a).
In regard to their physical behaviour, they are refrigerants which
AG. Volkswagen AG
agen does
can be liquefied under pressure. They are subject Vo lksw to Regulations not
gu
for Pressure Tanks and may be chargedeonly d by into approved and ara
nte
identified pressurised gas containers.thoris
eo
au ra
Specific conditions which apply forsssafe and proper use must be c
ce
le

maintained.
un

pt
an
d
itte

1.10.2 Handling refrigerants


y li
rm

ab
pe

ility
ot

wit
, is n

WARNING
h re
hole

spec

Danger of freezing injuries.


es, in part or in w

t to the co

The refrigerant can emerge as liquid or as vapour.


Do not open containers in which this refrigerant is present.
rrectness of i
l purpos

If refrigerant containers are opened, the contents may escape in


liquid or vapour form. The higher the pressure in the container,
nform
ercia

the more energetic the emergence will be.


m

How high the pressure is depends on two factors:


com

tion in
r

• What type of refrigerant is in the container. “This is because


te o

thi

the lower the boiling point, the higher the pressure.”


s
iva

do
r
rp

cum

• How high the temperature is. “This is because the higher the
fo

en
g

temperature, the higher the pressure.”


n

t.
yi Co
Cop py

1.10.3 Wear protective glasses


ht. rig
rig ht
py by
co Vo
by lksw
Put on protective glasses. This will prevent the refrigerant enter‐ cted agen
Prote AG.
ing the eyes, which in certain circumstances can cause severe
injury due to frostbite.

10 Rep. gr.00 - Technical data


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Air conditioning system with refrigerant R134a - Edition 10.2014

1.10.4 Wear protective gloves and apron


Refrigerants dissolve fats and oils very well. Therefore, when they
come in contact with the skin, they take away the protective layer
of fat. Skin from which the natural
agen
AG. Voloil
kswand
agenfat have
AG does
been removed
is vulnerable to coldVoand
lksw germs. not
g by ua
ed ran
1.10.5 thDo not allow liquid refrigerant to come
oris tee
or in
au
contact with the skin
ac
ss

ce
e
nl

pt
du

The refrigerant will draw its latent heat of evaporation from its

an
itte

y li
surroundings. That can be your skin. This can result in very low
erm

ab
temperatures. The result is local frostbite (boiling point of R134a

ility
ot p

is -26.5°C at normal atmospheric pressure).

wit
, is n

h re
1.10.6 Do not breath in refrigerant vapour
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
In high concentrations, emerging refrigerant vapours can mix with
the air and displace the oxygen necessary for breathing.
l purpos

1.10.7 Absolutely NO SMOKING

nform
ercia

Refrigerant can decompose in a burning cigarette. The resulting


m

at
om

i
substances are poisonous and must not be breathed in.
on
c

in t
or

1.10.8 Welding and soldering on refrigeration


his
ate

do
riv

systems
p

cum
for

en
ng

t.
yi
Before welding and brazing on vehicles (in the vicinity of the air
Co
op py
conditioning system components), extract the refrigerant and
. C rig
ht ht
rig
then purge the system by blowing through with compressed air py by
co Vo
and using nitrogen.
by lksw
cted agen
Prote AG.
The products of decomposition of refrigerants under heat are not
only poisonous but are strongly corrosive, so that pipework and
system parts could be attacked. This refers primarily to hydrogen
fluoride.

1.10.9 Pungent smell


A pungent odour indicates that the products of decomposition
mentioned above are already present. Breathing in these sub‐
stances must be avoided under all circumstances, or the bron‐
chial tubes, lungs and other organs could be injured.

1.10.10 First aid


• In the event of contact with the eyes or mucous membranes,
wash immediately with copious running water and summon an
eye specialist.
• In the event of contact with the skin, remove wetted clothing
and wash the affected skin with copious water.
• If refrigerant vapours are breathed in high concentrations, take
the patient immediately into the fresh air. Summon a doctor. If
the patient has trouble breathing, administer oxygen. If the
patient's breathing is restricted or stops, bend the head at the
neck and commence resuscitation.

1.10.11 Handling pressure tanks


• Secure vessels against falling over!
Secure standing cylinders against falling over and lying cylinders
from rolling away.

1. General notes on air conditioning systems 11


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
. Volkswage
Air conditioning system with refrigerant R134a -
w gen AG 10.2014 n AG doe
Edition
a
olks s no
yV t gu
db ara
• Do not throw pressure vessels! rise nte
tho eo
au ra
When falling, the containers may becomesseverely deformed
s so c
that they may be torn open. The refrigerant evaporates immedi‐

ce
le
un

pt
ately, releasing violent forces. Flying fragments of cylinders can

an
d
itte

y li
cause severe injuries.

erm

ab
ility
ot p
Bottle valves can brake during improper transport. To protect cyl‐

wit
is n
inder valves, bottles may be transported only with protective

h re
covers screwed on.
ole,

spec
urposes, in part or in wh
• Do not place near radiators!

t to the co
High temperatures can occur near radiators. Higher temperatures
however also mean higher pressures, which may exceed the rat‐
ed pressure of the vessel.

rrectne
1.10.12 Do not heat above 50°C

ss o
cial p

f
To prevent danger, the Regulations for Pressure Tanks provide

inform
that tanks shall not be heated to more than 50°C.
mer

atio
1.10.13 Do not apply uncontrolled heat
om

n
c

i
or

n thi
Do not heat with an open flame under any circumstance. The local
te

sd
va

overheating that will result can change the structure of the con‐
i

o
pr

c
tainer's materials, thereby reducing the safe maximum pressure

um
r
fo

en
ng

limit of the container. In addition, the danger arises that the re‐
t.
yi Co
frigerant decomposes due to localised overheating. Cop py
t. rig
gh ht
yri
1.10.14 Seal empty containers
p by
co Vo
by lksw
cted agen
Prote AG.
Empty refrigerant containers must in all cases be sealed so as to
prevent intrusion of moisture. Moisture causes steel containers to
rust. This weakens the walls of the containers. In addition, rust
particles which enter the refrigerant system from the container
cause malfunctions.

1.10.15 Safety instructions for using extraction


and charging equipment
• Before connecting the charging system to the air conditioning
system, make sure that all existing shut-off valves are closed.
• Before the charging equipment is decoupled from the air con‐
ditioning system, ensure that the process has finished. The
reason for this is to ensure that no refrigerant oil escapes into
the atmosphere.
• After the cleaned refrigerant from the charging system has
been charged into an external pressurised gas cylinder, close
the hand shut-off valves on the bottle and the charging system.
• Do not expose charging system to moisture or use it in a wet
environment.
• Before performing service work and the charging system, dis‐
connect the current supply.
• To reduce danger of fire, avoid using extension cords. If nev‐
ertheless it is necessary to use an extension cable, use an
extension cable with a cross-section of at least 2.5 mm2.
• In case of fire, remove external cylinder.
• If entrained oil from the air conditioning system suction accu‐
mulator is trapped in the measuring beaker supplied, be sure
subsequently to pour the oil into a container that can be
sealed, since the oil contains a small amount of refrigerant.
Refrigerants must not be released into the environment.
• When the air conditioner service station is switched off, it must
be secured against rolling away.

12 Rep. gr.00 - Technical data


AG. Volkswagen AG d
agen oes
olksw not
by Amarok 2011 ➤ , Beetle 2012g➤ ua , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
V
ed ran
thoris Air conditioning system
tee with refrigerant R134a - Edition 10.2014
or
au ac
ss
1.11 Safety precautions for when working on

ce
e
nl

pt
du
vehicles with air conditioning and when

an
itte

y li
erm

ab
handling refrigerant R134a

ility
ot p

wit
, is n

Air conditioning service station - VAS 6007A- (and further service

h re
stations currently available)
hole

spec
es, in part or in w

⇒ Workshop equipment

t to the co
WARNING

rrectness of i
♦ It is recommended that a bottle containing water be kept
l purpos

at hand for purging out the eyes.


♦ Should liquid refrigerant get into the eyes, thoroughly

nf
ercia

purge the eyes with water for about 15 minutes. Then ad‐

orm
minister eye drops and visit a doctor immediately even if
m

atio
m

the eyes do not hurt.


o

n in
or c

thi
♦ The doctor must be informed that the frostbite has been
te

sd
a

caused by refrigerant R134a. If, in spite of these safety


iv

o
r
rp

cu
measures, refrigerant comes into contact with other body
o

m
f

en
ng

parts, these areas must also be immediately purge with


t.
yi Co
cold water for at least 15 minutes. Cop py
t. rig
gh ht
yri
♦ Work on the air conditioning system refrigerant circuit in
p by
o Vo
by c
well ventilated rooms only. Switch on exhaust gas fume
lksw
cted agen
Prote
extractor (if there is one).
AG.

♦ Refrigerant must not be stored in low-lying rooms (e.g.


cellars) or their stairways or window shafts.

• 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. During painting op‐
erations, temperatures of objects in the drying oven or in its
pre-heating 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.
Precautions:
– Use the air conditioner service station to evacuate the refrig‐
erant circuit.

Note

Damaged or leaking components of the air conditioning system


must not be repaired by welding or soldering. They must always
be renewed.

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


service station) must never be subjected to excessive heat or ex‐
posed to direct sunlight.
Precautions:
– Never charge a container completely with liquid refrigerant.
Without sufficient expansion space (gas cushion), the con‐
tainer will burst should the temperature rise, with devastating
consequences ⇒ page 5 .

1. General notes on air conditioning systems 13


AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 d by➤ , CC 2012 ➤ , ...
V gu
ara
e nte
Air conditioning system with refrigerant R134a - Editionhoris
10.2014 eo
aut ra
ss c
Under no circumstances may refrigerant be charged into systems

ce
le
un
or vessels containing air.

pt
an
d
itte

y li
Precautions:

rm

ab
pe

ility
– Evacuate systems and containers before charging with refrig‐

ot

wit
, is n
erant.

h re
hole

spec
es, in part or in w
1.12 Basics for working on refrigerant circuit

t to the co
• Observe instructions specific to the workplace; ⇒ Volkswagen
ServiceNet; Handbooks; Service handbook; Environmental

rrectness of i
protection . Refrigerant from air conditioning systems / refrig‐
erant oils - to be displayed at refrigerant designated working

l purpos
area.
• Observe the utmost cleanliness when working.

nform
ercia
• When handling refrigerants and nitrogen, wear protective
m

a
com

t
clothing, protective glasses and protective gloves.

ion in
r
te o
• Switch on exhaust gas fume extractor (if there is one).

thi
s
iva

do
r

• Extract the refrigerant circuit using only the air conditioner


rp

cum
fo

service station, and only then loosen the threaded joints and

en
ng

t.
yi
renew the defective components.
Co
Cop py
t. rig
• Protect units and hoses against moisture and dirt using sealing
gh ht
pyri by
caps.
o Vo
by c lksw
cted agen
Prote AG.
• Use only tools and materials that are intended for use with
refrigerant R134a.
• Protect refrigerant oil by sealing container to prevent ingress
of moisture.
– Blow through refrigerant circuit with compressed air and nitro‐
gen ⇒ page 65 :
– Purge refrigerant circuit with refrigerant R134a. ⇒ page 67
In vehicles that have an air conditioner compressor without a
magnetic clutch:

14 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If the engine is being started for the first time after the refrig‐
erant circuit has been reassembled.
♦ If possible, start engine only with refrigerant circuit charged.
♦ The air conditioner compressor is driven permanently by the
poly V-belt pulley or elastic drive coupling (it is not fitted with
a magnetic clutch).
♦ If an air conditioner compressor seizes, the overload protec‐
tion separates from the air conditioner compressor shaft. Even
if no bulges are visible in the V-belt pulley or overload protec‐
tion, it may be that the air conditioner compressor has seized.
Another indication is abraded rubber material around the poly
V-belt pulley or overload protection.
n AG. Volkswagen A
♦ The air conditioner
olks
compressor has Gan
wage dointernal
es n
o
oil circuit to
ensure that bythe air conditioner compressor isgunot
V t
ara damaged
ed
when other refrigerant circuit is empty. This meansntethat
is
eo
about
40s toth 3
au 50 cm refrigerant oil remain in the air conditioner r a com‐
c
pressor.
s
ce
e
nl

pt
du

♦ The engine may be started only when the refrigerant circuit is an


itte

y li
properly assembled. If, for example, the refrigerant lines are
erm

ab
not connected to the air conditioner compressor and the en‐
ility
ot p

gine is running, the compressor may heat up so much through


wit
, is n

internal warming that it will be destroyed.


h re
hole

spec

♦ The air conditioner compressor regulating valve - N280- is not


es, in part or in w

activated when the refrigerant circuit is empty and the air con‐
t to the co

ditioner compressor idles with the engine.


♦ If it is necessary to start engine with an empty refrigerant cir‐
rrectness of i

cuit:
l purpos

♦ The refrigerant circuit must be fully assembled.


♦ At least ¼ of the quantity of refrigerant oil specified for this
nform
ercia

refrigerant circuit must be in the air conditioner compressor.


m

♦ The engine speed must not exceed 2000 rpm.


at
om

ion
c

in t

♦ The engine should run < 10 minutes.


or

his
ate

do
priv

1.12.1 O-ring
um
for

en
ng

t.
yi Co
♦ Use only O-rings that are resistant to refrigerant R134a and
Cop py
related refrigerant oils. O-rings are no longer colour-coded.
t. rig
gh ht
yri by
Coloured and black O-rings are used.
cop Vo
by lksw
cted agen
Prote
♦ Check that the O-rings used have the correct internal diame‐
AG.

ters.
⇒ Rep. gr. 87
⇒ Parts catalogue
♦ Never reuse O-rings.
♦ Before installing, moisten O-rings lightly with refrigerant oil
(PAG oil).

1. General notes on air conditioning systems 15


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ When purging components with compressed air and nitrogen,


always collect the gas mixture exiting the component with suit‐
able exhaust gas extraction equipment (workshop fume ex‐
tractor).
♦ After completing repair work, screw sealing caps (with seals)
onto valve and service connections.

Before operating the air conditioning system. Check the vehicle-


specific charge quantities ⇒ Rep. gr. 87 .
Do not top up a charged refrigerant circuit; discharge refrigerant
present and recharge system.

1.12.2 Before operating the air conditioning


system after recharging with refrigerant
– After installing a new air conditioner compressor or filling with
fresh refrigerant oil (e.g. after blowing out refrigerant circuit),
turn compressor pulley 10 revolutions by hand before starting
engine. This will prevent damagegen AG to the airnconditioner
. Volkswage AG
does com‐
swa
pressor. y Volk not
gu b ara
ed
– On 5-cyl. or 10-cyl.
ho
ris diesel engine, turn air conditioner com‐
nte
eo
aut
pressor at overload protection 10 times by hand. Then install ra
s c
compressor.s This will prevent damage to the air conditioner
ce
le

compressor.
un

pt
an
d
itte

y li

– Start the engine with the air conditioning system switched off
rm

ab

(the air conditioning system magnetic clutch - N25- and the air
pe

ility

conditioner compressor regulating valve - N280- are not acti‐


ot

wit
, is n

vated).
h re
hole

spec

– After the engine has stabilised at its idling speed, switch on


es, in part or in w

the air conditioner compressor and allow the engine to idle for
t to the co

at least 10 minutes at maximum cooling power.


rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

16 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2 General information on refrigerant


circuit

2.1 Refrigerant circuit components

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)


may cause damage or adversely influence the system.
Only tools and materials approved by the manufacturer may
be used.
Use of non-approved tools or materials will render the warranty
void.

• All components of the refrigerant circuit that were submitted


for quality monitoring must always be sealed (use the original
sealing caps from the genuine part).
• Renew damaged or leaky components of the refrigerant circuit
⇒ page 159 .
• The genuine parts (air conditioner compressor, reservoir, re‐
ceiver, evaporator and condenser) are charged with nitrogen
before shipment. This filling is being gradually discontinued.
Therefore, when the sealing plugs are unscrewed from the
genuine part little or no pressure equalisation is noticeable.

2.1.1 Distribution of the refrigerant circuit


components and their influence on the
AG. Volkswagen AG d
high-pressure
Vol
ksw
a and low-pressure
gen oes
not sides
y gu
db a
On the high-pressure ris side, there are the condenser, the receiver
e ran
tee
and the restrictorthoor expansion valve that acts as the separation or
au a
between the shigh-pressure
s fluid and low-pressure fluid sides. c
ce
e
nl

pt

High pressure is created because the restrictor or expansion


du

an
itte

valve forms a restriction and holds back the refrigerant, leading


y li
erm

ab

to increased pressure and temperature.


ility
ot p

Excessive pressure results if the circuit is filled with too much re‐
wit
, is n

h re

frigerant or refrigerant oil, or the condenser is dirty, the radiator


hole

fan is defective, there is a blockage in the system or there is


spec

moisture in the refrigerant circuit (causing the restrictor or expan‐


es, in part or in w

t to the co

sion valve to ice up).


On the low-pressure side, there are the evaporator, the reservoir,
the temperature sensor for the evaporator and the air conditioner
rrectness of i

compressor that acts as the separation between the high-pres‐


l purpos

sure and low-pressure gas sides.


A loss of pressure in the system can be due to loss of refrigerant,
nf
ercia

restrictor or expansion valve failure (not creating a restriction),


or

defective air conditioner compressor or an iced-up evaporator.


m
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. General information on refrigerant circuit 17


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC A2012 G. Vol➤
ksw,a...
gen AG
Air conditioning system with refrigerant R134a - Edition 10.2014 agen does
olksw not
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ris
2.1.2 Air conditioning system compressor with au
tho eo
ra
magnetic clutch: ss c

ce
e
nl

pt
du

an
The air conditioner compressor is driven by a V-belt from the en‐

itte

y li
gine.

erm

ab
ility
ot p
An electromagnetic clutch is fitted to the air conditioner compres‐

wit
, is n
sor. When the air conditioning system is switched on, it transmits

h re
the mechanical drive between the V-belt pulley and the air con‐

hole

spec
ditioner compressor drive shaft.

es, in part or in w

t to the co
A fusible link is incorporated in the air conditioner compressor V-
belt pulley. In the event of stiffness in the air conditioner com‐
pressor, it trips the electromagnetic clutch and protects the V-belt

rrectness of i
drive from overload.
The air conditioner compressor draws refrigerant gas from the l purpos
evaporator, compresses it and sends it to the condenser.

nf
ercia

orm
m

Note

atio
om

n in
or c

♦ The air conditioner compressor contains refrigerant oil, which

thi
te

sd
a

can be mixed with R134a refrigerant at any temperature.


iv

o
r
rp

cu
o

m
♦ The maker's nameplate states the refrigerant for which the air
f

en
ng

t.
conditioner compressor is suitable. A valve regulates the pres‐
yi Co
op py
sure on the low-pressure side within the specified range (reg‐
. C rig
ht ht
ulation characteristic).
rig by
copy Vo
by lksw
cted
♦ So that the air conditioner compressor suffers no damage
agen
Prote AG.
when the refrigerant circuit is empty, the magnetic clutch is
disconnected and the regulating valve for the air conditioner
compressor - N280- is no longer activated (the air conditioner
compressor idles with the engine).

18 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.3 Air conditioner compressor without


magnetic clutch
The air conditioner compressor is driven by a V-belt from the en‐
gine.
A shear link is incorporated in the air conditioner compressor V-
belt pulley. In the event of stiffness in the air conditioner com‐
pressor, it shears off and protects the V-belt drive from overload.
The air conditioner compressor draws refrigerant gas from the
evaporator, compresses it and sends it to the condenser.

Note

♦ The air conditioner compressor contains refrigerant oil, which


is miscible with R134a refrigerant at all temperatures.
♦ The maker's nameplate states the refrigerant for which the air
conditioner compressor is suitable. A valve regulates the pres‐
sure on the low-pressure side within the specified range (reg‐
ulation characteristic).
♦ The regulating valve for this air conditioner compressor is ex‐
ternally activated.
♦ The engine should be started only
swa
when
gen AG.the refrigerantdocircuit
Volkswagen AG
es
has been fully assembled ⇒
by
Vpage
olk 14 . not
gu
d ara
ise
♦ The air conditioner compressor
thor has an internal oil circuit to nte
eo
ensure that the air sconditioner
au compressor is not damaged ra
c
when the refrigerant circuit is empty. This means that about
s
ce
le

40 to 50 cm3 refrigerant oil remain in the air conditioner com‐


un

pt
an
d

pressor.
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. General information on refrigerant circuit 19


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.4 Air conditioner compressor without


magnetic clutch, with elastic drive cou‐
pling
The air conditioner compressor is driven directly by the power
steering vane pump.
There is an overload protection on the drive shaft of the air con‐
ditioner compressor, which shears in the event of the air condi‐
tioner compressor seizing, thus permitting the power steering
vane pump to remain operational.
The air conditioner compressor draws
wage
n AG. refrigerant
Volkswagen Agas
G do from the
es n
evaporator, compresses yitVand
olks sends it to the condenser. ot g
u b ara
ed nte
oris e
th or
Note au ac
ss

ce
e
nl

pt
du

♦ The air conditioner compressor contains refrigerant oil, which

an
itte

y li
is miscible with R134a refrigerant at all temperatures.
erm

ab
ility
ot p

♦ The maker's nameplate states the refrigerant for which the air

wit
, is n

conditioner compressor is suitable. A valve regulates the pres‐

h re
sure on the low-pressure side within the specified range (reg‐
hole

spec
ulation characteristic).
es, in part or in w

t to the co
♦ The regulating valve for this air conditioner compressor is ex‐
ternally activated.
♦ The engine should be started only when the refrigerant circuit
has been fully assembled ⇒ page 14 . rrectness of i
l purpos

♦ The air conditioner compressor has an internal oil circuit to


ensure that the air conditioner compressor is not damaged
nf
ercia

when the refrigerant circuit is empty. This means that about


or

40 to 50 cm3 refrigerant oil remain in the air conditioner com‐


m
m

atio
m

pressor.
o

n in
or c

thi
te

sd
iva

2.1.5 Electrical air conditioner compressor for


o
r
rp

cu
o

m
f

high-voltage system
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
WARNING op Vo
by c lksw
cted agen
Prote AG.
♦ High voltage on high-voltage system of hybrid vehicle!
Health risks for persons wearing medical devices!
♦ Following procedure also requires work on high-voltage
system. All work on vehicles with a high-voltage system
may only be done by trained electricians. Work must be
advised by a high-voltage technician.
♦ Observe the general warning instructions for work on the
high-voltage system ⇒ Electric drive, Repair group 93;
General warning instructions for work on the high-voltage
system.
♦ Now, ensure there is no voltage in high-voltage system ⇒
Electric drive, Repair group 93; Ensuring there is no volt‐
age in high-voltage system.

20 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

WARNING

The electrical air conditioner compressor requires a different


refrigerant oil!
For capacities, see workshop manual for specific vehicle.

Electrical air conditioner compressor

WARNING

Danger of short circuit


The air conditioner compressor operates with 288 volts and at
a speed range of 800 to 8,600 rpm.
Do not touch air conditioner compressor when drive units are
starting. Danger of short circuit!

The air conditioner compressor draws refrigerant gas from the


evaporator, compresses it and sends it to the condenser.

Note

♦ The air conditioner compressorencontains


AG. Volkswrefrigerant
agen AG oil, which
is miscible with R134a Vrefrigerant
olks
wag at all temperatures.
does
not
by gu
a
♦ The maker's nameplate
or
ise
d
states the refrigerant for which theraair
nte
conditioner compressor
au
th is suitable. The flow rate is controllede or a
via the engine
s speed.
s c
ce
e
nl

pt

♦ The engine should be started only when the refrigerant circuit


du

an
itte

has been fully assembled ⇒ page 14 .


y li
erm

ab
ility

♦ The air conditioner compressor has an internal oil circuit to


ot p

ensure that the air conditioner compressor is not damaged


wit
, is n

h re

when the refrigerant circuit is empty. This means that about


hole

40 to 50 cm3 refrigerant oil remain in the air conditioner com‐


spec
es, in part or in w

pressor.
t to the co

♦ The air conditioner has a pressure relief valve.


rrectness of i

2.1.6 Condenser
l purpos

The condenser transfers heat from the compressed refrigerant


nform

gas to the surrounding air.


mercia

This allows the refrigerant gas to condense into liquid form.


at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. General information on refrigerant circuit 21


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.7 Evaporator
The liquid refrigerant evaporates in the tubes of the evaporator.
The latent heat of evaporation is taken from the air streaming past
the evaporator fins. The air cools. The refrigerant evaporates and
is drawn into the air conditioning system compressor carrying with
it the heat it has absorbed.
A restrictor or an expansion valve allows a defined quantity of
refrigerant to flow to the evaporator. In systems with an expansion
valve, the flow is regulated such that only gaseous refrigerant ex‐
its the evaporator.

2.1.8 Reservoir
The reservoir collects the vaporised and gaseous mixture coming
from the evaporator to ensure the air conditioner
AG. Volkswacompressor
gen A re‐
agen
ceives only gaseous refrigerant.olGaseous refrigerant isG formed
does
ksw not
from the vapour. db
yV gu
ar
e an
ris tee
Refrigerant oil flowing uinthothe circuit does not remain in the reser‐ or
voir, as an oil extraction
ss
a
hole has been provided. ac

ce
e
nl

Moisture which has entered the refrigerant circuit during repairs


pt
du

will be collected by a filter (dryer bag) in the reservoir. an


itte

y li
erm

Gaseous refrigerant with oil is drawn in by the air conditioner ab


ility
ot p

compressor. wit
, is n

h re
hole

spec

Note
es, in part or in w

t to the co

♦ Renew the reservoir if the refrigerant circuit has stood open


for any length of time (more than the normal repair time) and
rrectness of i

moisture has entered the system, or if it is required because


of a specific complaint ⇒ page 159 .
l purpos

♦ Do not remove sealing plugs -A- and -B- until just before in‐
stallation.
nf
ercia

orm

♦ The dryer bag in an unsealed reservoir will become saturated


m

atio
m

with moisture within a short time and is then unusable.


o

n in
or c

♦ When installing, observe arrow indicating direction of flow, if


thi
te

sd
a

applicable.
iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

22 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.9 Restrictor
The restrictor creates a restriction. This restriction limits the flow,
separating the high-pressure and low-pressure sides in the re‐
frigerant circuit. Upstream of the restrictor, the refrigerant is warm
due to the high pressure. Downstream of the restrictor, the refrig‐
erant is cold due to the low pressure. Upstream of the narrow point
is a strainer to catch dirt and downstream of the narrow point is a
strainer to atomise the refrigerant before it enters the evaporator.

Note

♦ Arrow -A- on the restrictor points to the evaporator.


♦ Renew it every time the refrigerant circuit is opened.
♦ Observe different versions.

⇒ Rep. gr. 87 agen


AG. Volkswagen AG d
oes
olksw not
V gu
⇒ Parts catalogue d by ara
rise nte
tho eo
u ra
2.1.10 Receiver s a c
s

ce
le
un

pt
The receiver collects the liquid droplets and directs them in a

an
d
itte

y li
continuous stream to the expansion valve. Moisture which has
rm

ab
entered the refrigerant circuit during assembly is collected by the
pe

ility
dryer bag in the receiver.
ot

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
♦ Renew the receiver if the refrigerant circuit has stood open for
any length of time (more than the normal repair time) and

rrectness of i
moisture has entered the system, or if it is required because
of a specific complaint ⇒ page 159 .
l purpos

♦ Do not remove sealing plugs until just before installation.

nform
ercia

♦ The dryer bag in an unsealed receiver will become saturated


with moisture within a short time and is then unusable.
m

a
com

tio
♦ When installing, observe arrow indicating direction of flow, if

n in
r

applicable.
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi
The new generation of receivers are mounted directly on the con‐
Co
Cop py
denser and contain a dryer cartridge.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

♦ Renew the dryer cartridge if the refrigerant circuit has stood


open for any length of time (more than the normal repair time)
and moisture has entered the system, or if it is required be‐
cause of a specific complaint ⇒ page 159 .
♦ Remove the dryer cartridge from its packaging only immedi‐
ately before installing it.
♦ A dryer cartridge in unsealed packaging will become saturated
with moisture within a short time and is then unusable.

2. General information on refrigerant circuit 23


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.11 Expansion valve


The expansion valve atomises incoming refrigerant and regulates
the flow so that, depending on the heat transport, the vapour does
not become a gas until it reaches the outlet of the evaporator.

2.1.12 O-ring
These O-rings seal the joints between the individual components
of the refrigerant circuit.
Use only seals that are resistant to refrigerant R134a and its as‐
sociated refrigerant oils. This is assured by using genuine re‐
placement parts.
⇒ Parts catalogue
O-ring:
• Never reuse seals!
• Check that diameters -a- and -b- are correct.
• Before fitting a seal, coat it lightly with refrigerant oil.
n AG. Volkswagen AG do
swage es n
Note byV
olk ot g
ua
d ran
ir se tee
o
The colour coding of O-rings for R134aau refrigerant circuits has
th or
ac
been discontinued. Coloured and black O-rings are used. ss
ce
e
nl

pt
du

an

⇒ Rep. gr. 87
itte

y li
erm

ab

⇒ Parts catalogue
ility
ot p

wit
, is n

h re

2.1.13 Pipes and hoses in refrigerant circuit


hole

spec
es, in part or in w

The mixture of refrigerant oil and refrigerant R134a attacks certain


t to the co

metals (e.g. copper) and alloys and dissolves certain hose mate‐
rials. Therefore, always use genuine replacement parts.
rrectness of i

The hoses and pipes are held together with screwed joints or
special push-fit joints.
l purpos

nform
ercia

Note
m

at
om

When assembling screwed joints, be careful to comply with the


ion
c

prescribed torques, and when working on push-fit joints, be care‐


in t
or

ful to use the disconnection tools provided.


his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

24 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.14 High-pressure safety valve


The high-pressure safety valve is fitted to the air conditioner com‐
pressor or the receiver.
The valve opens at a pressure above approx. 38 bar and closes
again when the pressure has dropped (approx. 30 bar).
Not all the refrigerant is lost from the system.
Depending on the version, a transparent plastic disc may be fitted,
which breaks when the valve opens.

2.2 Design of refrigerant circuit agen


AG. Volkswagen AG d
oes
olksw not
V gu
by
2.2.1 Refrigerant circuit with expansion valve orised ara
nte
eo
and evaporator
h
aut ra
ss c

ce
e

1- Evaporator
nl

pt
du

an
itte

y li
2- Expansion valve
erm

ab
ility
ot p

3- Valve for extracting, charging and measuring

wit
, is n

h re
4- Receiver with dryer bag or dryer cartridge
hole

spec
5- Condenser
es, in part or in w

t to the co
6- Air conditioner compressor

rrectness of i
Note
l purpos

Arrows show the direction of refrigerant flow.

nform
mercia

2.2.2 Refrigerant circuit with restrictor and

at
om

ion
reservoir
c

in t
or

his
ate

do

1- Air conditioner compressor


priv

cum
for

2- Condenser
en
ng

t.
yi Co
op
3- Restrictor
C py
t. rig
gh ht
yri by
4- Evaporator
op Vo
by c lksw
cted agen
Prote AG.
5- Reservoir with dryer cartridge

Note

Arrows show the direction of refrigerant flow.

2.3 Evacuation and charging valves for


quick-release couplings of air condition‐
er service station on refrigerant circuit
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783- (2…10 Nm) with 1/4" ratchet
adapter - VAS 6234-

2. General information on refrigerant circuit 25


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

WARNING

Danger of freezing injuries. n AG. Volkswagen AG do


lkswage es n
If refrigerant circuit has not been evacuated, refrigerant will d by Vo ot g
ua
escape. o
ir se
ran
tee
th or
u
Extract refrigerant before opening refrigerant circuit. If sthe
s a re‐ ac
frigerant circuit is not opened within 10 minutes after it has

ce
le
un
been evacuated, pressure may develop in coolant circuit due

pt
an
d
itte
to re-evaporation. Extract refrigerant again.

y li
erm

ab
ility
ot p

wit
is n
• Only valves and connections resistant to R134a refrigerant

h re
ole,
and the related refrigerant oils may be used.

spec
urposes, in part or in wh
• The connectors for the high-pressure and low-pressure sides

t to the co
are different (outside diameter).
• Always screw on sealing caps.

rrectne
Arrangement within the vehicle.

s
See vehicle-specific repair manual ⇒ Rep. gr. 87

s o
cial p

f i
2.3.1 Evacuation and charging valve with

nform
mer

Schrader valve

atio
om

n
c

i
or

n thi
te

sd
Note
iva

o
pr

cum
r
fo

♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS

en
ng

t.
yi Co
6234- t. Cop py
rig
gh ht
♦ Appropriate insert - T10364- to remove Schrader valve core pyri by
Vo
co
⇒ page 172
by lksw
cted agen
Prote AG.

A - Service port (soldered in)


B - Valve core (2.4 ± 0.2 Nm)
C - O-ring (for the valve)
D - Sealing cap with seal

2.3.2 Extraction and charging valve, high-


pressure side

Note

♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS


6234-
♦ Appropriate insert - T10364- to remove valve core
⇒ page 172

1- Base with external or internal thread


2- O-ring: 10.8 mm; 1.8 mm identification: black or coloured
3- Valve with M12 x 1.5 mm external thread and groove for O-
ring (7 ± 1 Nm)
4- O-ring for cap, 10.8 mm; 1.8 mm identification: black or col‐
oured
5- Cap

26 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.3.3 Extraction and charging valve, low-pres‐


sure side

Note

♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS


6234-
♦ Appropriate insert - T10364- to remove valve core
⇒ page 172

1- Connection with external thread and groove for O-ring


2- O-ring: 7.6 mm; 1.8 mm identification: black or coloured
3- Valve with M10 x 1.25 mm external thread and groove for
O-ring (7 ± 1 Nm)
4- O-ring for cap, 7.6 mm; 1.8 mm identification: black or col‐
oured
5- Cap

2.4 Switch and sender in refrigerant circuit


and related connections

Note

See vehicle-specific refrigerant circuit for switching pressures, . Volkswag


removing and fitting switches, together with switch arrangement
ksw
agen
AG en AG
does
and versions. by Vol not
gu
a
ed ran
oris tee
h
⇒ Rep. gr. 87 au
t or
ac
ss
2.4.1 High-pressure switch for air conditioning
ce
le
un

pt
an
d

system - F23-
itte

y li
erm

ab
ility
ot p

Function:
wit
is n

Switches radiator fan to next higher speed when pressure increa‐ h re


ole,

ses in refrigerant circuit (approx. 16 bar).


spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. General information on refrigerant circuit 27


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.4.2 High-pressure switch for magnetic


clutch - F118-
Function:
In the event of excess pressure in the refrigerant circuit, switches
the air conditioner compressor off (at approx. 32 bar).

2.4.3 Low-pressure switch for air conditioning


system - F73-
Function:
In the event of pressure loss in the refrigerant circuit, switches the
air conditioner compressor off (at approx. 2 bar).

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

2.4.4 Connections to valves for switches in

pt
du

an
itte

y li
the refrigerant circuit
erm

ab
ility
ot p

wit
, is n

WARNING

h re
hole

spec
Danger of freezing injuries.
es, in part or in w

If refrigerant circuit has not been evacuated, refrigerant will t to the co


escape. rrectness of i

The refrigerant must be extracted before the valve -C- is re‐


moved. If the refrigerant circuit is not opened within 10 minutes
l purpos

after it has been evacuated, pressure may develop in coolant


circuit due to re-evaporation. Extract refrigerant again.
nform
mercia

at
om

• The switches on the high-pressure and low-pressure sides


ion
c

have different threads.


in t
or

his
ate

• Use only valves and O-rings that are resistant to refrigerant


do
priv

R134a and its associated refrigerant oils.


um
for

en
ng

t.
yi
A - Connection (soldered in)
Co
Cop py
t. rig
B - O-ring
gh ht
pyri by
Vo
co lksw
by
C - Valve (with O-ring) cted agen
Prote AG.

28 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.4.5 Air conditioning system pressure switch


- F129-
This pressure switch has 3 functions:
1. Switches radiator fan to next higher speed when pressure in‐
creases in refrigerant circuit (approx. 16 bar).
2. Switches the air conditioning system off in the event of excess
pressure (approx. 32 bar) (e.g. because of lack of engine cooling).
3. Switches the air conditioning system off in the event of insuffi‐
cient pressure (approx. 2 bar) (e.g. because of loss of refrigerant).

Note
G. Volkswagen AG d
The air conditioning system pressure switch - F129- replaces lthe wage
nA oes
o ks not
high-pressure switch for air conditioning system - F23- , dthe
by low-
V gu
ara
pressure switch for air conditioning system - F73- andoristhe
e high- nte
pressure switch for magnetic clutch - F118- . au
th eo
ra
ss c

ce
e
nl

pt
du

2.4.6 High-pressure sender - G65-

an
itte

y li
erm

ab
ility
This high-pressure sender - G65- is fitted in place of the air con‐
ot p

ditioning system pressure switch - F129- .

wit
, is n

h re
hole

When voltage is applied to the high-pressure sender, it generates

spec
a square wave signal, or data telegram. This signal changes when
es, in part or in w

the pressure in the system changes.

t to the co
Using this signal, the control units that are connected in-line (ra‐
diator fan control unit, engine control unit, operating and display

rrectness of i
unit for Climatronic air conditioning system - E87- or Climatronic
control unit - J255- etc.) calculate the pressure in the refrigerant
l purpos

circuit and actuate the radiator fan, the engine, the air conditioning
system magnetic coupling - N25- accordingly and/or alter actua‐

nform
ercia

tion from the air conditioning system compressor regulating valve


- N280- .
m

at
om

ion
c

in t
2.4.7 Refrigerant pressure and temperature
or

his
ate

sender - G395-
do
priv

cum
for

en
ng

t.
yi Co
WARNING t. Cop py
rig
gh ht
yri by
Danger of freezing injuries.
cop Vo
by lksw
cted agen
Prote AG.
If refrigerant circuit has not been evacuated, refrigerant will
escape.
The refrigerant must be extracted before removing the refrig‐
erant pressure and temperature sender - G395- . If the refrig‐
erant circuit is not opened within 10 minutes after it has been
evacuated, pressure may develop in coolant circuit due to re-
evaporation. Extract refrigerant again.

2. General information on refrigerant circuit 29


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

This refrigerant pressure and temperature sender - G395- is fitted


in place of the high-pressure sender - G65- or air conditioning
system pressure switch - F129- .
The pressure signal is monitored continuously, whereas the tem‐
perature signal is monitored only at temperatures greater than 0°
C.
The Climatronic control unit - J255- works with this information
and controls the coolant radiator fans accordingly and actuates
the air conditioning system compressor regulating valve - N280- .

2.4.8 Air conditioner compressor regulating


valve - N280-
The regulating valve is fitted to the air conditioner compressor. It
is activated by the operating and display unit for Climatronic air
conditioning system - E87- or the Climatronic control unit - J255-
The regulating valve influences the pressure in the low-pressure
side and thus the temperature at the evaporator. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris
Note tho
tee
or
au ac
ss
The air conditioner compressor regulating valve - N280- is an in‐

ce
le
un

pt
tegral part of the air conditioner compressor and cannot be re‐

an
d
itte

newed individually.

y li
erm

ab
ility
ot p

wit
is n

h re
2.5 Electrical components not installed in
ole,

spec
refrigerant circuit
urposes, in part or in wh

t to the co
2.5.1 Control and regulating unit for air condi‐
tioning system - J127-

rrectne
This control and regulating unit switches off the refrigerant flow
s
through the second evaporator if the temperature at the cooling
fins of the second evaporator falls to the freezing point of water s o
cial p

f in
(icing protection).
form
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5.2 Radiator fan control unit - J293-

Note

Available in various designs, sometimes separately.

30 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

This control unit switches the magnetic clutch and thus the air
conditioner compressor on and off. It controls the radiator fan, and
for vehicles with high-pressure sender - G65- or refrigerant pres‐
sure and temperature sender - G395- , it calculates the pressure
in the refrigerant circuit.

2.5.3 Radiator fan control unit - J293-

Note

Available in various designs, sometimes fitted to the radiator fan


-arrows-.

This control unit switches the magnetic clutch and thus the air
conditioner compressor on and off. It controls the radiator fan, and
for vehicles with high-pressure sender - G65- or refrigerant pres‐
sure and temperature sender - G395- , it calculates the pressure
in the refrigerant circuit.

2.5.4 Temperature switch for evaporator - lksw


agen
AG. Volkswagen AG d
oes
not
E33- Vo gu
d by ara
se n ri tee
ho
Function: aut or
ac
ss
The temperature switch for evaporator - E33- senses the tem‐
ce
le
un

pt
perature between the cooling fins of the evaporator. It prevents
an
d
itte

the possibility of ice forming between the evaporator cooling fins


y li
rm

ab

by interrupting the current to the air conditioner compressor mag‐


pe

ility

netic clutch if the temperature at the fins falls to the freezing point
ot

wit
, is n

of moisture in the air.


h re
hole

spec

The insertion depth of the sensor tube is marked on the device or


es, in part or in w

is given in the repair manual ⇒ Rep. gr. 87 .


t to the co

Note
rrectness of i

Fitted to VW vehicles with air conditioning systems driven by V-


l purpos

belt
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
31
by c lksw
cted
2. General information on refrigerant circuit
agen
Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

2.5.5 Evaporator output temperature sender -


AG. Volkswagen AG d
G263- or evaporator temperatureolksw sen‐
agen oes
not
sor - G308- yV
b gu
d ara
e nt
ris ee
tho or
Function: s au ac
s

ce
e
The evaporator output temperature sender - G263- or evaporator

nl

pt
du
temperature sensor - G308- reads the temperature downstream

an
itte

y li
from the evaporator. This value is transmitted to the air condi‐
erm

ab
tioning system control unit and serves as a reference signal for

ility
ot p

regulating the air conditioner compressor. This prevents icing of

wit
, is n

the evaporator.

h re
hole

spec
es, in part or in w

t to the co
2.6 Pressures and temperatures in the re‐
frigerant circuit

rrectness of i
WARNING
l purpos

When working on the refrigerant circuit, observe generally ap‐

nform
ercia

plicable safety rules and the Regulations for Pressure Tanks.


m

at
om

ion
c

in t
r

The pressures and temperatures in the refrigerant circuit depend


o

his
te

on the momentary operating conditions (e.g. engine speed, speed


a

do
riv

1, 2, or 3 of radiator fan, engine temperature, whether air condi‐


p

cum
or

tioner compressor is on or off) as well as environmental influences


f

en
ng

t.
(e.g. ambient temperature, humidity, required cooling output).
yi Co
Cop py
t. rig
In vehicles with air conditioner compressor regulating valve -
gh ht
pyri by
N280- , the pressure on the low-pressure side is varied by acti‐
o Vo
by c lksw
cted
vating the valve.
agen
Prote AG.

Therefore, the values given in the following tables may only be


considered as guidelines. They occur at an engine speed of 1,500
to 2,000 rpm and an ambient temperature of 20°C after about 20
minutes.
The locations of connections provided for pressure measure‐
ments can be found in the vehicle-specific coolant circuits.
⇒ Rep. gr. 87
At 20°C and with the engine stopped, the refrigerant circuit will
adjust itself to a pressure of 4.7 bar positive pressure ⇒ page 3 .

2.7 Refrigerant circuit with expansion valve


A- low-pressure side of the refrigerant circuit.
B- high-pressure side of the refrigerant circuit.

32 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Component Overall state Pressure (in bar) Temperature in degrees
l purpos

of the refriger‐ Celsius


ant
nform
ercia

-1- evaporator, from inlet to Vapour approx. 1.2 bar1) approx. -7°C2)
m

outlet
com

tion in

(approx. 1.8 bar)3) approx. -1°C3)


r
te o

thi

-2- Air conditioning system Gas approx. 1.2 bar1) approx. -1℃
s
iva

do
r

compressor A-side
rp

cum
fo

en
g

(approx. 1.8 bar)3) (approx. +1°C)3)


n

t.
yi Co
op
-3- Air conditioning system Gas approx. 14 bar approx. +65℃
C py
ht. rig
compressor B-side
rig ht
py by
co Vo
by lksw
-4- Condenser Gas, vapour,cted approx. 14 bar at outlet approx. + 55°C
agen
Prote AG.
liquid
-5- Receiver Liquid approx. 14 bar approx. +55℃
-6- Extraction and charging Liquid approx. 14 bar approx. +55℃
valve, B side
-7-Expansion valve Liquid, re‐ approx. 14 bar approx. +55°C, reduced
leased into to -7°C
vapour
-8- Extraction and charging Gas approx. 1.2 bar1) approx. -7°C2)
valve, A side

2. General information on refrigerant circuit 33


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Component Overall state Pressure (in bar) Temperature in degrees


of the refriger‐ Celsius
ant
(approx. 1.8 bar)3) approx. -1°C3)
1) The pressure in refrigerant circuits with regulating air conditioner compressor is held to approx. 2 bar despite changing heat transport
and differing engine speeds. This applies however only within the rated range of the air conditioner compressor; if the rated range of the
air conditioner compressor is exceeded, the pressure will increase ⇒ page 127 .
2) The temperature in refrigerant circuits with regulating air conditioner compressor is held within
AG. Vthe
olkregulation
swagen AGrange of the air conditioner
compressor despite changing heat transport and differing engine speeds. This applies agen
ksw however only within the rated
does range of the air
l not
conditioner compressor ; if the rated range of the air conditioner compressor is by Vo
exceeded, the temperature will increase g⇒
uapage 127 .
d ran
rise tee
3) Measured values for air conditioning systems with two evaporators tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

♦ Air conditioning system compressors that do not self-regulate

h re
their load are switched off by the respective control unit via the
hole

spec
air conditioner compressor regulating valve - N280- when an
es, in part or in w

evaporator temperature less than 0°C is sensed.

t to the co
♦ In vehicles with air conditioner compressor regulating valve -
N280- , the pressure on the low-pressure side is varied by

rrectness of i
activating the valve.
l purpos

2.8 Refrigerant circuit with restrictor and reservoir

nform
ercia

Arrows show the direction of refrigerant flow.


m

at
om

A- low-pressure side of the refrigerant circuit.

ion
c

in t
or

B- high-pressure side of the refrigerant circuit.

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

34 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

Component Overall state of Pressure (in bar) Temperature in degrees


t.
yi Co
op
the refrigerant Celsius
C py
t. rig
gh ht
yri
-1- Air conditioning system com‐ Gas up to 20 bar to +70℃
p by
o Vo
by c lksw
pressor B-side Prote
cted AG.
agen

-2- Condenser from gas up to 20 bar to +70℃


through vapour
to liquid
-3- Restrictor from liquid to va‐ B-side up to 20 bar, A-side B-side up to +60℃, A-
pour greater than 1.5 bar side warmer than -4°C
-4- Evaporator from vapour to greater than 1.5 bar warmer than -4℃
gas
-5- Reservoir Gas
-6- Air conditioning system com‐ Gas
pressor A-side
The pressures on the A-side are held at approx. 2 bar by the
“regulating” air conditioner compressor even at differing engine
speeds. This applies however only within the rated range of the
air conditioner compressor ; if the rated range of the air condi‐
tioner compressor is exceeded, the pressure will increase
⇒ page 127 .

2. General information on refrigerant circuit 35


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

In vehicles with air conditioner compressor regulating valve -


N280- , the pressure on the low-pressure side is varied by acti‐
vating the valve.

2.9 Test and measurement work that can be


performed using a pressure gauge
Displays on the pressure gauge agen AG. Volkswagen AG do
ksw es n
Vol o
1 - Temperature scale for d byrefrigerant R134a CF3–CH2F ort guara
CH2F–CF3. ho
ris
e nte
e t or
au ac
2- Pressure scale
ss

ce
e
nl

In addition to the pressure scale, the pressure gauges can have

pt
du

an
itte

one or more temperature scales. The scale values for R134a are

y li
erm

ab
assigned according to the vapour pressure table. Because differ‐

ility
ot p

ent refrigerants have different vapour pressures at the same

wit
temperature, each temperature scale is labelled for the respective
, is n

h re
refrigerant.
hole

spec
es, in part or in w

t to the co
2.9.1 Pressure gauges enable the following
test and measurement work rrectness of i
l purpos

a – Pressure and temperature measurement in the refrigerant cir‐


cuit
nf
ercia

♦ The high-pressure gauge allows the pressure and tempera‐


or

ture to be measured with the air conditioning system switched


m
m

atio

on irrespective of whether this is at the outlet of the air condi‐


om

n in

tioner compressor through the condenser up to the restriction


or c

thi

(restrictor or expansion valve).


te

sd
iva

o
r

♦ The low-pressure gauge allows the pressure and temperature


rp

cu
o

to be measured with the air conditioning system switched on


f

en
ng

t.
yi
irrespective of whether this is at the restriction (restrictor or
Co
op py
expansion valve) through the evaporator up to the inlet to the
. C rig
ht ht
rig
air conditioner compressor. py by
co Vo
by lksw
cted agen
Prote AG.

Note

The relationship between pressure and temperature shown on


the pressure gauge is valid only where the refrigerant in the circuit
is liquid or vapour, but not when it is gas. In the gaseous state,
the temperature is approx. 10°C to 30°C higher than indicated on
the pressure gauge.

b– Evidence of refrigerant in a closed container


Refrigerant R134a is present in a closed container or refrigerant
circuit if the temperature indicated on the pressure gauge corre‐
sponds to the temperature of the refrigerant (the temperature of
a standing liquid stabilises at ambient temperature).
A closed container or switched-off refrigerant circuit is empty if the
temperature indicated on the pressure gauge is below the tem‐
perature of the refrigerant.

36 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
olksw AG. V agen AG
agen does
olksw not
yV gu
db ara
ise nte
Note tho
r eo
au ra
c
ss
The dependency between pressure and temperature described

ce
e
nl

pt
on the pressure gauge no longer applies when there is no liquid

du

an
itte
and the pressure is created by gas alone.

y li
erm

ab
ility
ot p

2.10 Air conditioner service and recycling

wit
, is n

h re
equipment
hole

spec
es, in part or in w

At present, various manufacturers offer air conditioner service

t to the co
devices on the market for evacuating, cleaning and charging re‐
frigerant in vehicle air conditioning systems.

rrectness of i
2.10.1 Classification of extraction systems in
l purpos

groups
Group 3:

nf
ercia

orm
Portable extraction and charging devices linking the air condi‐
m

atio
m

tioning system to a fixed compressed gas container.


o

n in
or c

The fixed compressed gas container is charged with refrigerant

thi
te

sd
a

or refrigerant/oil mixture. The portable extraction and charging


iv

o
r
rp

cu
device is then permanently attached to the pressure vessel. In
o

m
f

accordance with § 3 section 5 no. 3 of the Regulations for Pres‐

en
ng

t.
yi
sure Tanks, in this case the terms "compressed gas container"
Co
Cop py
and "pressure tank" are equivalent.
t. rig
gh ht
pyri by
Vo
o
Charging devices require: by c lksw
cted agen
Prote AG.
♦ no permit
♦ no checking by an authorised official, since the gas is held in
the compressed gas container, which is equivalent to a pres‐
sure tank. (Devices for filling refrigerant from these pressure
tanks into compressed gas containers that are intended for
third-party use, in turn, require licensing and they are subject
to checking by an authorised official.)

Note

The air conditioner service and recycling devices used in vehicle


workshops are Group 3 extraction and charging devices which do
not require a permit, but which can be operated only by skilled
staff. Refer to the manufacturer's documentation for instructions
on operating and maintaining these devices.

2.10.2 Charging devices that do not require a


permit
Charging devices that do not require a permit are mobile charging
devices into which pressurised gases are charged into com‐
pressed gas containers for exclusive use of one company.
Note:
Some air conditioner service devices are charging devices that
do not require a permit. When these devices are used, the refrig‐
erant is charged not into locally mobile compressed gas contain‐
ers, but into a permanently installed charging cylinder with a
visible contents gauge and float switch.

2. General information on refrigerant circuit 37


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Recommendation:
When surplus refrigerant is transferred for one's own require‐
ments, it is recommended that a portable charging cylinder with
visible level gauge and pressure relief valve be used.
Make sure to observe the corresponding technical rules (e.g.
TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRBS 3145/
TRGS 725) when handling compressed gases and, in particular,
when filling compressed gases from one compressed gas con‐
tainer into another one.

2.11 Notes to repairs on refrigerant circuit


olkswagen AG
en AG. V does
not WARNING olkswag
b gu
ara yV
ed
ris nte
When workingthon the refrigerant circuit, observe generally ap‐
o eo
plicable safety
ss
a rules and the Regulations for Pressure Tanks. r ac
u

ce
le
un

pt
an
d
itte

y li
erm

ab
Caution

ility
ot p

wit
is n

Non-authorised tools or materials (e.g. leak inhibitor additive)

h re
ole,

may cause damage or adversely influence the system.

spec
urposes, in part or in wh

Only tools and materials approved by the manufacturer may


t to the co
be used.
Use of non-approved tools or materials will render the warranty
rrectne

void.
ss o

Special tools and accessories:


cial p

f inform

To ensure a correct and professional repair to an air conditioning


mer

system:
atio
om

n
c

• Special tools and materials are required; these are listed on


i
or

n thi
e

⇒ page 165 .
t

sd
iva

o
pr

• The essential information on the leak detector should be re‐


um
r
fo

en

ferred to ⇒ page 58 .
ng

t.
yi Co
op py
• Expert knowledge is necessary. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.

Releasing refrigerant into the environment is not permitted


⇒ page 39 .

38 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

3 Statutory texts and instructions

3.1 Statutes and regulations

AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
d
♦ The laws and regulations
orise
listed below are valid in the Federal nte
eo
Republic of Germany.ut Other or additional laws and regulations
h
a ra
may apply in other
s countries.
s c

ce
e
nl

pt
du

♦ Sources in other countries may be obtained from the respon‐

an
itte

sible authorities.

y li
erm

ab
ility
ot p

The effects concerning the changing climate can be seen world-

wit
, is n

h re
wide. The protection of the climate is therefore one of the most
hole

important tasks for the human race. This task is a massive chal‐

spec
lenge for all concerned.
es, in part or in w

t to the co
The so called Kyoto Protocol defines, amongst other items, world-
wide targets to protect the climate. This protocol defines apart
from the reduction targets for carbon dioxide, the reduction tar‐

rrectness of i
gets for fluoride containing greenhouse gases e.g. for refrigerant
l purpos

R134a due to the high greenhouse potential.


Within Europe a large number of respective statutes exist for the

nform
ercia

motor industry. Nationally (Federal Republic of Germany) for ex‐


ample in addition to European legislation, from the 1st of August
m

at
2008 the climate protective regulation concerning chemicals
om

ion
comes into force.
c

in t
or

his
te

♦ Regulation (EU) No. 1005/2009


a

do
priv

cum
or

♦ Regulation (EU) No. 2037/2000


f

en
ng

t.
yi Co
♦ Regulation (EU) No. 842/2006 ht. Cop py
rig
rig ht
♦ Regulation (EU) No. 706/2007 py by
co Vo
by lksw
cted agen
♦ Regulation (EU) No. 307/2008 Prote AG.

♦ Guideline 2006/40/EU
♦ Climate protective regulation concerning chemicals; closed
substance cycle waste management and ensuring environ‐
mentally compatible waste disposal (only Germany)
Maintenance and repairs to refrigerant circuits for air conditioning
systems
All personnel performing maintenance and repairs on air condi‐
tioning systems for motorized vehicles must have attended the
respective training programme and have the appropriate knowl‐
edge (certified). Other legislation may apply outside the European
Union.
In general the following applies:
Operation, maintenance, decommissioning, duty to accept re‐
turned material
♦ It is prohibited to allow the release into the atmosphere of ma‐
terials contained in products containing refrigerants during the
operation, maintenance or removal from service of such prod‐
ucts.
♦ The quantities used during operation and maintenance work
should be documented (see Refrigerant Logbook, ⇒ Volks‐
wagen InfoNet, Service handbook; Environmental protection;
Environmental protection in the dealership and in the work‐
shop; Emission protection; Air contaminating substances, re‐

3. Statutory texts and instructions 39


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

frigerant for vehicle air conditioning systems ) so that a proof


of use document is available for presentation to the responsi‐
ble authorities upon request. A record sheet need no longer
be kept within the EU due to respective European parliament
legislation from 2005. Other legislation may apply in countries
not belonging to the EU.
♦ Companies which sell materials and preparations listed in the
above mentioned legislation have the duty of accept returned
materials and preparations after they have been used, or to
ensure that a specified third party will accept them.
♦ Maintenance work and decommissioning of products that con‐
tain refrigerant referred to in the above mentioned legislation
as well as the acceptance of returned substances and prepa‐
rations referred to in this legislation may only be carried out by
persons who have the necessary specialist knowledge and
technical equipment.
Offences and breaches of the regulations
♦ A person is in breach of the regulations and laws referred to if
that person performs acts of wilful misconduct or negligence
when operating, performing maintenance work on or decom‐
missioning products that contain the refrigerants referred to,
contrary to the norms of technical practice, allows the sub‐
stances contained in them to escape into the atmosphere or
wilfully or negligently breaches the applicable regulations and
laws mentioned above.
Make sure to observe the corresponding technical rules (e.g.
TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS
3145) when handling compressed gases and, in particular, when
filling compressed gases from one compressed gas container into
another one.

Note

The following paragraphs are only extracts from the Technical


Rules for Hazardous Substances (TRGS) (relevant for automo‐AG. Volkswagen AG d
bile manufacturers and workshops). lksw
agen oes
no
o t gu
yV
edb ara
ris nte
♦ TRGS 400 (Risk assessment for activities
tho involving hazardous eo
substances). au ra
c
ss
ce
e

♦ TRGS 402 (Identification and assessment of the risks from


nl

pt
du

activities involving hazardous substances: inhalation expo‐


an
itte

y li

sure).
erm

ab
ility
ot p

♦ TRGS 407 (Risk assessment for activities involving gaseous


wit
, is n

substances).
h re
hole

spec

♦ TRGS 510 (Storage of hazardous substances in non-station‐


es, in part or in w

ary containers).
t to the co

♦ TRBS 3145/TRGS 725 (Non-stationary compressed gas con‐


tainers – charging, storage, in-house transportation, empty‐
rrectness of i

ing).
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

40
co Vo
by lksw
cted
Rep. gr.00 - Technical data
agen
Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note
G. Volkswagen AG d
♦ The Technical Rules for Compressed Gases lk(TRG),
swa
gen Athe Tech‐ oes
nical Rules for Hazardous Substances (TRGS) and the Tech‐
o not
V gu
by ara
nical Rules for Operational Safety (TRBS)rised
reflect the state of nte
technology, occupational safety and ut health, occupational hy‐
ho eo
ra
giene as well as other definite knowledge relating to provision
s a c
s
and use of work equipment, operation of facilities requiring

ce
le
un

pt
supervision and activities involving hazardous substances.

an
d
itte

y li
rm
♦ The technical rules stated here are valid in Germany and do

ab
pe

ility
not necessarily reflect the rules and regulations valid in other
ot

wit
countries.
, is n

h re
hole

spec
Make sure to observe the corresponding technical rules (e.g.
es, in part or in w

TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS

t to the co
3145) when handling compressed gases and, in particular, when
filling compressed gases from one compressed gas container into
another one.

rrectness of i
♦ Filling stations – general provisions.
l purpos

♦ Terms and definitions.

nform
ercia

♦ Filling stations – set-up and operation.


m

a
com

Filling stations

tion in
r
te o

♦ This does not apply to vehicle manufacturers and workshops.

thi
s
iva

do
♦ Filling stations are systems for charging non-stationary com‐
r
rp

cum
pressed gas containers. A filling station comprises its corre‐
fo

en
ng

sponding premises and equipment.


t.
yi Co
Cop py
t. rig
♦ Charging systems that require authorisation are charging sys‐ yri
gh by
ht
tems which are filled with compressed gases in mobile com‐
op Vo
by c lksw
pressed gas containers for transfer to other containers.
cted agen
Prote AG.

♦ Filling stations that do not require authorisation are filling sta‐


tions in which compressed gases are filled into non-stationary
compressed gas containers for exclusive use within a compa‐
ny.
Employees and their instruction
Employees are to be instructed in the following points before be‐
ginning work as well as at regular, appropriate intervals, but at
least annually:
• The particular hazards arising when handling compressed
gases;
• The safety regulations, particularly the existing Technical
Rules for Hazardous Substances (TRGS) and the Technical
Rules for Operational Safety (TRBS);
• The actions to be taken in the event of defects, damage or
accidents;
• The handing of fire extinguishers and protective equipment;
• The operation and maintenance of filling stations, with partic‐
ular reference to the user's manual.
Filling stations may be operated and maintained only by persons
who
• are at least 18 years of age;
• possess the required technical knowledge;
• can be expected to fulfil their duties reliably.

3. Statutory texts and instructions 41


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Supervised work may be done by persons who do not fulfil the


requirements according to item 2.1, figures 1 and 2.
Charging pressure tanks (for tanks from other countries, other
technical rules that are not mentioned here may apply).
♦ A compressed gas container may be charged only with the
compressed gas that is listed on its label, and only up to the
quantity indicated on the container in terms of pressure, weight
and volume (see Regulations for Pressure Tanks).
♦ A container that can be used for different types of compressed
gas must have a label on it listing the compressed gases with
which it may be charged. If the compressed gas concerned
has a tc ≥ -10°C (tc = critical temperature), the max. permis‐
sible charging weight in accordance with TRGS must also be
indicated on the container before it is connected for charging. wagen AG. Volkswagen AG does
ks not
Vol gu
♦ Compressed gas containers for which the max. permissible db
y ara
se nte
charge overpressure at 15°C is given in bar must be tho
ri charged eo
by pressure gauge (manometer). If during charging
s au the tem‐ ra
c
perature differs from 15°C, the pressure corresponding
s
to the

ce
le

different temperature should be determined by the charging


un

pt
an
d

equipment; it must be ensured that the permissible positive


itte

y li
pressure for charging at 15°C in the compressed gas container
rm

ab
pe

ility
is not exceeded. To determine possible overcharging, the
ot

wit
charged containers must be checked through random pres‐
, is n

h re
sure tests.
hole

spec
♦ Compressed gas containers on which the maximum permis‐
es, in part or in w

t to the co
sible charging quantity is indicated by the net weight (charged
weight, permissible weight of the contents) in kilograms must
be charged according to weight (gravimetrically). The contain‐
ers must be weighed during charging and, to determine pos‐

rrectness of i
sible overcharging subsequently subjected to a weight check
l purpos

on a special scale. Scales for control weighing must be cali‐


brated.

nform
ercia

♦ Under particular conditions, gases with tc ≥ +70°C from com‐


pressed gas containers with a capacity of no more than 150 l
m

a
may be charged into a compressed gas container with a ca‐
com

tion in
pacity of no more than 1000 cc. The conditions of the TRGS
r
te o

thi
apply to charging mechanic's bottles with liquid gas.

s
iva

do
r

♦ For vehicle containers, different TRGS apply:


rp

cum
fo

en
ng

– For gases with tc ≥ +70°C.


t.
yi Co
Cop py
t. rig
– For technical gas mixtures with tc ≥ +70°C. opyri
gh by
Vo
ht
by c lksw
– Liquid, deep-cooled compressed gases in variance to those Prote
cted agen
stated under item 4 may be charged by volume (volumetrical‐
AG.

ly), if the charging device and/or the container with equipment


is equipped with devices for measuring or limiting the volume
of the charge and (except vehicle containers as specified un‐
der item 3) for measuring the temperature of the charge. When
charging by volume it must be ensured that the permitted
charge weight shown on the container is not exceeded. To
determine possible overcharging, the charged containers are
to be checked gravimetrically on a calibrated scale or – provi‐
ded that the pressurised gases are not highly toxic – volumet‐
rically. Volumetric checking presupposes that the appropriate
equipment is in place; charging and checking equipment must
be independent of each other.
♦ The charge and check measurements must not be performed
by the same person. Check measurements must be per‐
formed immediately upon conclusion of the charging process.
♦ Overcharged containers must be discharged immediately to
the permissible charge quantity and in a manner without haz‐
ard. Following this, the quantity of compressed gas charged
must be determined once again.

42 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

♦ Some regulations of the TRGS 407 do not (fully) apply to con‐


tainers for liquid, deep-cooled compressed gases which are
neither flammable nor toxic; regulations for traffic law remain
unaffected.
♦ When compressed gas containers are to be charged with
gases in the liquid state at a charging temperature of ≤ -20°C,
the compressed gas container must not be released from the
charging system for transportation until the container wall has
achieved a temperature ≥ +20°C (applies for vessel materials
not tested for temperatures ≤ -20°C).
Converting R12 refrigerant circuits to R134a refrigerant circuits
and repairing them (retrofitting)

Note

♦ Due to the environmental situation and the consequent legis‐


lation, refrigerant R12 is currently neither in production nor
available. Refrigerant R134a was developed as a replacement
for R12.
♦ However, air conditioning systems developed and designed
for refrigerant R12 cannot simply be charged gen AG with refrigerant
. Volkswagen AG
doe
swa
R134a. To ensure trouble-free operation
yV
olk of the air conditioning s not gu
system following a retrofit, various
ed
b
components of the refrig‐ ara
nte
ris
erant circuit must be replaced.
ut
ho eo
r
sa ac
♦ An exact description ofs the procedure for conversion and in‐

ce
e

structions for repair of converted refrigerant circuits can be


nl

pt
du

an
found in the ⇒ Repair manual for air conditioning systems with
itte

y li
refrigerant R12 parts 2 and 3 . This workshop manual is only
erm

ab
available as a hard copy.

ility
ot p

wit
, is n

h re
Maintaining records on refrigerant
hole

spec
es, in part or in w

According to the environmental statistics law, a record concerning


t to the co
the use of refrigerants must be kept.
Car manufacture and repair businesses must be prepared to fur‐
nish information concerning use of refrigerants to the statistical
rrectness of i

office for the country in which the work is being performed. It is


l purpos

therefore recommended to keep records of the amounts of refrig‐


erant handled during operation and maintenance (Refrigerant
Logbook) ⇒ Volkswagen ServiceNet, Environmental Protection;
nform
ercia

Service handbook; Emission protection; Air contaminating sub‐


stances, refrigerant for vehicle air conditioning systems ) which
m

at
om

must be available for presentation to the responsible authorities


on
c

in t

upon request.
or

his
ate

do
priv

cum
or

Note
f

en
ng

t.
yi Co
op py
A record sheet need no longer be kept within the EU due to re‐
. C rig
ht ht
rig
spective European parliament legislation from 2005. Other legis‐ py by
co Vo
lation may apply in countries not belonging to the EU.
by lksw
cted agen
Prote AG.

3. Statutory texts and instructions 43


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

3.2 Recycling and refuse law

Note

♦ The laws and regulations listed below are valid in the Federal
Republic of Germany. Other or additional laws and regulations
may apply in other countries.
♦ Sources in other countries may be obtained from the respon‐
sible authorities.

Statutes and regulations concerning the use and disposal of re‐


frigerants and refrigerant machine oils are contained within the
climate protective regulation concerning chemicals and closed
substance cycle waste management and ensuring environmen‐
tally compatible waste disposal (only for Germany, in other coun‐
tries other statutes and regulations may apply).

3.2.1 Disposal of refrigerant and refrigerant


machine oil
Refrigerant
Refrigerants intended for disposal are to be charged into marked
recycling containers under the observation of permissible charge
quantities. Observe, for example in the Federal Republic of Ger‐
many, the climate protective regulation concerning chemicals;
closed substance cycle waste management and ensuring envi‐
ronmentally compatible waste disposal (in other countries other
statutes and regulations may apply)
Refrigerant machine oil
Disposing of used oil: Volkswagen InfoNet; Operation; Manuals
and dealership documentation; Service handbook; 15. Environ‐ swa
gen AG
. Volkswagen AG
does
mental Protection; Follow link “Environmental protection in the by V olk not
gu
dealership and in the workshop” in "General notes"; 4. Waste rdis‐
ised ara
nte
posal; 6. Disposal channels; g. Disposal of used oil; Refrigerant
ut
ho eo
ra
oils ss a c

ce
e
nl

Used refrigerant machine oils from systems with halogenated hy‐


pt
du

an
drocarbons (at least one hydrogen atom has been replaced by
itte

y li
e.g the halogens flourine, chlorine, bromine or iodine) must be
erm

ab
ility
disposed of as waste requiring particular care. It is impermissible
ot p

wit
to mix such oils with other oils or materials. Proper storage and
, is n

disposal must be performed according to guidelines in the country h re


hole

where the work is being performed. Observe, for example in the


spec
es, in part or in w

Federal Republic of Germany, the climate protective regulation


t to the co

concerning chemicals; closed substance cycle waste manage‐


ment and ensuring environmentally compatible waste disposal (in
other countries other statutes and regulations may apply)
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

44 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Reference sources for technical rules


gen AGand safetyn A
. Volkswage atG work / acci‐
does
swa
dent prevention for the Federal
yV
olk Republic of Germany not gu
b ara
ed n
Sources in other countries
tho
ris may be obtained from the responsibletee o
authorities s au ra
c s

ce
le
3.3 Converting R12 refrigerant circuits to
un

pt
an
d
itte

R134a refrigerant circuits and repairing

y li
erm

ab
them (retrofitting)

ility
ot p

wit
is n

h re
ole,

spec
Note
urposes, in part or in wh

t to the co
♦ The laws and regulations listed below are valid in the Federal
Republic of Germany. Other or additional laws and regulations
may apply in other countries.

rrectne
♦ Sources in other countries may be obtained from the respon‐

s
sible authorities.

s o
cial p

f i
♦ Due to the environmental situation and the consequent legis‐

nform
lation, refrigerant R12 is currently neither in production nor
mer

available. Refrigerant R134a was developed as a replacement

atio
m

for R12.
o

n
c

i
or

n thi
e

♦ However, air conditioning systems developed and designed


t

sd
va

for refrigerant R12 cannot simply be charged with refrigerant


i

o
pr

cum
r

R134a. To ensure trouble-free operation of the air conditioning


fo

en
ng

system following a retrofit, various components of the refrig‐


t.
yi Co
op
erant circuit must be replaced. C py
ht. rig
rig ht
by
♦ An exact description of the procedure for conversion and in‐ copy Vo
by lksw
structions for repair of converted refrigerant circuits can be cted agen
Prote AG.
found in the ⇒ Repair manual for air conditioning systems with
refrigerant R12 parts 2 and 3 . This workshop manual is only
available as a hard copy.

3.4 Maintaining records on refrigerant

Note

♦ The laws and regulations listed below are valid in the Federal
Republic of Germany. Other or additional laws and regulations
may apply in other countries.
♦ Sources in other countries may be obtained from the respon‐
sible authorities.

The quantities used during operation and maintenance work


should be documented (see Refrigerant Logbook, ⇒ Volkswagen
ServiceNet, Environmental Protection; Service handbook; Emis‐
sion protection; Air contaminating substances, refrigerant for ve‐
hicle air conditioning systems ) or proof of use document which
must be available for presentation to the responsible authorities
upon request. A record sheet need no longer be kept within the
EU due to respective European parliament legislation from 2005.
Other legislation may apply in countries not belonging to the EU.

3. Statutory texts and instructions 45


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

4 Refrigerant circuit

4.1 Important repair notes on air condition‐


ing
• Air conditioning systems designed for refrigerant R12 must not
be charged with refrigerant R134a until specific conversion
measures have been performed ⇒ page 45 .
• The refrigerant oils specifically developed for R134a refriger‐
ant circuits must never be mixed with the refrigerant oils spe‐
cifically developed for R12 refrigerant circuits.
• Air conditioner service stations that come into contact with re‐
frigerants may be used only for the refrigerant for which they
are intended.
• Components for R134a refrigerant circuits are identified with
a legend or a green label, or are so designed (e.g. with different
threads), that they cannot be confused with components for
R12 refrigerant circuits.
• Within the engine compartment, on the bonnet catch striker
plate or in the plenum chamber there is an information plate
which states what refrigerant is used.
• Different refrigerants must never be mixed together.

Note

When working on the refrigerant circuit please refer to the infor‐


mation listed under “Safety precautions” ⇒ page 13 and “Basic
procedures for working on refrigerant circuits” ⇒ page 14 .

4.2 Retrofitting refrigerant circuit from R12


refrigerant to R134a refrigerant olksw
agen
AG. Volkswagen AG d
oes
not
byV gu
ara
Chlorofluorocarbon (CFC) is no longer used as a refrigerant in ris the
e d
nte
automotive sector. ut
ho eo
ra
s a c
s
R12Converting refrigerant circuits from refrigerant R12 to refrig‐
ce
le
un

erant R134a and repairing the converted circuits.


pt
an
d
itte

y li

⇒ Repair manual for air conditioning systems with refrigerant R12


erm

ab

parts 2 and 3 . This workshop manual is only available as a hard


ility
ot p

copy.
wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo

46
by lksw
cted agen
Rep. gr.00 - Technical data Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

5 Working with the air conditioner serv‐


ice station

Caution

♦ If there is evidence to suggest that chemical substances


have been added in the vehicle to seal leaks, do not con‐
nect the air conditioner service station and do not extract
the refrigerant.
♦ Chemical substances used to seal leaks form deposits in
the refrigerant circuit. These can impair the function of the
air conditioning system and cause the air conditioning
system (and your air conditioner service station) to fail.
♦ Make your customer aware of the fact that there are sub‐
stances in his/her air conditioning system that do not have
VW approval. This air conditioning system cannot be
drained or repaired by you.

Note

♦ Volkswagen AG does not authorise the use of chemical sub‐


stances (leak inhibitor additives) for purposes of sealing leaks
in refrigerant circuits. There are currently no permanent,
agen
AG. Vef‐
olkswagen AG
does
fective or material compatible tests that guarantee
Volksw never caus‐ not
ing damage or malfunctions in an air conditioning
edb
y system or gu
ara
air conditioner service station. thoris nte
eo
au ra
♦ The leak inhibitor additives currently
ss available on the market c

ce
have differing physical and chemical characteristics that may
le
un

pt
subsequently affect the function of the air conditioning system

an
d
itte

y li
and air conditioner service station or even cause a total failure.
rm

ab
pe

ility
♦ Volkswagen rejects the use of chemical substances for pur‐
ot

wit
, is n

poses of sealing leaks in refrigerant circuits.


h re
hole

♦ Chemical substances used for sealing leaks in refrigerant cir‐ spec


es, in part or in w

cuits often react with the surrounding air and the humidity
t to the co

contained within. They cause deposits to build up in the re‐


frigerant circuit (and your air conditioner service station),
valves to malfunction and defects in other components with
rrectness of i

which they come into contact. These deposits cannot be com‐


pletely removed from the components.
l purpos

♦ It is often not possible to detect from the outside whether


chemical substances have been used to seal leaks in the re‐
nform
ercia

frigerant circuit. The adhesive label that serves to identify its


use can usually not be found. Therefore, exercise caution on
m

a
com

ti

vehicles for which you have no service or repair record.


on in
r
te o

thi

♦ Containers or tanks are offered as accessories on the open


s
iva

market that are designed to separate these chemical substan‐


do
r
rp

ces (to seal leaks). Since Volkswagen rejects the use of these
um
fo

en
g

substances, no statement can be made at this point regarding


n

t.
yi Co
the effectiveness and separation rate of these filters. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Working with the air conditioner service station 47


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

5.1 Important notes for working with the air


conditioner service station
To operate the air conditioner service station - VAS 6007A- , the
following must be observed (also applies to other and latest avail‐
able air conditioner service stations).
⇒ Workshop equipment
• The fitted filter and dryer must be renewed at the latest when
the operational time specified in the related operating instruc‐
tions has been reached.
• Fill only with refrigerant oils which have been approved for the agen
AG. Volkswagen AG d
oes
vehicle-specific refrigerant circuit. Volksw not
gu
by ara
d
⇒ Parts catalogue rise nte
tho eo
au ra
Refrigerant that has been extracted may not be reused, even
ss after c
cleaning within the station, in any of the following circumstances:

ce
le
un

pt
an
d
itte
• If there is damage to the air conditioner compressor, such that

y li
rm

ab
decomposition of the refrigerant due to overheating might
pe

ility
have occurred.
ot

wit
, is n

h re
• If there are dark sticky deposits in the refrigerant circuit (these
hole

can be detected only by opening up the system).

spec
es, in part or in w

• If there is any doubt about the composition of the refrigerant

t to the co
extracted from the refrigerant circuit.
In all of these circumstances the air conditioner service station

rrectness of i
must be drained ⇒ page 49 , the system must be cleaned if
necessary, the filter and dryer and also the refrigerant oil must be
l purpos

renewed.
Contaminated refrigerant can, e.g. in the Federal Republic of

nform
ercia

Germany, be returned to the supplier in so-called recycling bottles


m

for recycling or for environmentally sound disposal (in other coun‐

a
com

tio
tries other or additional regulations may apply).

n in
r
te o

thi
Commercially available air conditioner service stations can be

s
iva

do
divided into 2 groups:
r
rp

cum
fo

en
g

♦ A. Air conditioner service stations that clean the extracted re‐


n

t.
yi Co
frigerant for reuse (so-called evacuating and recycling sta‐ t. Cop py
tions) e.g. air conditioner service station - VAS 6007A- .
rig
gh ht
pyri by
Vo
co
♦ B. Air conditioner service stations, called extraction stations,
by lksw
cted agen
Prote
that charge the extracted refrigerant into recycling bottles (for
AG.

reprocessing in bulk).

5.2 Connecting air conditioner service sta‐


tion for measuring and checking
• Depending on the type of equipment chosen, there may be
variations in the required procedure; therefore always follow
the user's manual for the equipment being used.

Note

Always follow the procedure described in the user's manual for


your air conditioner service station - VAS 6007A- (or later model).

To prevent air or moisture from entering the refrigerant circuit


through the charging hoses, they must be connected after the
following procedure:
– Switch off ignition.

48 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Connect air conditioner service station to power supply.


– Unscrew the sealing caps from the service connections, or
unscrew the connections with the valve (see vehicle-specific
refrigerant circuit).
⇒ Rep. gr. 87
– Evacuate charging hose.
. Volkswagen AG
gen AG does
swa
Note byV
olk not
gu
d ara
ise nte
or
Connect the charging hose to the service connectionsaut
h of the re‐ eo
ra
frigerant circuit using quick-release couplings. ss c

ce
e
nl

pt
du

an
itte

y li
Caution
erm

ab
ility
ot p

wit
Do not open the valves in the low- or high-pressure sides when
, is n

h re
the engine is running. Otherwise, if the air conditioning is
hole

spec
switched on, the air conditioner compressor or the air condi‐
es, in part or in w

tioner service station may be destroyed by a “short circuit”

t to the co
between the high- and low-pressure sides of the refrigerant
circuit.

rrectness of i
– Turn hand wheel into quick-release coupling adapter until the
l purpos

valve in the service connection is definitely open (observe


pressure gauge; do not over-tighten valve).

nform
ercia

– Start the engine and perform the planned tests and measure‐
m

at
ments.
om

ion
c

in t
r

– Compare determined values with specifications ⇒ page 127 .


o

his
ate

do
riv

– Before disconnecting the quick-release coupling, close it by


p

cum
turning out the handwheel.
for

en
ng

t.
yi Co
5.3 Draining refrigerant circuit using air con‐ Cop py
ht. rig

ditioner service station


rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

WARNING

High-voltage on high-voltage system. Danger of electric shock


on air conditioner compressor!
Models with a high-voltage system: now de-energise the high-
voltage system ⇒ Electric drive; Rep. gr. 93 ; De-energising
the high-voltage system .

• Depending on the type of equipment chosen, there may be


variations in the required procedure (always follow user's man‐
ual for the equipment being used).
• The refrigerant circuit must be discharged if parts of the re‐
frigerant circuit must be removed, if there is uncertainty about
the quantity of refrigerant in the circuit or if safety measures
require it.
• All important operating instructions associated with the air
conditioner service station for working with refrigerants can be
found in the air conditioner service station operator's manual.
Discharging:
– Switch off ignition.

5. Working with the air conditioner service station 49


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Connect air conditioner service station to service connections


as described in the user's manual for the vehicle ⇒ Rep. gr.
87 and bring into operation.

Note

♦ The possibility cannot be excluded that, along with the refrig‐


erant, refrigerant oil is extracted from the refrigerant circuit. In
order to ensure the lubrication of the air conditioner compres‐
sor, the refrigerant oil quantity should be topped up with fresh
oil ⇒ Rep. gr. 87 .
♦ On vehicles with air conditioner compressor and no magnetic
coupling (with air conditioner compressor regulating valve -
N280- ) the engine should only run for < 10 minutes with empty
refrigerant circuit and closed refrigerant circuit (the air condi‐
tioner compressor runs with it continually). The engine speed
must not exceed 2000 rpm.
♦ On vehicles with air conditioner compressor and magnetic
G. Volkswage
coupling, the engine may be started as the air
ksw
ageconditioning
nA n AG d
oes
system pressure switch - F129- or high-pressure sender -
ol not
y V gu
b ara
G65- (checks whether refrigerantoris
ise in the circuit) switches off
d
nte
the magnetic coupling as soonauas
t there is no refrigerant in the
h eo
ra
refrigerant circuit. ss c

ce
le
un

pt
an
d

5.4 Evacuating refrigerant circuit using air


itte

y li
erm

ab
conditioner service station

ility
ot p

wit
is n

• Always follow the procedure described in the user's manual

h re
ole,

for your air conditioner service station.

spec
urposes, in part or in wh

• The procedure described here is that for air conditioner service

t to the co
station - VAS 6007A- .
Before the refrigerant circuit is charged with refrigerant, it should
be evacuated (air empty) for 45 minutes for single evaporator rrectne
system and 60 minutes for 2 evaporator systems. In addition, all
moisture should be extracted from the circuit.
ss o
cial p

Leakage can be determined when evacuating the refrigerant cir‐


inform

cuit.
mer

atio
m

Evacuating:
o

n
c

i
or

n thi
te

sd

Caution
iva

o
pr

cum
r
fo

♦ The engine must not be started during the evacuation pro‐


en
ng

t.
yi Co
cedure and as long as there is a vacuum present in the Cop py
refrigerant circuit.
t. rig
gh ht
pyri by
Vo
co
♦ The air conditioner compressor may be damaged if the
by lksw
cted agen
engine is started when a vacuum is present in the refrig‐
Prote AG.

erant circuit.
♦ Only start engine when refrigerant circuits are charged.

– Switch off ignition.


– If necessary, check the refrigerant oil quantity in the refrigerant
circuit; see vehicle-specific repair manual ⇒ Rep. gr. 87 .
– Connect air conditioner service station to power supply.
– Check the refrigerant quantity in the air conditioner service
station.

50 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Connect the charging hose of the air conditioner service sta‐


tion to the vehicle refrigerant circuit using quick-release cou‐
pling adapters (see vehicle-specific refrigerant circuit).
⇒ Rep. gr. 87
– Turn the handwheel of the quick-release coupling adapter far
enough inwards to ensure that the valves on the service con‐
nections are open (do not overstress the valve).

Note

Where a vehicle has a service connection on only one side of the


refrigerant circuit, if the system pressure has to be measured after
charging, use the valve adapter and charging hose with valve
opener.

– Initiate the vacuum phase on the air conditioner service sta‐


tion. The refrigerant circuit will be evacuated automatically
(observe preset evacuation period).
olkswagen AG
en AG. V
When the vacuum phase has been completed, the leakageotest ksw
ag does
not
V l
of the refrigerant circuit will start. The displays show theed
bvacuum
y gu
ara
in bar and the time in seconds. ho
ris nte
eo
t
au ra
If the vacuum is not maintained, proceed as follows:
ss c

ce
e
nl

pt
– Initiate the vacuum phase on the air conditioner service station
du

an
itte

again. The refrigerant circuit will be evacuated automatically

y li
erm

ab
(observe preset evacuation period). Observe vacuum gauge

ility
ot p

for a longer period. Charging may be done only when vacuum

wit
is maintained.
, is n

h re
hole

♦ If a leak is present of a magnitude where air enters during the

spec
evacuation phase so that the air conditioner service station
es, in part or in w

t to the co
cannot create sufficient vacuum or the vacuum gauge indi‐
cates an ingress of air so that the vacuum collapses immedi‐
ately after switching off the air conditioner service station.

rrectness of i
– Search for the leak in the refrigerant circuit as follows:
l purpos

⇒ page 55

5.5 Charging refrigerant circuit using air

nform
ercia

conditioner service station


m

at
om

ion
c

in t
r

WARNING
o

his
ate

do
priv

High-voltage on high-voltage system. Danger of electric shock


um
for

on air conditioner compressor!


en
ng

t.
yi Co
op
Models with a high-voltage system: now de-energise the high-
C py
t. rig
gh
voltage system ⇒ Electric drive; Rep. gr. 93 ; De-energising
ht
pyri by
Vo
o
the high-voltage system .
c by lksw
cted agen
Prote AG.

• Always follow the procedure described in the user's manual


for your air conditioner service station.
• Before charging the refrigerant, check the refrigerant oil quan‐
tity ⇒ Rep. gr. 87 .
• The entire refrigerant charging quantity can be introduced ei‐
ther into the high-pressure or the low-pressure side.
Charging the refrigerant circuit
– Switch off ignition.
– Evacuating refrigerant circuit using air conditioner service sta‐
tion ⇒ page 50 .

5. Working with the air conditioner service station 51


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Turn handwheel of quick-release coupling adapters outwards


(close).
– Allow refrigerant to flow into charging hose.
– Turn handwheel of quick-release coupling adapter inwards (do
not overstress the valve) and charge system with prescribed
quantity of refrigerant.
– Switch off air conditioner service station.

Note

If the air conditioner compressor was removed, the V-belt pulley /


freewheel must be turned by hand approx. 10 times prior to initial
operation. This does not apply for the electrical air conditioner
compressor. This prevents any damage occurring from a fluid
hammer in the air conditioner compressor when the air condition‐
ing system is switched on for the first time. If there is oil in the
cylinder of the air conditioner compressor, it will be forced out by
the rotation.

– Start with engine with air conditioner compressor switched off


(if it is the type with a magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect "ECON" mode or "A/C Off" (if version without magnetic
clutch, but with regulating valve).
– Wait until idling speed has stabilised.
– Switch air conditioner compressor on and let system run for at
least 2 minutes with engine idling.
– If necessary, check pressures
swage
n AGin refrigerant
. Volkswagen AG
circuit
does using air
conditioner service
by
Vstation.
olk not
gu
ara
ed nte
ris
– Switch off engine.
tho u
e or
sa ac
– Turn out shandwheel on quick-release coupling adapter.
ce
e
nl

pt

– Detach the charging hose from the refrigerant circuit.


du

an
itte

y li
erm

– Screw on sealing caps again.


ab
ility
ot p

5.6 Bringing air conditioning system into


wit
, is n

h re

service after charging


hole

spec
es, in part or in w

t to the co

Note
rrectness of i

If the air conditioner compressor was removed, the V-belt pulley /


freewheel must be turned by hand approx. 10 times prior to initial
l purpos

operation. This prevents any damage occurring from a fluid ham‐


mer in the air conditioner compressor when the air conditioning
nf
ercia

system is switched on for the first time. If there is oil in the cylinder
o

of the air conditioner compressor, it will be forced out by the ro‐


rm
m

atio

tation.
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

52 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Start with engine with air conditioner compressor switched off


(if it is the type with a magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect "ECON" mode or "A/C Off" (if version without magnetic
clutch, but with regulating valve).
– Wait until idling speed has stabilised.
– Switch air conditioner compressor on and let system run foragat
en AG. V
olkswagen AG
does
least 2 minutes with engine idling. V olksw not
g by ua
ed ran
– If necessary, check pressures in refrigerant circuit
ris using air tee
conditioner service station. tho or
au ac
ss
– Switch off engine.

ce
e
nl

pt
du

an
itte
– Turn out handwheel on quick-release coupling adapter.

y li
erm

ab
– Detach the charging hose from the refrigerant circuit.

ility
ot p

wit
, is n

– Screw on sealing caps again.

h re
hole

spec
es, in part or in w

5.7 Charging container in air conditioner

t to the co
service station with refrigerant
• Always follow the procedure described in the user's manual

rrectness of i
for your air conditioner service station.
l purpos

• For every air conditioning system, a certain amount of refrig‐


erant is prescribed as the required charge To ensure that the

nf
ercia

system is neither overcharged nor undercharged with refrig‐

or
erant (both circumstances will impair the function of the air

m
m

atio
conditioning system), the refrigerant container is on a weigh‐
om

n in
ing machine.
or c

thi
te

sd
a

5.8 Draining air conditioner service station


iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
♦ If it becomes necessary to drain the air conditioner service
by c lksw
cted agen
station (e.g. because contaminated refrigerant was extracted),
Prote AG.

all filters and dryers are to be renewed as a rule. Do not take


the filters and dryers out of their airtight packaging until im‐
mediately prior to installation in order to keep moisture ab‐
sorption (hygroscopic property) as low as possible.
♦ Refrigerant bottles that have been charged with contaminated,
used refrigerant are referred to as “recycling bottles”.
♦ Recycling bottles must be evacuated as a rule before being
filled for the first time with refrigerant. Refrigerant bottles that
have air in them must not be filled with refrigerant.
♦ Different types of refrigerants must not be mixed with each
other. Mixed refrigerants cannot be processed for reuse. They
have to be disposed of. If the composition of the contents of
the bottle is uncertain, the refrigerant recycler must be in‐
formed of this.

5. Working with the air conditioner service station 53


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

WARNING

♦ When charging recycling bottles (compressed gas con‐


tainers), observe existing regulations, technical rules and
laws.
♦ Never overcharge recycling bottles. The gas cushion (ex‐
pansion space) of overcharged recycling bottles is too
small to accommodate expansion of the fluid caused by a
rise in temperature. There is a risk that the bottle will burst.
G. Volkswage
♦ For your own safety, use only recycling
lksw
agen bottles with aAbuilt-
A n Gd
oes
not
in safety release valve. d by Vo gu
a ran
ise
♦ Recycling bottles must ho be weighed on a calibrated scale
r tee
ut or
while being charged. ss The maximum permitted charge
a ac
quantity is 75% (fill factor 0.75) of the charge weight shown

ce
le
un

on the recycling bottle (the possibility cannot be excluded

pt
an
d
itte

that along with the refrigerant, refrigerant oil is drawn into

y li
erm

ab
the recycling bottle).

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

54 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

6 Detecting leaks in refrigerant circuit

Note

♦ Different processes are described in this workshop manual for


leak detection in the refrigerant circuit. These processes have
been tested and lead to a positive result under the different
conditions of use if the application is carried out correctly and
in accordance with the complaint. AG. Volkswagen A gen G do
swa es n
♦ When leak detection using compressed air/nitrogen
by
Vol
k or vac‐ ot g
ua
uum does not produce results, use electronic
ris
ed leak detector or ran
tee
UV leak detector additive. ut
ho
or
sa ac
♦ Small leaks can be detected with, for
s
example, an electronic

ce
e

leak detector or a UV leak detector lamp.


nl

pt
du

an
itte

y li
♦ A wide range of processes are offered on the open market for
erm

ab
finding leaks in refrigerant circuits. These processes do not

ility
ot p

always produce conclusive results. If they are not used pre‐

wit
, is n

cisely according to the specifications, they may even cause

h re
hole

components of the refrigerant circuit to develop leaks where

spec
there were none before. Furthermore, certain processes can
es, in part or in w

t to the co
cause preliminary or permanent damage to the components
of the refrigerant circuit
♦ Components that are found to be leaking must not be repaired.

rrectness of i
They have to be replaced with genuine parts.
l purpos

♦ A leaking refrigerant circuit must not be charged with refriger‐


ant, therefore evacuate an empty refrigerant circuit and check
for leaks before charging the system with refrigerant

nf
ercia

o
⇒ page 50 .

rm
m

atio
om

n in
or c

thi
Caution
te

sd
iva

o
r
rp

cu
♦ If there is evidence to suggest that chemical substances
o

m
f

en
ng

have been added in the vehicle to seal leaks, do not con‐


t.
yi Co
op
nect the air conditioner service station and do not extract C py
t. rig
the refrigerant.
gh ht
pyri by
Vo
co lksw
by
♦ Chemical substances used to seal leaks form deposits in cted agen
Prote AG.
the refrigerant circuit. These can impair the function of the
air conditioning system and cause the air conditioning
system (and your air conditioner service station) to fail.
♦ Make your customer aware of the fact that there are sub‐
stances in his/her air conditioning system that do not have
VW approval. This air conditioning system cannot be
drained or repaired by you.

6. Detecting leaks in refrigerant circuit 55


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Volkswagen rejects the use of chemical substances for pur‐


poses of sealing leaks in refrigerant circuits.
♦ Chemical substances used for sealing leaks in refrigerant cir‐
cuits often react with the surrounding air and the humidity
contained within. They cause deposits to build up in the re‐
frigerant circuit (and your air conditioner service station),
valves to malfunction and defects in other components with
which they come into contact. These deposits cannot be com‐
pletely removed from the components (not even by purging).
♦ It is often not possible to detect from the outside whether
chemical substances have been used to seal leaks in the re‐
frigerant circuit. The adhesive label that serves to identify its
use can usually not be found. Therefore, exercise caution
when working on vehicles for which you have no service or
repair record.
♦ Containers or tanks are offered as accessories on the open
market that are designed to separate these chemical substan‐
ces (to seal leaks). Since Volkswagen rejects the use of these
substances, no statement can be made at this point regarding
the effectiveness and separation rate of these filters.
G. Volkswagen nA AG do
wage es n
Volks ot g
6.1 Leak detection in refrigerant circuit us‐ ris
ed
by ua
ran
tee
ing compressed air or nitrogen tho
or
s au ac
s ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

56 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ A leak in the refrigerant circuit can be detected, for example,


by pressurising the circuit to a maximum of 15 bar using
cleaned and dried compressed air or nitrogen ⇒ page 65 . If
the leak is large, the leakage point can be detected by sound
as the air or gas escapes.
♦ Introduce the compressed air or the nitrogen through the serv‐
ice connection.
♦ The quick-release coupling adapter for service connection can
be fitted with a modified charging hose -A- (e.g. with a 5/8"-18
UNF thread, depending on the thread of the quick-release
coupling adapter) and a suitable adapter -B- to connect to the
workshop compressed air system ⇒ page 174 . To ensure no
moisture, oil or other contaminants can enter the refrigerant
circuit from the workshop compressed air system, use, for ex‐
ample, a supplementary combination fine filter element with
an oil, dirt and water separator as normally used in paint
shops. Install it between the compressed air system and the
charging hose -A- ⇒ Workshop equipment catalogue .
♦ Using the manifold gauge with pressure reducer for nitrogen
(maximum reduced pressure: 15 bar) -1- you can connect a
full nitrogen gas cylinder -3- via a charging hose -2- (e.g. with
5/8"-18 UNF threaded connection) to the service connection,
to which a quick-release coupling adapter is connected, of a
closed refrigerant circuit. ⇒ page 174

– Slowly increase pressure in refrigerant circuit to a maximum


of 15 bar.

AG. Volkswagen AG d
WARNING
agen oes
olksw not
byV gu
ara
d
♦ Maximum permissible
orise working pressure: 15 bar nte
eo
h
ut ra
♦ When searching
ss a for leaks using nitrogen, work only with a c
pressure reducer for nitrogen cylinders.
ce
e
nl

pt
du

an
itte

y li
erm

ab

– Search for leak by sound, which is created by the escaping


ility
ot p

gas. Use Ultrasonic tester - V.A.G 1842- to ease localisation


wit
, is n

of sounds.
h re
hole

spec

– Press nitrogen out of refrigerant circuit using cleaned and


es, in part or in w

dried compressed air. Nitrogen must not enter the service cyl‐
t to the co

inder. This prevents the service cylinder from being filled with
condensable gases.
rrectness of i

– Rectify leak.
l purpos

– Evacuate again and observe the vacuum display over a period


of hours. Charging may be done only when vacuum is main‐
tained.
nform
ercia

♦ If a leak is present of a size where no or very little air is drawn


m

at

in and the air conditioner service station can create sufficient


om

ion

vacuum. The vacuum gauge does not increase or increases


c

in t
or

very slowly after switching the air conditioner service station


his
ate

off, this indicates there may be a very small ingress of air and
do
priv

the vacuum is lost.


um
for

en
ng

t.
yi
– Charge circuit with 100 g of refrigerant and search for the pos‐
Co
op py
sible leak using an electronic leak tester and rectify fault as
. C rig
ht ht
rig
necessary ⇒ page 58 or add an approved UV contrast sub‐ py by
co Vo
stance to the refrigerant and search for the possible leak in the
by lksw
cted agen
Prote
circuit using leak detector system VAS 6201 or later model and
AG.

rectify fault as necessary ⇒ page 59 .

6. Detecting leaks in refrigerant circuit 57


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Evacuating refrigerant circuit if necessary ⇒ page 49


– Evacuate refrigerant circuit and observe the vacuum gauge
over a period of hours. Charging may be done only when vac‐
uum is maintained.

6.2 Searching for leaks in refrigerant circuits


using leak detector - V.A.G 1796- AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Note horis nte
eo
aut ra
s c
Small leaks can be detected with, for example, an electronic leak s

ce
e
nl
detector.

pt
du

an
itte

y li
erm

ab
– Evacuate refrigerant circuit using an air conditioner service

ility
ot p

station ⇒ page 50 .

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
♦ If a larger leak is detected during the evacuation process, de‐
termine cause and rectify as described ⇒ page 50 .

rrectness of i
♦ If during the evacuation process no leak is detected or a very
l purpos

small leak is detected that but cannot be located, proceed as


follows ⇒ page 56 .

nform
ercia

♦ Refrigerant gas is quickly dispersed by air motion. Therefore


drafts must be avoided during a search for leaks.
m

at
om

io
♦ If the refrigerant circuit is completely empty, charge with about

n
c

in t
r

10% of refrigerant capacity (sticker R134a or vehicle-specific


o

his
te

workshop manual).
a

do
priv

cum
for

en
g

Leak detection:
n

t.
yi Co
op py
– Prepare leak detector for operation according to its operating
t. C rig
gh ht
yri
instructions. p by
o Vo
by c lksw
cted agen
– Always hold probe tip under location of suspected leak. Prote AG.

If the rate of clicks rises or a howl occurs, depending on model, a


leak has been found (see operating instructions for leak detector).

58 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

6.3 Detecting leaks in refrigerant circuit us‐


ing leak detecting system - VAS 6196-
or leak detecting system - VAS 6201- or
a later model

Note

Small leaks can be detected with, for example, an UV leak de‐


tector additive.

– Evacuate refrigerant circuit using an air conditioner service


station ⇒ page 50 .

Note

♦ If a larger leak is detected during the evacuation process, de‐


termine cause and rectify as described ⇒ page 50 .
♦ If during the evacuation process no leak is detected or a very
small leak is detected that but cannot be located, proceed as
follows ⇒ page 56 .
♦ Refrigerant gas is quickly dispersed by air motion. Therefore
drafts must be avoided during a search for leaks.
♦ If the refrigerant circuit is completely empty, charge with about
10% of refrigerant capacity (sticker R134a or vehicle-specific
workshop manual).
AG. Volkswagen AG d
agen oes
Leak detecting system - VAS 6196- Volksw not
gu
by ara
d
or orise nte
eo
th
au ra
ss c
Leak detecting system - VAS 6201- or later model
ce
le
un

pt
an
1- Hand pump with low-pressure service hose, service cou‐
d
itte

y li

pling and non-return valve - VAS 6201/1-


erm

ab
ility
ot p

2- Cartridge - VAS 6201/2-


wit
is n

h re

3- Cleaning solution - VAS 6201/3-


ole,

spec
urposes, in part or in wh

4- UV leakage detector lamp - VAS 6201/4-


t to the co

5- UV absorbing eye protection - VAS 6201/6-


6- Label - VAS 6201/7-
rrectne

7- Tube
VAS 6201/8
ss o
cial p

8- Protective gloves - VAS 6201/9-


inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6. Detecting leaks in refrigerant circuit 59


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Injecting leak detecting additive to an empty refrigerant circuit


olkswagen AG
en AG. V
The cartridge -A- contains 15.4 ml of leak detecting additive (oneolkswag does
not
unit -B- equates to 2.5 ml). ed
by
V gu
ara
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Assemble hand pump - VAS 6201- item -1- and cartridge item
-2- -VAS 6201/2- .
– Connect filler hose - VAS 6201/8- ( ⇒ page 59 item -7-) to hand

rrectness of i
pump.
l purpos

– Open service valve of hand pump.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

60 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

The leak detecting additive can be injected into the empty refrig‐
erant circuit via an open circuit connection.
– Open an easily assessable connection in the refrigerant cir‐
cuit.
– Cover area of connection with foil or absorbent paper.
– Hold tube upwards
– Turn T-bar of hand pump until the leak detecting additive flows
out of the tube.
– Inject 2.5 ± 0.5 ml (millilitre = cm3) of leak detecting additive
into the refrigerant circuit.

Note

Note the following, if a leak detecting additive has been ninjectedAG. Volkswagen AG d
during a previous repair of the refrigerant circuit, oonlylksw inject new
age oes
not
leak detecting additive if the refrigerant machined by oil has been re‐
V gu
ara
placed. If only some of the refrigerant machine
orise oil was replaced nte
eo
then only the respective amount of leakaudetecting
th additive should ra
be injected. If for example 100 ml of machine
ss oil was replaced on c

ce
a vehicle with 250 ml of refrigerant machine oil, inject only 1 ml
e
nl

pt
du

(cm3) of leak detecting additive.

an
itte

y li
erm

ab
ility
ot p

– Renew O-rings at opened connection.

wit
, is n

h re
– Reassemble refrigerant circuit again.
hole

spec
– Attach a label, close to the service connection, which has in‐
es, in part or in w

formation showing that the refrigerant circuit has been injected

t to the co
with a leak detecting additive.
– Evacuate and fill the refrigerant circuit as per specifications

rrectness of i
⇒ page 51 and ⇒ page 50 .
l purpos

– Start air conditioning system.

nf
ercia

o
Note
rm
m

atio
om

n in

The air conditioning system must be operated for at least 60 mi‐


or c

thi

nutes to ensure that the injected leak detecting additive is distrib‐


te

sd
a

uted throughout the entire refrigerant circuit (air conditioner


iv

o
r
rp

cu

compressor must run). The leak may become visible after a short
o

m
f

en

period, but this depends on the size of the leak.


ng

t.
yi Co
Cop py
t. rig
gh
– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
ht
pyri by
Vo
erant circuit ⇒ page 63 .
o
by c lksw
cted agen
Prote AG.

Note

Using cleaning solution - VAS 6201/3- , clean the engine com‐


partment and, if necessary, the components of the refrigerant
circuit, to remove leak detection additive residue left from the re‐
pair work.

6. Detecting leaks in refrigerant circuit 61


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Injecting leak detecting additive to a charged refrigerant circuit

Note

♦ Note the following, if a leak detecting additive has been injec‐


ted during a previous repair of the refrigerant circuit, only inject
new leak detecting additive if the refrigerant machine oil has
been replaced. If only some of the refrigerant machine oil was
replaced then only the respective amount of leak detecting
additive should be injected. If for example 100 ml of machine
oil was replaced on a vehicle with 250 ml of refrigerant ma‐
chine oil, inject only 1 ml (cm3) of leak detecting additive.
♦ A small amount of leak detecting additive remains in the serv‐
ice connection. Carefully remove the remains as this will help
to prevent these remains being falsely identified as a leak
when leak detection is carried out in the future.

The cartridge -A- contains 15.4 ml of leak detecting additive (one


unit -B- equates to 2.5 ml).

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re

– Switch off ignition.


hole

spec

– Remove sealing cap from service connection on the low-pres‐


es, in part or in w

t to the co

sure side of the refrigerant circuit.


– Assemble hand pump - VAS 6201- item -1- and cartridge item
-2- -VAS 6201/2- .
rrectness of i
l purpos

Note
nform
ercia

Ensure the hose of the hand pump is completely filled with leak
detecting additive.
m

at
om

ion
c

in t
or

– Fit the quick release coupling to the service connection of the


his
ate

low-pressure side and open the service coupling by turning the


do
riv

hand wheel. Hold hose upwards and turn T-bar of hand pump
p

cum
for

until the leak detecting additive starts to flow out of the tube.
en
ng

t.
yi Co
Cop py
t. rig
– Cover area of service connection on vehicle with foil or ab‐ gh ht
yri by
sorbent paper. cop Vo
by lksw
cted agen
Prote AG.
– Turn T-bar of hand pump and inject 2.5 ± 0.5 ml (millilitre =
cm3) of leak detecting additive into the refrigerant circuit.

62 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Close the service coupling and remove it from the service


connection.
– Remove the remains of the leak detecting additive from the
service connection, with for example, absorbent paper.
– Seal service connection using the sealing cap.
– If necessary, clean the area of the service connection using
the cleaning solution. n AG. Volkswagen A ge G do
swa es n
– Attach a label, close to the service connection, y Vwhich has in‐
olk ot g
ua
formation showing that the refrigerant circuit ed b been injected
has ran
ris tee
with a leak detecting additive. ut
ho or
a ac
ss
– Start air conditioning system.

ce
le
un

pt
an
d
itte

y li
erm

ab
Note

ility
ot p

wit
is n

The air conditioning system must be operated for at least 60 mi‐

h re
ole,

nutes to ensure that the injected leak detecting additive is distrib‐

spec
uted throughout the entire refrigerant circuit (air conditioner
urposes, in part or in wh

compressor must run). The leak may become visible after a short

t to the co
period, but this depends on the size of the leak.

rrectne
– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
erant circuit ⇒ page 63 .

ss o
cial p

f i
Note

nform
mer

atio
Using cleaning solution - VAS 6201/3- , clean the engine com‐
om

n
partment and, if necessary, the components of the refrigerant
c

i
or

n
circuit, to remove leak detection additive residue left from the re‐

thi
te

sd
a

pair work.
iv

o
pr

cum
r
fo

en
ng

Searching for leaks in the refrigerant circuit using UV lamp VAS


t.
yi Co
op
6196/4 C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
WARNING cted agen
Prote AG.

Do not look into the UV lamp.


Do not point the UV lamp at another person.

6. Detecting leaks in refrigerant circuit 63


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ The air conditioning system must be operated for at least


60 minutes to ensure that the injected leak detecting additive
is distributed throughout the entire refrigerant circuit (air con‐
ditioner compressor must run). The leak may become visible
after a short period, but this depends on the size of the leak.
♦ For leaks on the evaporator, the additive can wash off with the
condensed water and leak out from the condensed water
drain-off. As the evaporator is not accessible on the majority
of models without a great amount of pre-preparation, a check
of the condensed water drain point can indicate a leaking
evaporator. The additive must have been in the refrigerant cir‐
cuit for a long time to make this possible.
♦ The eye protect is not only required to protect the eyes, it also
amplifies the illumination of the additive under the UV lamp.
♦ Independent of the accessibility to the various components of
the refrigerant circuit, it may become necessary to remove
certain components from the vehicle (e.g. bumper or air filter).

– Position the vehicle in a darker area of the workshop (in day‐


light or under strong lighting the effect of the UV lamp is greatly
AG. Volkswagen AG d
reduced). lkswagen oes
n o ot g
yV ua
– Check the accessibility to ithe ed various components of the re‐
b ran
rs
frigerant circuit and removetho components in the vicinity of the tee
or
au
refrigerant circuit thatssobstruct the view of the respective circuit ac
components (e.g. sound insulation and bumper).
ce
e
nl

pt
du

an

– Protect eyes with protective glasses.


itte

y li
erm

ab

– Connect UV lamp to a 12 V battery (vehicle battery). Ensure


ility
ot p

that it is connected to the correct terminals.


wit
, is n

h re

– Switch on UV lamp and illuminate components of the refriger‐


hole

spec

ant circuit. Locations where leaking refrigerant along with


es, in part or in w

refrigerant oil and leak detecting additive can leak out, light-up
t to the co

(fluorinate) under UV light.


rrectness of i

Note
l purpos

♦ The leak detection additive can be allowed to remain in the


refrigerant circuit.
nf
ercia

or

♦ Using cleaning solution - VAS 6201/3- , clean the engine com‐


m
m

atio

partment and, if necessary, the components of the refrigerant


om

n in

circuit, to remove leak detection additive residue left from the


or c

thi

repair work.
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

64 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

7 Clearing refrigerant circuit of contam‐


inants

7.1 Blowing through refrigerant circuit with


compressed air and nitrogen
• Use compressed air to force moisture and other contaminants
out of the refrigerant circuit and use nitrogen to force moisture
out of the refrigerant circuit.
• The method of blowing through the refrigerant circuit with
compressed air and nitrogen often requires a lot more work
than purging with refrigerant R134a. When purging with re‐
frigerant R134a, cleaning of the components is considerably
better. It is therefore always best to purge the system in the
event of complaints (the method of blowing through should
only be selected for certain complaints and for individual com‐
ponents).
Only individual components are to be blown through if:
♦ There is no way of purging the refrigerant circuit with refriger‐
ant R134a.
♦ If there is dirt or contamination in individual components of the
refrigerant circuit.
♦ If during evacuation of a leak-tight refrigerant circuit the vac‐
uum display is not constant on gauge (moisture in the refrig‐
erant circuit, which generates vapour wpressure).
agen
AG. Volkswagen AG d
oes
ks not
Vol gu
♦ If the refrigerant circuit has been d b left open for longer than nor‐
y ara
se nte
mally required for repairs (e.g.
tho
ri following an accident) eo
au ra
♦ Pressure and temperaturess measurements in the circuit indi‐ c
ce
le

cate that there is moisture in the refrigerant circuit.


un

pt
an
d
itte

♦ The vehicle-specific repair manual ⇒ Heating, air conditioning


y li
erm

ab

deems it necessary after replacement of certain components.


ility
ot p

wit
is n

h re
ole,

Note
spec
urposes, in part or in wh

t to the co

♦ Blowing through the refrigerant circuit with compressed air and


nitrogen will not achieve the same degree of cleanliness as
purging with refrigerant R134a. When purging with refrigerant
rrectne

R134a, the refrigerant oil is shifted and cleaning of the com‐


ponents is better ⇒ page 67 .
s

♦ When blowing through, a maximum working pressure of 15 bar


s o
cial p

must not be exceeded (if necessary, use pressure limiter for


f in

compressed air as well).


form
mer

atio
om

n
c

i
or

WARNING
thi
te

sd
iva

o
r

♦ Nitrogen can escape from the bottle in an uncontrolled


p

cum
r
fo

way.
en
ng

t.
yi Co
op
♦ Work only with pressure regulator for nitrogen bottles
C py
t. rig
gh
(max. working pressure 15 bar).
ht
pyri by
Vo
co lksw
by
♦ The gas mixture escaping from the components must be
cted agen
Prote AG.
collected with appropriate extraction equipment.

7. Clearing refrigerant circuit of contaminants 65


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Always blow through components opposite the direction of re‐


frigerant flow.
Compressed air and nitrogen cannot be blown through the re‐
strictor, expansion valve, air conditioner compressor, receiver or
reservoir.
– In cases where condensers have a drying agent cartridge in
the integrated receiver, this drying agent cartridge must be re‐
moved.
– First blow out soiling using compressed air and then dry com‐
ponents with nitrogen.
– Fit adapter for connection of pressure hose to refrigerant cir‐
cuit ⇒ page 86 and ⇒ Heating, air conditioning .
To prevent oil and moisture from the compressed air system
making its way into the refrigerant circuit, the following points must
be observed.
♦ The compressed air must be fed through a compressed air
cleaning unit to clean and dry it. Therefore, use compressed
air filter and dryer (included in items supplied with tools for
painting work) ⇒ Workshop equipment and Special tools cata‐
logue .
AG. Volkswagen AG d
♦ If refrigerant pipes have threads or union nuts at connections, lkswagen oes
not
use adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- tod by Vo gu
ara
connect to 5/8" - 18 UNF charging hose. These adapters ris can
e nte
tho
be found in the adapter case for VW/Audi passengerauvehicle eo
ra
set - VAS 6338/1- and adapter case for commercial ss vehicle c
set - VAS 6338/50- .

ce
e
nl

pt
du

an
itte

♦ On refrigerant pipes without thread or union nut on the con‐

y li
erm

ab
nection, use adapter from adapter case for VW/Audi passen‐

ility
ot p

ger vehicle set - VAS 6338/1- or adapter case for commercial

wit
, is n

vehicle set - VAS 6338/50- or proprietary air gun with rubber

h re
nozzle.
hole

spec
es, in part or in w

t to the co
Note

♦ Always extract any escaping air and/or nitrogen from the com‐

rrectness of i
ponents using appropriate local exhaust ventilation LEV (e.g.
l purpos

workshop extraction system).


♦ Certain contaminants and old refrigerant oil cannot be shifted
nf
ercia

from the refrigerant circuit at all with compressed air or if the or


compressed air is insufficient. These contaminants can only
m
m

atio

be removed by purging with refrigerant R134a ⇒ page 67 .


om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

66 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

7.1.1 Blowing out refrigerant circuit

Note

♦ On vehicles where no adapters fit the refrigerant pipes, blow


through individual components using an air gun, for example,
with rubber nozzle. When doing this, be particularly careful not
to damage the connections (do not crush or scratch them).
♦ The evaporator should be blown through from the connection
to the low-pressure side (large diameter), with the expansion
valve or restrictor removed.
♦ Always blow through components opposite the direction of re‐
frigerant flow.
♦ Examine the expansion valve; renew if dirty or corroded.
AG. Volkswagen
♦ If components bear dark, sticky deposits
lksw which cannot be re‐ es n
agen AG do
moved with compressed air, renew db
y Vthese components.
o ot g
ua
ran
rise tee
♦ Thin, light grey deposits onutthe
ho insides of refrigerant pipes do or
not impair the function ofssthe
a components. ac

ce
le

♦ After blowing out the system, always renew the receiver or


un

pt
an
d

reservoir and the restrictor. If the condenser has a dryer, re‐


itte

y li
new the dryer cartridge or dryer.
erm

ab
ility
ot p

wit
is n

7.2 Purging (cleaning) refrigerant circuit

h re
ole,

with refrigerant R134a

spec
urposes, in part or in wh

t to the co
Vehicles with high-voltage system (hybrid vehicles)
Observe the additional warning instructions for working on vehi‐

rrectne
cles with high-voltage system ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .
ss o
cial p

f in

WARNING
form
mer

atio
m

Risk of injury due to unexpected engine start


o

n
c

i
or

n thi

When working on a high-voltage vehicle, switch off the ignition,


te

sd
a

and deposit the ignition key somewhere outside the passenger


iv

o
pr

compartment.
um
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
WARNING
co Vo
by lksw
cted agen
Prote AG.

Handling high-voltage cables:


• Do not support yourself or your tools on high-voltage ca‐
bles and their components --> risk of damage to the insu‐
lation.
• High-voltage cables must not be extensively bent or
kinked --> risk of damage to the insulation.
• The round high-voltage connectors are colour-coded with
a coloured ring on the outside and mechanically coded
with respective guide lugs. Always observe the coding
when connecting the round high-voltage connectors in or‐
der to prevent any mechanical damage to the high-voltage
connectors.

7. Clearing refrigerant circuit of contaminants 67


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

DANGER!

Hazardous voltage resulting from damaged high-voltage com‐


ponents
Observe the following when working in the vicinity of high-volt‐
age components and cables:
♦ Work involving metal-removing, deforming and sharp-
edged tools or heat sources such as welding, soldering,
hot air and thermal bonding is not permitted.
♦ Before starting work, carry out a visual check on the high-
voltage components in the area of work.
♦ When working in the engine compartment, carry out a vis‐
ual check on the power and control electronics for electric
drive - JX1- , the electric drive motor - V141- , the air con‐
ditioner compressor - V470- and the high-voltage cables.
♦ When working on the underbody, carry out a visual check
on the high-voltage cables and covers.
♦ When working on the rear end, carry out a visual check on
the high-voltage cables and the maintenance connector
for high-voltage system - TW - .
♦ Carry out a visual check on all potential equalisation lines.
When carrying out the visual check, observe the following:
♦ The high-voltage components must not reveal any exter‐
nal damage.
♦ The insulation of the high-voltage cables and the potential
n AG. Volkswagen AG do
equalisation lines must not be damaged. olkswage es n
o V t gu
by
♦ The high-voltage cables must not show any unusual
ris
ed de‐ ara
nte
formations. utho eo
ra
sa c
♦ Each high-voltage component must be clearly
s
identified
ce
e
nl

with a red warning sticker. pt


du

an
itte

y li
erm

ab
ility
ot p

If repair work in the vicinity of high-voltage components and ca‐ wit


, is n

bles is necessary, “carry out a visual check for damage on high-


h re

voltage components and cables”, and “observe the general


hole

spec

warning instructions for work on the high-voltage system” ⇒ Elec‐


es, in part or in w

trical system; Rep. gr. 93 ; General warning instructions for work


t to the co

on the high-voltage system .


If repair work on high-voltage components is necessary, de-en‐
rrectness of i

ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;


De-energising high-voltage system , and “observe the general
l purpos

warning instructions for work on the high-voltage system” ⇒ Elec‐


trical system; Rep. gr. 93 ; General warning instructions for work
on the high-voltage system .
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

68 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Caution

♦ If there is evidence to suggest that chemical substances


have been added in the vehicle to seal leaks, do not con‐
nect the air conditioner service station and do not extract
the refrigerant.
♦ Chemical substances used to seal leaks form deposits in
the refrigerant circuit. These can impair the function of the
air conditioning system and cause the air conditioning
system (and your air conditioner service station) to fail.
♦ Make your customer aware of the fact that there are sub‐
stances in his/her air conditioning system that do not have
VW approval and therefore the refrigerant circuit cannot
be purged. The refrigerant circuit can only be repaired by
replacing all components that have come into contact with
this substance.

Note

♦ Volkswagen rejects the use of chemical substances for pur‐ .V olkswagen AG


gen AG does
swa
poses of sealing leaks in refrigerant circuits. y Vol
k not
gu
db ara
ise nte
♦ Chemical substances used for sealing leaks inthrefrigerant cir‐
or eo
cuits often react with the surrounding air and
ss
authe humidity ra
c
contained within. They cause deposits to build up in the re‐

ce
e
nl

frigerant circuit (and your air conditioner service station),

pt
du

an
valves to malfunction and defects in other components with
itte

y li
erm

which they come into contact. These deposits cannot be com‐

ab
ility
pletely removed from the components (not even by purging).
ot p

wit
The refrigerant circuit can only be repaired by replacing all
, is n

h re
components that have come into contact with this substance.
hole

spec
♦ It is often not possible to detect from the outside whether
es, in part or in w

t to the co
chemical substances have been used to seal leaks in the re‐
frigerant circuit. The adhesive label that serves to identify its
use can usually not be found. Therefore, exercise caution on
vehicles for which you have no service or repair record.

rrectness of i
l purpos

• To work as cleanly as possible and avoid the task becoming


labour intensive when removing contaminants (e.g. friction
nf
ercia

dust and particles from defective air conditioner compressor) or


and old refrigerant oil, the refrigerant circuit must be purged
m
m

atio

using refrigerant R134a.


om

n in
or c

On vehicles with electrical air conditioner compressor, observe


thi
e

the notes on renewing the electrical air conditioner compressor -


t

sd
iva

V470-. If the electronics of the air conditioner compressor are


r
rp

cu
o

damaged, the refrigerant circuit must not always be cleaned


f

en
ng

t.
⇒ page 161 .
yi Co
Cop py
t. rig
The refrigerant circuit must be purged with refrigerant R134a if: gh ht
pyri by
Vo
co lksw
by
♦ Dirt or other contaminants are in the refrigerant circuit. Prote
cted AG.
agen

♦ If during evacuation of a leak-tight refrigerant circuit the vac‐


uum display is not constant on gauge (moisture in the refrig‐
erant circuit, which generates vapour pressure).
♦ If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
♦ Pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the refrigerant circuit.
♦ There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit. If the air conditioner compressor is to be reinstal‐
led, drain refrigerant oil out of air conditioner compressor via

7. Clearing refrigerant circuit of contaminants 69


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

the drain plug. To facilitate this process, turn the air conditioner
compressor over by hand at the poly V-belt pulley or coupling
disc of the magnetic coupling. After purging, fill refrigerant cir‐
cuit with total amount of refrigerant oil (50 g direct into air
conditioner compressor) according to ⇒ vehicle-specific work‐
shop manual . Observe additional oil requirements for systems wagen AG. Volkswagen AG doe
with second evaporator. yV
olks s no
t gu
b ara
ed
♦ The air conditioner compressor has to be exchanged hbecause
or
is nte
e
of internal damage (e.g. noisy or no output). s aut or
ac
s
♦ the vehicle-specific repair manual deems it necessary after

ce
e
nl

pt
du
replacement of certain components.

an
itte

y li
erm

ab
♦ a different air conditioner compressor with other refrigerant oil

ility
ot p
is to be fitted.

wit
, is n

h re
Tools required
hole

spec
♦ Air conditioner service station with purging device - VAS 6381-
es, in part or in w

t to the co
or air conditioner service station with purging device - VAS
6337- . These air conditioner service stations feature an ad‐
ditional function for “purging the refrigerant circuit with R134a”
and the purging device for refrigerant circuits necessary for

rrectness of i
this procedure ⇒ Workshop equipment and special tools cata‐
l purpos

logue .
♦ Adapter case VW/Audi passenger vehicle set - VAS 6338/1-

nform
ercia

⇒ page 86 and ⇒ Workshop equipment and special tools


catalogue .
m

at
om

io
♦ Adapter case commercial vehicle set - VAS 6338/50-

n
c

in t
or

⇒ page 86 and ⇒ Workshop equipment and special tools

his
te

catalogue .
a

do
priv

cum
for

en
ng

t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
♦ If the above mentioned air conditioner service stations are not
op Vo
by c lksw
available in the workshop, purging device for refrigerant cir‐ cted agen
Prote AG.
cuits - VAS 6336/1- or purging device for refrigerant circuits -
VAS 6337/1- can be used to purge the refrigerant circuit,
depending on the type of air conditioner service station in
service (min. 7 kg refrigerant R134a in refrigerant bottle). The
purging process must then be carried out manually
⇒ page 75 .
♦ On vehicles with threaded connections on the refrigerant cir‐
cuit, adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- from
adapter case VW/Audi passenger vehicle set - VAS 6338/1-
or adapter case commercial vehicle set - VAS 6338/50- can
be used. On vehicles with threaded connections on the air
conditioner compressor and on the reservoir, the adapter -
V.A.G 1785/8- is required two-fold.
♦ In the adapter case there is also a charging hose - VAS
6338/31- with 5/8 - 18 UNF connections and large internal di‐
ameter to bridge components (commercially available type).

Preliminary measures
– Drain refrigerant circuit ⇒ page 49 .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing .
On vehicles with restrictor and reservoir.
– Remove restrictor (vehicle-specific) and join the refrigerant
lines together again ⇒ Heating, air conditioning .
– Remove reservoir (vehicle-specific) ⇒ Heating, air condition‐
ing and join refrigerant pipes together again (to do this, use

70 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

adapter and charging hose - VAS 6338/31- from adapter case


VW/Audi passenger vehicle set - VAS 6338/1- )
⇒ page 86 .

Note

The collector could be purged but due to its large inner volume it
would require too much refrigerant. During extraction, the refrig‐
erant ices up the reservoir heavily and the extraction procedure
takes much longer as a result.

On vehicles with expansion valve and receiver.


– Remove the receiver ⇒ Heating, air conditioning (vehicle-
specific, not necessary on all vehicles) and join the refrigerant
lines together (use the adapter and the charging hose - VAS
6338/31- to do this) ⇒ page 86 .
– Remove the expansion valve ⇒ Heating, air conditioning (ve‐
hicle-specific) and insert an adapter in its place ⇒ page 86 .

Note

If there is not a suitable adapter for the expansion valve in the


adapter case VW/Audi passenger vehicle set - VAS 6338/1- or
adapter case commercial vehicle set - VAS 6338/50- , the re‐
moved expansion valve can also be drilled out (the old expansion
valve must be subsequently renewed).

Caution

♦ When drilling out, ensure that the sealing surfaces on the


expansion valve are not damaged.
♦ Refrigerant would otherwise escape.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

71
co Vo
by lksw
7. Clearing refrigerant circuit of contaminants
cted agen
Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Before drilling out, some parts have to be removed from the


expansion valve.
♦ There are two types of expansion valve. For type -A-, parts
-B-, -C- and -D- must be removed. Separate regulator -E- from
component -D-. Then drill through expansion valve in area
-F- using a suitable 6 mm drill.
♦ On version -G-, parts -H-, -I- and -K- must be removed and
then area -L- drilled out withGa. Vsuitably
olkswagensized drill bit (6 mm in
diameter). lksw
agen
A AG do
es n
o ot g
yV
♦ Clean away iany
se swarf from the drilled out expansionranvalve.
db a u
r tee
tho
♦ Reinstall
sa
uparts -B-, -C- and -D- on type -A- or part -H- onotype
ra
c
-G-. s

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

h re
On vehicles with two evaporators, the circuit to the second evap‐
hole

orator must be isolated from the circuit to the first evaporator and
spec
purged in a separate procedure ⇒ Heating, air conditioning and
es, in part or in w

t to the co
⇒ page 86 .

Drill open shut-off valve.


rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

72 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Two shut-off valves are required for purging the refrigerant


circuit. A shut-off valve must be drilled open, ifAno
G. Vshut-off
olkswagentap
AG do
agen
- VAS 6338/42- is available, for example.
Volksw es n
ot
y gu
db ara
♦ Remove the solenoid -A- and othe
ris solenoid valve -B- before
e nte
drilling open the shut-off valve.
au
th eo
ra
ss c
♦ Drill open the shut-off valve -C- using a suitable drill bit (e.g.

ce
e
nl

pt
5 mm in diameter).
du

an
itte

y li
♦ Remove any metal shavings resulting from drilling hole -D-
erm

ab
ility
from shut-off valve -C-.
ot p

wit
, is n

♦ Reinstall the solenoid valve -B- with the respective seal -E- to

h re
hole

the shut-off valve -C- which has been drilled open.

spec
es, in part or in w

t to the co
Purging
– Check the refrigerant volume in the air conditioning bottle.

rrectness of i
There must be at least 7 kg of R134a refrigerant.
l purpos

Note

nf
ercia

o
Switch on the heater attached to the refrigerant bottle 30 minutes

rm
m

atio
before the first purging process, if necessary. In this way, pres‐
om

sure in the refrigerant bottle is increased and charging of the

n in
or c

purging circuit is accelerated.

thi
te

sd
iva

o
r
rp

cu
– Drain the waste oil container of the air conditioner service sta‐
o

m
f

en
ng

tion.
t.
yi Co
Cop py
– Connect the supply hose (high-pressure side) of the air con‐
t. rig
gh ht
yri
ditioner service station with an adapter ⇒ page 86 to the low-
p by
o Vo
by c lksw
pressure line leading to the air conditioner compressor (line Prote
cted AG.
agen
with larger diameter).
– Connect the return hose (low-pressure or suction side) of the
air conditioner service station to the outlet of the purging de‐
vice for refrigerant circuits.
– Connect the inlet of the purging device for refrigerant circuits
with an adapter ⇒ page 86 to the high-pressure line leading
to the air conditioner compressor (line with smaller diameter).

7. Clearing refrigerant circuit of contaminants 73


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

AG. Volkswagen AG d
agen oes
Note y Volksw not
gu
d b ara
rise nte
♦ The components must always be ut purged against the direction
ho eo
ra
of refrigerant flow when the air
ss a
conditioning system is in oper‐ c
ation (not applicable for electrical air conditioner compressor)

ce
le
un

pt
⇒ page 77 .

an
d
itte

y li
erm

♦ When purging, contaminants from the refrigerant circuit enter

ab
ility
the purging device for refrigerant circuits and the air condi‐
ot p

wit
tioner service station and are retained in the filters and dryers
is n

h re
installed within. Depending on the contaminants, these com‐
ole,

spec
ponents must be changed at shorter intervals in accordance
urposes, in part or in wh

with the operating instructions for the air conditioner service

t to the co
station or purging device for refrigerant circuits.
♦ The filter in the purging device for refrigerant circuits should

rrectne
be changed after about 2 purging cycles (purged vehicles),
depending on the level of contamination from the purged re‐
frigerant circuits. If a heavily contaminated refrigerant circuit is

ss
purged (the refrigerant oil from the refrigerant circuit is black

o
cial p

f
and viscous or there are large amounts of shavings in the re‐

inform
frigerant circuit) renew filter after purging refrigerant circuit.
mer

After such heavy contamination of the refrigerant circuit, we

atio
m

suggest purging the system again after changing the filter.


o

n
c

i
or

n thi
♦ Depending on the type of contamination, deposits (old refrig‐
te

sd
a

erant oil and abrasive wear particles from the air conditioner
iv

o
pr

c
compressor) will gather in the sight glass(es) of the purging

um
r
fo

en
ng

device for refrigerant circuits. Clean sight glass(es) after purg‐


t.
yi Co
ing and purge refrigerant circuits again. Cop py
t. rig
gh ht
yri
♦ Fluid refrigerant cannot flow at the necessary speed through p by
co Vo
the expansion valve, the restrictor and the dryer cartridge of
by lksw
cted agen
Prote
certain receivers. These components must therefore be re‐
AG.

moved and an adapter installed in their place ⇒ Heating, air


conditioning .
♦ Adapters to connect air conditioner service station and to
bridge certain components of refrigerant circuit ⇒ page 86 .

– Switch on the air conditioner service station and purge the re‐
frigerant circuit (duration approx. 1 to 1.5 hours for one purging
cycle with three purgings using approx 4 Kg refrigerant
R134a).

74 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note
. Volkswagen AG
gen AG does
swa
♦ The purging process of the refrigerant circuit should be carried y Volk not
gu
out in accordance with the operating instructions of therisair
ed
b ara
nte
conditioner service station ut
ho eo
ra
s a c
♦ Depending on the type of air conditioner service station, the
s

ce
e
nl
waste oil container has a capacity of only approx. 125 cm3. If

pt
du

an
a system with a greater amount of refrigerant oil has to be

itte

y li
erm
purged, it may be necessary to empty the waste oil container

ab
ility
after the first purge of the purging cycle.

ot p

wit
, is n
♦ Watch the refrigerant that flows out of the refrigerant circuit.

h re
hole
When the refrigerant flows through the sight glass of the purg‐

spec
ing device into the air conditioner service station clear and
es, in part or in w

t to the co
completely free of colour, the refrigerant circuit is cleaned.
♦ When purging, the whole amount of refrigerant oil from the
refrigerant circuit is cleaned (except for a small amount in the

rrectness of i
evaporator, though this is not important).
l purpos

♦ Where contamination is particularly high, it may be necessary


to carry out the purging cycle twice (two purging cycles with

nf
ercia

three purges each). Purging device filter must be renewed be‐

or
fore starting second purging cycle.

m
m

atio
om

n in
c

Sequence of purging process (sequence is carried out automati‐


or

thi
e

cally in accordance with the air conditioner service station pro‐


t

sd
iva

gramme)

o
r
rp

cu
o

m
f

en
♦ After switching on, the purging cycle (refrigerant circuit with
ng

t.
yi Co
connection hoses and purging device for refrigerant circuits) Cop py
is first evacuated and the refrigerant circuit thereby checked
t. rig
gh ht
yri by
for leaks. Depending on the type of air conditioner service sta‐ op Vo
by c lksw
tion, it may be necessary to continue the sequence manually. cted agen
Prote AG.

♦ In the evacuated purging circuit, a predetermined amount of


refrigerant is filled (e.g. 4 kg) via the high-pressure side of the
air conditioner service station (against the normal direction of
flow for air conditioner operation and thereby on the low-pres‐
sure side of the vehicle refrigerant circuit). Depending on the
type of air conditioner service station, refrigerant is filled until
the purging circuit is completely filled with liquid refrigerant.
This can be identified, for example, by the fact that after a cer‐
tain period of time no more refrigerant flows through.
♦ Once the predetermined amount of refrigerant has been filled
in the system, the heater, for example, of the purging device
for refrigerant circuits is switched on depending on the type of
air conditioner service station and purging device for refriger‐
ant circuits (only if the refrigerant is extracted in gaseous form
out of the purging device for refrigerant circuits).
♦ When the refrigerant has been extracted, the heater of the
purging device (if fitted) for refrigerant circuits is switched off,
the refrigerant circuit may have to be evacuated briefly again
depending on the design, and following evacuation so that the
air conditioner service station can separate out the refrigerant
oil.
♦ The sequence for filling with refrigerant, extracting (and evac‐
uating) is carried out twice (that means a total of three times).
♦ After extracting for the third time, the purging circuit is evacu‐
ated depending on the type of air conditioner service station.

7. Clearing refrigerant circuit of contaminants 75


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Once the purging cycle is complete, check the sight glass (or
sight glasses) for refrigerant circuits. If this is dirty, clean it in
accordance with the operating instructions of the purging de‐
vice for refrigerant circuits or the air conditioner service station.
Carry out a purging cycle once more as a precautionary meas‐
ure. One purging cycle is sufficient (approx. 30 min.).
– Check the pressure in the refrigerant circuit. There must be no
pressure in the refrigerant circuit (evacuate again briefly if
necessary).
– Remove the connections to the air conditioning service station
from the refrigerant circuit of the vehicle (there should be no
pressure in the refrigerant circuit)
– Renew these components according to the type of vehicle.
♦ Restrictor and reservoir
♦ Expansion valve and receiver or dryer cartridge in receiver AG. Volkswagen AG d
agen oes
– ⇒ Heating, air conditioning and ⇒ Parts catalogue . olksw not
y V gu
d b ara
se nte
– Replace air conditioner compressor depending onthcomplaint
ori
eo
⇒ Heating, air conditioning and ⇒ Parts catalogue
s a or drain
u ra
c
the remaining refrigerant oil from the removed air conditioner
s

ce
le

compressor ⇒ page 159 (renewing components of refrigerant


un

pt
an
d

circuit) and fill it with the prescribed amount of fresh refrigerant


itte

y li
oil ⇒ vehicle-specific workshop manual .
rm

ab
pe

ility
ot

wit
, is n

h re
Note
hole

spec
es, in part or in w

♦ There is a predetermined amount of refrigerant oil in the gen‐

t to the co
uine air conditioner compressor. On vehicles with two evapo‐
rators, a certain amount of refrigerant oil may have to be added
to the circuit as appropriate ⇒ vehicle-specific workshop man‐

rrectness of i
ual .
l purpos

♦ If the air conditioner compressor does not have to be renewed,


the volume of refrigerant oil in the air conditioner compressor
must be replenished in accordance with the fill volume (pour

nform
ercia

out refrigerant oil and refill the prescribed amount in the air
m

a
conditioner compressor or the refrigerant circuit)
com

tio
⇒ page 159 (renewing components of refrigerant circuit) and
n in
r

⇒ vehicle-specific workshop manual .


te o

thi
s
iva

do
r
rp

cum

– Assemble the refrigerant circuit back together again complete‐


fo

en
g

ly ⇒ Heating, air conditioning .


n

t.
yi Co
Cop py
– Evacuate and fill the refrigerant circuit as per specifications
t. rig
gh ht
yri
⇒ page 51 and ⇒ page 50 . p by
co Vo
by lksw
cted agen
– Bring the air conditioning system into operation as per speci‐ Prote AG.

fications ⇒ Heating, air conditioning and ⇒ page 52 .

76 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

7.2.1 Principle circuit diagrams for various


purging circuits

Note

♦ The arrows in the following illustrations show the direction of


flow of the refrigerant during purging. The refrigerant flows
against the direction of flow during normal conditioning of the
air, which is why the high-pressure system of the air condi‐
tioner service station is connected to the low-pressure con‐
nection of the refrigerant circuit to the air conditioner
compressor.
♦ These principle circuit diagrams show a refrigerant circuit with
restrictor and reservoir and a refrigerant circuit with expansion
valve, receiver and a second evaporator (extra equipment on
certain vehicles).
♦ Depending on the design of the air conditioner service station,
non-return valves may be installed between the refrigerant
circuit and the air conditioner service station. This ensures the
correct direction of flow of refrigerant during purging.

Refrigerant circuit with restrictor and reservoir


AG. Volkswagen AG d
agen oes
olksw not
V
Note ed by gu
ara
ris nte
ho eo
ut
On vehicles withssrestrictor and reservoir, the restrictor and the
a ra
c
reservoir are removed. The refrigerant pipes of the restrictor are
ce
le
un

assembled again. The refrigerant pipes to the removed reservoir


pt
an
d

are joined together with two adapters and the charging hose -
itte

y li
erm

ab

VAS 6338/31- (from adapter case VW/Audi passenger vehicle set


ility

- VAS 6338/1- .
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

7. Clearing refrigerant circuit of contaminants 77


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

1 - Air conditioner service sta‐


tion
❑ With electronics and a
purging programme e.g.
air conditioner service
station - VAS 6380- with
purging device or air
conditioner service sta‐
tion with purging device
- VAS 6337- .
❑ If an air conditioner
service station without
purging programme is
used, the sequence has
to be carried out man‐
ually (evacuate, purge
3 times with at least 4 kg
of refrigerant each time
and extract refrigerant
again, evacuate).
2 - Refrigerant hose of air con‐
ditioner service station
❑ From high pressure side
of air conditioner service
station (normally col‐
oured red) to connection
for low pressure side of
air conditioner compres‐
sor on refrigerant circuit
(larger diameter)
3 - Adapter to connection for AG. Volkswagen AG d
low-pressure side on refriger‐ agen oes
olksw not
ant circuit d byV gu
ara
ise nte
❑ Different versions de‐ hor eo
ut
pending on vehicle ss a ra
c
⇒ page 86 .

ce
le
un

pt
❑ From adapter case VW/

an
d
itte

y li
Audi passenger vehicle
rm

ab
set - VAS 6338/1- .
pe

ility
ot

wit
4 - Connection for low-pressure side on refrigerant circuit
, is n

h re
hole

❑ Different versions depending on vehicle ⇒ page 86 .


spec
es, in part or in w

❑ On refrigerant line from air conditioner compressor to reservoir t to the co

5 - Connection to reservoir
❑ Different versions depending on vehicle ⇒ page 86 .
rrectness of i

❑ On refrigerant line from air conditioner compressor to reservoir


l purpos

6 - Adapter to bridge removed reservoir


❑ Different versions depending on vehicle ⇒ page 86 .
nform
ercia

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .


m

a
com

ti

7 - Charging hose for refrigerant ⇒ page 86


on in
r
te o

❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS
thi
s

6338/1- ).
iva

do
r
rp

cum

8 - Adapter to bridge removed reservoir


fo

en
ng

t.
yi
❑ Different versions depending on vehicle ⇒ page 86 .
Co
Cop py
ht. rig
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- . rig ht
py by
co Vo
by lksw
9 - Connection to reservoir Prote
cted AG.
agen

❑ Different versions depending on vehicle ⇒ page 86 .

78 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

10 - Evaporator
11 - Location of restrictor
❑ The restrictor is removed.
❑ Removing restrictor ⇒ Heating, air conditioning .
12 - Threaded connection in refrigerant line
n AG. Volkswagen AG do
❑ After removing the restrictor, screw back together again
olks
w⇒
ageHeating, air conditioning
es n
o
.
yV t gu
13 - Condenser db ara
rise nte
tho eo
14 - Connection for high-pressure side on refrigerant
ss
circuit au ra
c
❑ Different versions depending on vehicle ⇒ page 86 .

ce
e
nl

pt
du

an
itte
15 - Adapter to connection for high-pressure side on refrigerant circuit

y li
erm

ab
❑ Different versions depending on vehicle ⇒ page 86 .

ility
ot p

wit
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
, is n

h re
hole

16 - Charging hose of flushing device for refrigerant circuits

spec
es, in part or in w

❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐

t to the co
ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant
circuits - VAS 6337/1- .

rrectness of i
17 - Purging device for refrigerant circuits
❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging
l purpos

device for refrigerant circuits - VAS 6337/1- .


❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).

nf
ercia

o
❑ Depending on the design of the air conditioner service station and the purging device for refrigerant

rm
m

circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits

atio
m

(to assure the correct direction of refrigerant flow during purging).


o

n in
or c

thi
e

18 - Refrigerant hose of air conditioner service station


t

sd
iva

o
r

❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of
rp

cu
o

m
the purging device for refrigerant circuits
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
Refrigerant circuit with expansion valve, receiver and second
co Vo
by lksw
cted
evaporator
agen
Prote AG.

Note

♦ This principle circuit diagram shows a refrigerant circuit with


expansion valve, receiver and a second evaporator (extra
equipment on certain vehicles).
♦ On vehicles with expansion valve and receiver, the expansion
valve is removed and an adapter installed in its place. The
receiver must be purged, depending on the vehicle or the dryer
cartridge removed. Depending on the type of receiver, this
should be removed and the line connections to the receiver
joined together using two adapters and a charging hose.
♦ On vehicles with just one evaporator, the components from
position “16” are not installed or not required.

7. Clearing refrigerant circuit of contaminants 79


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

1 - Air conditioner service sta‐


tion
❑ With electronics and a
purging programme e.g. wagen AG. Volkswagen AG does
air conditioner servicey Volks not
gu
station - VAS 6380-rise with
d b ara
nte
purging deviceuthor
o air eo
ra
conditioner service
ss a sta‐ c
tion with purging device

ce
le
un

pt
- VAS 6337- .

an
d
itte

y li
rm

ab
❑ If an air conditioner
pe

ility
ot

service station is used

wit
, is n

which does not have a

h re
hole

purging programme,

spec
then the sequence must
es, in part or in w

t to the co
be performed manually.
– Extract refrigerant, if
there is any in the sys‐

rrectness of i
tem.
l purpos

– Connect purging device


for refrigerant circuits -

nform
ercia

VAS 6336/1- or purging


device for refrigerant cir‐
m

a
cuits - VAS 6337/1- be‐
com

tion in
tween air conditioner
r
te o

thi
service station and re‐ s
iva

turn line for refrigerant


do
r
rp

circuit.
um
fo

en
ng

t.
yi Co
– Evacuate refrigerant cir‐ t. Cop py
cuit for 20 minutes, then
rig
gh ht
yri by
fill system with 4 kg of cop Vo
by lksw
refrigerant R134a. Then cted agen
Prote AG.
extract again and repeat
process two further
times. If after the 3rd
purging process the re‐
frigerant in the sight
glass/glasses is not clear, repeat process again.

2 - Refrigerant hose of air conditioner service station


❑ From high pressure side of air conditioner service station (normally coloured red) to connection for low
pressure side of air conditioner compressor on refrigerant circuit (larger diameter)
3 - Adapter to connection for low-pressure side on refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 86 .
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
4 - Connection for low-pressure side on refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 86 .
5 - Adapter for removed expansion valve
❑ Different versions depending on vehicle ⇒ page 86 .
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
6 - Evaporator
7 - Connection to receiver
❑ Different versions depending on vehicle ⇒ page 86 .
❑ Not included on vehicles with a dryer cartridge in the receiver on the condenser or one in the receiver
integrated within the condenser ⇒ Heating, air conditioning .
8 - Adapter to bridge removed receiver
❑ Not required on all vehicles.

80 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
❑ Different versions depending on vehicle ⇒ page 86 .
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
9 - Charging hose for refrigerant ⇒ page 86
❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS
6338/1- ).
10 - Condenser
❑ If there is a receiver with dryer cartridge installed on the condenser, the dryer cartridge must be removed
(seal receiver again on or in condenser following removal) ⇒ Heating, air conditioning .
❑ If the receiver is attached directly to the condenser, remove the receiver after purging and renew ⇒
Heating, air conditioning .
11 - Connection for high-pressure side on refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 86 .
12 - Adapter to connection for high-pressure side on refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 86 .
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
13 - Charging hose of flushing device for refrigerant circuits
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
ameter) to inlet of purging device for refrigerant circuits.
14 - Purging device for refrigerant circuits AG. Volkswagen AG d
agen
❑ Different versions and different design e.g. purging Vol ksw device for refrigerant
oes
circuits
not
gu
- VAS 6336/1- or purging
device for refrigerant circuits - VAS 6337/1-ed by . ara
n
ris tee
❑ With filter, sight glass, safety valve, ut heating, refrigerant tank, etc. (depending on version).
ho or
a ac
❑ Depending on the design of the sair s
conditioner service station and the purging device for refrigerant

ce
le

circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits
un

pt
an
(to assure the correct direction of refrigerant flow during purging).
d
itte

y li
rm

ab
15 - Refrigerant hose of air conditioner service station
pe

ility
ot

❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of

wit
, is n

h re
the purging device for refrigerant circuits
hole

spec
16 - Adapter to seal outlet to second evaporator
es, in part or in w

t to the co
❑ Only required on certain vehicles with “second evaporator” (optional equipment).
❑ From adapter case commercial vehicle set - VAS 6338/50- .
17 - Adapter to seal outlet to second evaporator rrectness of i
l purpos

❑ Only required on certain vehicles with “second evaporator” (optional equipment).


❑ From adapter case commercial vehicle set - VAS 6338/50- .
nform
ercia

18 - Connection of low-pressure side on refrigerant circuit to second evaporator


m

❑ Different versions depending on vehicle ⇒ page 86 .


a
com

tion in

❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).


r
te o

thi
s

19 - Connection of high-pressure side on refrigerant circuit to second evaporator


iva

do
r
rp

❑ Different versions depending on vehicle ⇒ page 86 .


um
fo

en
ng

t.
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).
yi Co
Cop py
t. rig
20 - Adapter for removed expansion valve on second evaporator
gh ht
pyri by
Vo
o
❑ Different versions depending on vehicle ⇒ page 86 .
c by lksw
cted agen
Prote AG.
❑ Only required on certain vehicles with “second evaporator” (optional equipment).
❑ From adapter case commercial vehicle set - VAS 6338/50- .
21 - Second evaporator
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).

7. Clearing refrigerant circuit of contaminants 81


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

7.2.2 Purging electrical air conditioner com‐


pressor
Vehicles with high-voltage system
Observe the additional warning instructions AG. Vfor
olksworking
wagen AGon vehi‐
agen
cles with high-voltage system ⇒VolElectrical system; Rep.dgr. oes 93 ;
ksw not
General warning instructions ed bfor work on the high-voltage sys‐ guar
y
an
tem . ho
ris tee
t or
au ac
ss
WARNING

ce
le
un

pt
an
d
itte

y li
Risk of injury due to unexpected engine start
rm

ab
pe

ility
When working on a high-voltage vehicle, switch off the ignition,
ot

wit
, is n

and deposit the ignition key somewhere outside the passenger

h re
compartment.
hole

spec
es, in part or in w

t to the co
WARNING

rrectness of i
Handling high-voltage cables:
l purpos

• Do not support yourself or your tools on high-voltage ca‐


bles and their components --> risk of damage to the insu‐

nform
ercia

lation.
m

a
• High-voltage cables must not be extensively bent or
com

tion in
kinked --> risk of damage to the insulation.
r
te o

thi
s

• The round high-voltage connectors are colour-coded with


iva

do
r

a coloured ring on the outside and mechanically coded


rp

cum
fo

with respective guide lugs. Always observe the coding


en
ng

t.
yi
when connecting the round high-voltage connectors in or‐
Co
op py
der to prevent any mechanical damage to the high-voltage
t. C rig
gh ht
connectors. pyri by
Vo
co lksw
by
cted agen
Prote AG.

82 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

DANGER!

Hazardous voltage resulting from damaged high-voltage com‐


ponents
Observe the following when working in the vicinity of high-volt‐
age components and cables:
♦ Work involving metal-removing, deforming and sharp-
edged tools or heat sources such as welding, soldering,
hot air and thermal bonding is not permitted.
♦ Before starting work, carry out a visual check on the high-
voltage components in the area of work.
♦ When working in the engine compartment, carry out a vis‐
ual check on the power and control electronics for electric
drive - JX1- , the electric drive motor - V141- , theagair con‐
en AG. Volkswagen AG d
ditioner compressor - V470- and the high-voltage w cables.
s oes
lk not
Vo g y ua
db ran
♦ When working on the underbody, carry risout a visual check
e
tee
utho
on the high-voltage cables and covers. or
a ac
ss
♦ When working on the rear end, carry out a visual check on

ce
le
un

pt
the high-voltage cables and the maintenance connector

an
d
itte

for high-voltage system - TW - .

y li
erm

ab
ility
♦ Carry out a visual check on all potential equalisation lines.
ot p

wit
is n

When carrying out the visual check, observe the following:

h re
ole,

spec
♦ The high-voltage components must not reveal any exter‐
urposes, in part or in wh

nal damage.

t to the co
♦ The insulation of the high-voltage cables and the potential
equalisation lines must not be damaged.

rrectne
♦ The high-voltage cables must not show any unusual de‐
formations.

ss o
cial p

f
♦ Each high-voltage component must be clearly identified

inform
with a red warning sticker.
mer

atio
om

n
c

i
or

n
If repair work in the vicinity of high-voltage components and ca‐
thi
e

bles is necessary, “carry out a visual check for damage on high-


t

sd
iva

voltage components and cables”, and “observe the general


pr

cum
r
fo

warning instructions for work on the high-voltage system” ⇒ Elec‐


en
ng

t.
trical system; Rep. gr. 93 ; General warning instructions for work
yi Co
op
on the high-voltage system .
C py
t. rig
gh ht
yri by
If repair work on high-voltage components is necessary, de-en‐ cop Vo
by lksw
cted
ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;
agen
Prote AG.
De-energising high-voltage system , and “observe the general
warning instructions for work on the high-voltage system” ⇒ Elec‐
trical system; Rep. gr. 93 ; General warning instructions for work
on the high-voltage system .

Note

The electrical air conditioner compressor must be purged, if you


suspect that there is too much refrigerant oil in the refrigerant cir‐
cuit or if contaminated refrigerant oil (contaminated with moisture)
must be extracted from the air conditioner compressor. In these
cases the refrigerant circuit must be purged as well in order to
clean the refrigerant circuit and to re-establish the correct amount
of refrigerant oil.

If an electrical air conditioner compressor is renewed without hav‐


ing a mechanical fault (e.g. defective printed circuit board), the

7. Clearing refrigerant circuit of contaminants 83


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

amount of refrigerant oil from this electrical air conditioner com‐


pressor must be determined.

Note

♦ The air conditioner compressor must be purged in order to


extract the refrigerant oil which needs to be determined.
♦ Purge the air conditioner compressor in normal direction of
flow (from low-pressure inlet to high-pressure outlet).
♦ In order to purge as much refrigerant oil from the air condi‐
tioner compressor as possible make sure that the high-pres‐
sure outlet of the air conditioner compressor is in the lowest
position possible.
♦ If an air conditioner service station without purging programme
is used, the sequence has to be carried out manually (evacu‐
ate, purge 3 times with at least 2 kg of refrigerant each time
and extract refrigerant again, evacuate).

Determined amount e.g. 50 cm³


Then, remove as much refrigerant oil from the new air conditioner
compressor as is necessary to ensure that only the same amount
of refrigerant oil which has been purged from the old air condi‐
tioner compressor remains in the new one (plus 10 cm 3). If, for
example, the new original air conditioner compressor is filled with
e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
– Pour old refrigerant oil out of air conditioner compressor. Han‐
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐
book; Environmental protection; Waste disposal; Current
situation; Disposal channels; Disposal of used oils; Refrigerant
oils . agen
AG. Volkswagen AG d
w oes
olks not
byV gu
ara
d
ise nte
Note thor eo
au ra
c
ss
If the amount of refrigerant oil which can be removed from the
ce
e
nl

pt

new air conditioner compressor is not sufficient, the new air con‐
du

an
itte

ditioner compressor must be purged. After the new air conditioner


y li
erm

ab

compressor has been purged, fill the amount of refrigerant oil


ility
ot p

which has been determined when purging the old air conditioner
wit
, is n

compressor.
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

84 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

1 - Air conditioner service sta‐


tion

Note

The air conditioner compressor is


purged manually.

– Extract refrigerant, if
there is any in the sys‐
tem.

– Empty the used-oil con‐


tainer of the air condi‐
tioner service station.

Note

Some air conditioner service sta‐


tions first separate the oil in the vac‐
uum phase and then fill it into the
used-oil container.

– At the air conditioner


service station, set the
amount of refrigerant to
2 kg and the amount of
oil to 0.

– Connect purging device


for refrigerant circuits -
VAS 6336/1- or purging
device for refrigerant cir‐
cuits - VAS 6337/1- be‐
tween air conditioner wage
n AG. Volkswagen AG do
es n
service station and re‐ yV
olks ot g
ua
turn line for refrigerant ir se
d b ran
tee
circuit. utho
or
a ac
ss
– Evacuate the refrigerant
ce
e
nl

pt

circuit for 10 minutes. Then observe the vacuum gauge. If the vacuum persists, fill 2 kg of R134a refrig‐
du

an
itte

erant into the circuit. Then, extract and evacuate again and repeat the process.
y li
erm

ab
ility
ot p

2 - Refrigerant hose of air conditioner service station


wit
, is n

❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of
h re
hole

the purging device for refrigerant circuits


spec
es, in part or in w

3 - Purging device for refrigerant circuits


t to the co

❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging
device for refrigerant circuits - VAS 6337/1- .
rrectness of i

❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
l purpos

❑ Depending on the design of the air conditioner service station and the purging device for refrigerant
circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits
(to assure the correct direction of refrigerant flow during purging).
nf
ercia

or

4 - Charging hose of flushing device for refrigerant circuits


m
m

atio
m

❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
o

n in
c

ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant
or

thi
e

circuits - VAS 6337/1- .


t

sd
iva

o
r
rp

cu

5 - Adapter to connection for high-pressure side on refrigerant circuit


o

m
f

en
ng

❑ Adapter - VAS 6338/3- from adapter set for refrigerant circuits - VAS 6338/1-
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Clearing refrigerant circuit of contaminants 85


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
Note ris
ed ran
tee
tho
or
au ac
If the adapter - VAS 6338/40-
ss is
available, the charging hose can be

ce
e
nl

pt
du
connected directly to the air condi‐

an
itte

y li
tioner compressor. erm

ab
ility
ot p

6 - High-pressure side refrigerant line from air conditioner compressor

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
Will not be used if the adapter - VAS
6338/40- is available.

rrectness of i
– Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/3- fits properly.
l purpos

7 - Electrical air conditioner compressor


❑ Purge the air conditioner compressor in normal direction of flow (from low-pressure inlet to high-pressure

nform
ercia

outlet).
m

at
❑ In order to purge as much refrigerant oil from the air conditioner compressor as possible make sure that
om

ion
the high-pressure outlet of the air conditioner compressor is in the lowest position possible.
c

in t
or

his
te

8 - Low-pressure side refrigerant line to air conditioner compressor


a

do
priv

cum
for

Note

en
ng

t.
yi Co
Cop py
Will not be used if the adapter - VAS
t. rig
gh ht
yri by
6338/41- is available. cop Vo
by lksw
cted agen
Prote AG.
– Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/6- fits properly.

9 - Adapter to connection for low-pressure side on refrigerant circuit


❑ Adapter - VAS 6338/6- from adapter set for refrigerant circuits - VAS 6338/1-

Note

If the adapter - VAS 6338/41- is


available, the charging hose can be
connected directly to the air condi‐
tioner compressor.

10 - Refrigerant hose of air conditioner service station


❑ From high-pressure side of the air conditioner service station (usually coloured in red) for connection to
low-pressure line or directly to air conditioner compressor using adapter - VAS 6338/41- .

7.2.3 Adapters for setting up purging circuits


♦ The following table contains the various adapters that are nec‐
essary to connect the air conditioner service station to the
refrigerant circuit for purposes of purging and to bridge the re‐
moved reservoir or collector and expansion valve (vehicle-
specific).
♦ Using a filling hose with 5/8 -18 UNF connections (short ver‐
sion, e.g. charging hose - VAS 6338/31- ), join both adapters,
which were installed in place of the reservoir or receiver (in‐
cluded in adapter case VW/Audi passenger vehicle set - VAS
6338/1- ).
♦ If a purged refrigerant circuit is not going to be reassembled
straight after purging, leave the adapters on the connections
and seal the connections at the adapters using the sealing
caps - VAS 6338/30- (from adapter case VW/Audi passenger
vehicle set - VAS 6338/1- ).

86 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

♦ Depending on the type of air conditioner compressor and the


period of production, different joining and sealing techniques
have been applied in the refrigerant circuit ⇒ Heating, air con‐
ditioning .
Block or threaded connections
Threaded connection -A-
Block connection -B-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Clearing refrigerant circuit of contaminants 87


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Block connections with various types of seals


gen AG
. Volkswagen AG
d wa oes
olks not
Block connection with radial sealing
d b connection -A- (with guide
yV gu
ara
made from plastic or metal -B-)
orise nte
eo
h
ut ra
– Block connection with axial
ss
a
sealing connection -C- c

ce
le
un
Fox 2005

pt
an
d
itte

y li
rm

Vehicle Adapters re‐ Adapters required for Miscella‐

ab
pe

ility
quired for refrig‐ refrigerant pipes to re‐ neous
ot

wit
erant pipes to air ceiver
, is n

h re
conditioner com‐
hole

pressor

spec
es, in part or in w

t to the co
Fox ♦ Low-pres‐ – Remove dryer car‐ – Install
2005 ► sure side tridge and seal re‐ adapter
adapter - ceiver. - VAS
VAS 6338/3

rrectness of i
6338/12- – After flushing, in‐ 4- in
l purpos

stall a new dryer place of


♦ High-pres‐ cartridge. expan‐
sure side sion

nform
ercia

adapter - valve
VAS 6338/2- (or a
m

a
com

ti
drilled

on in
out ex‐
r
te o

thi
pan‐

s
iva

do
sion
r
rp

cum
valve
fo

en
g


n

t.
yi Co
op
pa C py
t. rig
ge 71 )
gh ht
pyri by
Vo
o
by c lksw
cted
– After
agen
Prote AG.
purg‐
ing, in‐
stall a
new ex‐
pan‐
sion
valve.

88 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Lupo 1999
Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor
Lupo ♦ Low-pres‐ – Remove receiver – Install
1999 ► sure side and bridge refriger‐ adapter
up to ve‐ adapter - ant pipes. - VAS
hicle VAS ♦ Adapter - VAS 6338/1
identifi‐ 6338/12- 6338/28- 9- in
cation place of
number ♦ High-pres‐ ♦ Adapter - VAS expan‐
70000 sure side 6338/29- sion
adapter - valve
VAS 6338/2- – After flushing, in‐
stall a new receiver. (or dril‐
led out
expan‐
sion
valve
e.g. 6N
0 820
679 C

pa
ge 71 )

– After
purg‐ n AG. Volkswagen AG do
wage es n
ing, in‐yV
olks ot g
stall
ir se
da
b ua
ran
hnew ex‐
o tee
t or
ss
au
pan‐ ac
sion

ce
e
nl

valve.

pt
du

an
itte

y li
Lupo ♦ Low-pres‐ Receiver – Install
erm

ab
1999 ► sure side – Can be flushed adapter

ility
ot p

from ve‐ adapter - through. - VAS

wit
, is n

hicle VAS 6338/1

h re
hole

identifi‐ 6338/12- – After flushing, in‐ 9- in

spec
cation stall a new receiver. place of
es, in part or in w

number ♦ High-pres‐ expan‐

t to the co
70001 sure side sion
adapter - valve
VAS 6338/2- (or dril‐

rrectness of i
or led out
l purpos

♦ Adapter - expan‐
VAS 6338/7- sion
valve
nform
ercia

e.g. 6N
0 820
m

at
om

679 C
ion
c


in t
or

his
e

pa
at

do
riv

ge 71 )
p

cum
for

en
g

– After
n

t.
yi Co
op
purg‐
C py
t. rig
ing, in‐
gh ht
pyri by
stall a
co Vo
by lksw
cted
new ex‐
agen
Prote AG.
pan‐
sion
valve.

7. Clearing refrigerant circuit of contaminants 89


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

up! 2012; e-up! 2014


Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐ . Volkswagen AG
pressor swa
gen AG does
k not
Vol gu
up! ♦ Low-pres‐ Receiver
db
y
– Re‐ ara
ise nte
2012 ►; sure side –
thor Can be flushed place eo
e-up! adapter - s au through. expan‐ ra
c
2014 ► VAS s
sion

ce
e
nl

6338/12- – After flushing, in‐ valve

pt
du

an
stall a new receiver. with
itte

y li
♦ High-pres‐
erm

adapter

ab
sure side

ility
- VAS
ot p

adapter -

wit
6338/3
, is n

VAS 6338/3-

h re
6- or
hole

spec
♦ Purging elec‐ adapter
es, in part or in w

trical air con‐ - VAS

t to the co
ditioner com‐ 6338/3
pressor, 4- (or
adapter - drilled-

rrectness of i
VAS out ex‐
6338/40- and pan‐
l purpos

Adapter - sion
VAS valve
e.g. 1S

nform
ercia

6338/41- ,
Observe 0 820
m

at
078
om

notes:

io

n
c

⇒ page 82

in t
r

pa
o

his
te

ge 71 ).
a

do
priv

cum
or

– After
f

en
ng

t.
yi
purg‐
Co
op py
ing, in‐
t. C rig
gh ht
stall a
pyri by
Vo
co
new ex‐
by lksw
cted agen
Prote
pan‐
AG.

sion
valve.

90 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Polo 1995
Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor
Polo Adapter - VAS – Remove receiver – Install
1995 ► 6338/14- and bridge refriger‐ adapt‐
up to ve‐ ant pipes. er -
hicle ♦ Adapter - VAS VAS
identifi‐ 6338/28- 6338/1
cation 9- in
number ♦ Adapter - VAS place
50000 6338/29- of ex‐
– After flushing, in‐ pan‐
stall a new receiver. sion
valve
gen AG. V(or
olkswdril‐
agen AG
does
a
y Volksw led out not
gu
isedb expan‐ ara
nte
hor
sion eo
ut
ss a valve ra
c
e.g. 6N

ce
le
un

0 820

pt
an
d

679 C
itte

y li
rm

⇒ page

ab
pe

ility
71 )
ot

wit
, is n

h re
– After
hole

spec
purg‐
es, in part or in w

ing, in‐

t to the co
stall a
new
expan‐

rrectness of i
sion
valve.
l purpos

Polo ♦ Low-pres‐ Receiver – Install


1995 ► sure side – Can be flushed adapt‐ nform
ercia

from ve‐ adapter - through. er -


hicle VAS 6338/7- VAS
m

a
com

identifi‐ – After flushing, in‐ 6338/1


ion in

cation ♦ High-pres‐ stall a new receiver. 9- in


r
te o

sure side
thi

number place
s
iva

adapter -
do

50001 of ex‐
r
rp

VAS 6338/2-
um

pan‐
fo

en
g

sion
n

t.
yi Co
op
valve C py
t. rig
(or dril‐
gh ht
pyri by
led out
o Vo
by c lksw
cted
expan‐
agen
Prote AG.
sion
valve
e.g. 6N
0 820
679 C
⇒ page
71 )

– After
purg‐
ing, in‐
stall a
new
expan‐
sion
valve.

7. Clearing refrigerant circuit of contaminants 91


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Polo 2002
Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor
Polo ♦ Low-pres‐ – Remove dryer car‐ – Install
2002 ► sure side tridge and seal re‐ adapt‐
adapter - ceiver. er -
VAS VAS
6338/12- – After flushing, in‐ 6338/3 AG. Volkswagen AG d
agen oes
ksw
stall a new dryer 4- in y Vol not
gu
♦ High-pres‐ cartridge. place rise d b ara
nte
sure side of ex‐ tho eo
adapter - pan‐
ss au ra
c
VAS 6338/2- sion

ce
le
un

pt
valve

an
d
(or a itte

y li
rm

ab
drilled
pe

ility
out ex‐
ot

wit
, is n

pan‐

h re
sion
hole

spec
valve
es, in part or in w

⇒ page

t to the co
71 )

– After

rrectness of i
purg‐
ing, in‐
l purpos

stall a
new

nform
ercia

expan‐
sion
m

a
com

t
valve.

ion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

92 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning
en AG. V
system
olkswagen AG with refrigerant R134a - Edition 10.2014
ag does
ksw not
Vol gu
Caddy 1996; Caddy 2004; Caddy ed 2011
by ara
nte
oris eo
th
Vehicle Adapters re‐ s au Adapters required for Miscella‐ ra
c
quired for refrig‐ refrigerant pipes to re‐
s neous

ce
e
erant pipes to air ceiver

nl

pt
du

an
conditioner com‐
itte

y li
pressor erm

ab
ility
ot p

Caddy ♦ Low-pres‐ – Remove receiver – Install

wit
, is n

1996 ► sure side and bridge refriger‐ adapt‐

h re
hole

adapter - ant pipes. er -

spec
VAS 6338/4- ♦ Adapter - VAS VAS
es, in part or in w

6338/28- 6338/1

t to the co
♦ High-pres‐ 9- in
sure side ♦ Adapter - VAS place
adapter - 6338/29- of ex‐

rrectness of i
VAS 6338/2- pan‐
or adapter - – After flushing, in‐
l purpos

stall a new receiver. sion


VAS valve
6338/14- (or dril‐

nf
ercia

led out

orm
expan‐
m

atio
m

sion
o

n in
c

valve
or

thi
e.g. 6N
te

sd
iva

0 820

o
r
rp

cu
679 C
o

m
f

en
ng

⇒ page
t.
yi Co
op
71 ) C py
t. rig
gh ht
yri by
– After
op Vo
by c lksw
purg‐
cted agen
Prote AG.
ing, in‐
stall a
new
expan‐
sion
valve.
Caddy ♦ Sanden / Receiver – Install
2004 ►; Denso air – Can be flushed adapt‐
Caddy conditioner through. er -
2011 ► compressor VAS
– After flushing, in‐ 6338/1
♦ Low-pres‐ stall a new receiver. 8- in
sure side place
adapter - of ex‐
VAS pan‐
6338/12- sion
♦ High-pres‐ valve
sure side (or a
adapter - drilled
VAS 6338/3- out ex‐
pan‐
♦ 7H0 820 803 sion
D air condi‐ valve
tioner com‐ ⇒ page
pressor 71 )
♦ Low-pres‐ – After
sure side purg‐
adapter - ing, in‐
VAS 6338/7- stall a
new
♦ High-pres‐ expan‐
sure side sion
adapter - valve.
VAS 6338/2-

7. Clearing refrigerant circuit of contaminants 93


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Polo 2010; Polo KH IN 2010; Polo KH IN 2015; Polo Lim IN 2011;


Polo Lim RUS 2011; Polo KH MY 2014; Polo KH MY 2015; Polo
Lim MY 2014; Polo 2014
Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor
Polo ♦ Low-pres‐ – Remove dryer car‐ – Install
2010 ►; sure side tridge and seal re‐ adapt‐
Polo KH adapter - ceiver. er -
IN 2010 VAS VAS
►; Polo 6338/12- – After flushing, in‐ 6338/3
HH IN stall a new dryer 4- in
2015; ♦ High-pres‐ cartridge. place
Polo sure side of ex‐
Lim IN adapter - pan‐
2011 ►; VAS 6338/3- sion
Polo ♦ For air condi‐ valve
Lim tioner com‐ (or a . Volkswagen AG
RUS pressors 6Q0 k
drilled
swa
gen AG does
2011 ►; 820 808 F by V out ex‐
ol not
gu
ara
Polo KH and 6Q0 820 rise
d pan‐ nte
MY 808 G on high utho
sion eo
ra
2014 ►; pressure side ss a
valve c
Polo KH ⇒ page

ce
e

adapter -
nl

pt
du

MY 71 )

an
VAS 6338/2-
itte

2015 ►;

y li
erm

ab
Polo – After

ility
ot p

Lim MY purg‐

wit
, is n

2014 ►; ing, in‐

h re
Polo stall a
hole

spec
2014 ► new
es, in part or in w

expan‐

t to the co
sion
valve.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

94 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Golf 1992; Vento 1992; Passat 1994


Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor
Golf Adapter - VAS – Remove receiver – Install
1992 ►, 6338/14- and bridge refriger‐ adapter
Vento ant pipes. - VAS
1992 ►, ♦ Adapter - VAS 6338/1
Passat 6338/28- 9- in
1994 ► place of
♦ Adapter - VAS expan‐
6338/29- sion
– After flushing, in‐ valve
stall a new receiver. (or dril‐
led out
expan‐
sion
valve
e.g. 6N
0 820
679 C

pa
ge 71 )

– After
purg‐
ing, in‐
stall a
new ex‐
pan‐
sion
valve.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

95
co Vo
by lksw
7. Clearing refrigerant circuit of contaminants
cted agen
Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Touran 2003; Golf 2004; Golf Plus 2005; Golf Plus 2009; Jetta
2005; Eos 2006; Golf Variant 2007; Tiguan 2008; Scirocco 2009;
Scirocco 2015; Golf 2009; Golf Variant 2010; Jetta 2011; Golf
Cabrio 2012; NMS 2012; Beetle 2012; Golf 2013
Vehicle Adapters re‐ Adapters required for AMiscella‐
G. Volkswagen AG d
quired for refrig‐ refrigerant pipeslkstoware‐
gen neous oes
not
erant pipes to air ceiver d byV
o gu
ara
conditioner com‐ orise nte
eo
pressor au
th ra
ss c
Touran ♦ Low-pres‐ There are two versions – Install

ce
le
un

pt
2003 ►; sure side of the fluid receiver: adapter

an
d
itte

Golf adapter - See vehicle specific re‐ - VAS

y li
erm

ab
2004 ►; VAS pair manual. 6338/1

ility
ot p

Golf 6338/12- ♦ Fluid receiver with 8- in

wit
is n

Plus permanently fitted place of

h re
2005 ►; ♦ High-pres‐ dryer expan‐
ole,

sure side

spec
Golf sion
urposes, in part or in wh

Plus adapter - – Can be flushed valve

t to the co
2009 ►; VAS 6338/3- through. (or a
Jetta – After flushing, in‐ drilled
2005 ►; stall a new receiver. out ex‐

rrectne
Eos ♦ Receiver with dryer pan‐
2006 ►; bag or cartridge sion

s
Golf valve

s
– Remove dryer bag/

o
Variant ⇒
cial p

f
cartridge and seal

in
2007 ►; pa

form
fluid receiver.
mer

Tiguan ge 71 )

atio
2008 ►;
m

– After purging, in‐


o

n
Sciroc‐ – After
c

stall a new dryer

i
or

n
co 2009 purg‐

thi
e

bag/cartridge.
t

sd
a

►; Scir‐ ing, in‐


iv

o
pr

c
occo stall a
um
r
fo

2015 ►; new ex‐


en
ng

t.
yi
Golf pan‐
Co
Cop py
2009 ►; sion
ht. rig
rig ht
Golf valve.
py by
co Vo
by lksw
Variant Prote
cted AG.
agen
2010 ►;
Jetta
2011 ►;
Golf
Cabrio
2012 ►;
NMS
2012
►Beetle
2012 ►

96 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Golf 2013; Golf Estate 2014; Golf 2014 (NAR); Golf SV 2015
Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver AG. Volkswagen AG d
conditioner com‐ agen oes
olksw not
pressor ed
byV gu
ara
ris nte
Golf ♦ Low-pres‐ – Remove dryer bag/uth–o Install eo
ra
2013 ►; sure side cartridge and seal ss
a
adapter c
Golf Es‐ adapter - fluid receiver. - VAS

ce
le
un

pt
tate VAS 6338/3

an
d
itte
2014 ►; 6338/12- – After purging, in‐ 8- in

y li
rm

ab
Golf stall a new dryer place of

pe

ility
2014 ♦ High-pres‐ bag/cartridge. expan‐

ot

wit
sure side
, is n
(NAR) sion

h re
►; Golf adapter - – If a Showa con‐
hole
valve

spec
SV 2015 VAS 6338/3- denser is fitted, (or a
es, in part or in w

► leave the receiver drilled

t to the co
fitted and purge the out ex‐
refrigerant circuit. pan‐
sion

rrectness of i
– After flushing, in‐ valve
stall a new receiver. ⇒
l purpos

pa
ge 71 )

nform
ercia

– After
m

a
com

t
purg‐

ion in
ing, in‐
r
te o

thi
stall a

s
iva

new ex‐

do
r
rp

c
pan‐

um
fo

en
g

sion
n

t.
yi Co
valve. Cop py
ht. rig
rig ht
by
Golf 1998; Golf Variant 1998; Vento 1999; New Beetle 1999; New copy Vo
by lksw
Beetle Cabrio 2003; Bora 1999 cted agen
Prote AG.

Golf ♦ Low-pres‐ – Remove receiver – Install


1998 ►, sure side and bridge refriger‐ adapter
Golf adapter - ant pipes. - VAS
Variant VAS 6338/7- 6338/1
1998 ►, – Connect two adapt‐ 9- in
Vento ♦ High-pres‐ ers - VAS 6338/2- place of
1999 ►, sure side with hose - VAS expan‐
New adapter - 6338/31- together. sion
Beetle VAS 6338/2- valve
1999 ►, – After flushing, in‐ (or a
New stall a new receiver. drilled
Beetle out ex‐
Cabrio pan‐
2003 ►, sion
Bora valve
1999 ► ⇒
pa
ge 71 )

– After
purg‐
ing, in‐
stall a
new ex‐
pan‐
sion
valve.

7. Clearing refrigerant circuit of contaminants 97


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Phaeton 2003 n AG. Volkswagen AG do


lkswage es n
o ot g
Vehicle Adapters re‐ Adapters requiredd bfory V Miscella‐ ua
ran
quired for refrig‐ refrigerant pipesor to re‐ neous
ise
tee
erant pipes to air ceiver/reservoir
auth or
ac
conditioner com‐ ss

ce
le
pressor

un

pt
an
d
itte
Phaeton ♦ Low-pres‐ – Remove reservoir – Restric‐

y li
erm

ab
2003 ► sure side (dryer), and bridge tor re‐

ility
ot p
adapter - refrigerant pipes. moved

wit
is n

VAS and re‐

h re
ole,

6338/12- – Join two adapters - friger‐

spec
VAS 6338/6- and ant pipe
urposes, in part or in wh

♦ High-pres‐ connect to hose - recon‐

t to the co
sure side, 12, VAS 6338/31- . nected.
8 and 6-cyl.
petrol en‐ – After flushing, in‐ – After

rrectne
gines: adapt‐ stall a new reser‐ flush‐
er - VAS voir. ing, in‐
6338/2- .

s
stall a

s
High-pres‐

o
new re‐
cial p

f i
sure side, 10

n
strictor.

form
and 6-
mer

atio
cyl. diesel en‐
om

gines: adapt‐

n
c

i
or

n
er - VAS

thi
te

sd
6338/3-
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

98 Rep. gr.00 - Technical data


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
risAmarok
e 2011 ➤ , Beetle 2012 ➤ , Bora 1999
nte ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
ho eo
aut
Air conditioning system with refrigerant
ra
c R134a - Edition 10.2014
ss

ce
e
nl
Passat 1997

pt
du

an
itte

y li
Vehicle Adapters re‐ Adapters required for Miscella‐ erm

ab
ility
quired for refrig‐ refrigerant pipes to re‐ neous
ot p

wit
erant pipes to air ceiver/reservoir
, is n

h re
conditioner com‐
hole

pressor

spec
es, in part or in w

t to the co
Passat ♦ Adapter - There are two versions – Restric‐
1997 ► V.A.G of the reservoir. tor re‐
up to 1785/7- – Remove reservoir moved
Sep‐ and bridge refriger‐ and re‐

rrectness of i
tember ♦ Adapter - ant pipes. friger‐
V.A.G
l purpos

2000 ant line


1785/8- – Connect adapter - recon‐
♦ Low-pres‐ VAS 6338/9- and nected.

nf
ercia

adapter - VAG

o
sure side

rm
1785/8- or adapter - – After
m

atio
adapter -
m

VAS 6338/10- to flush‐


o

VAS

n in
c

hose - VAS ing, in‐


or

6338/12-

thi
e

6338/31- . stall a
t

sd
iva

♦ High-pres‐ new re‐

o
r
rp

cu
sure side – After flushing, in‐ strictor.
o

m
f

en
ng

adapter - stall a new reser‐


t.
yi Co
op
VAS 6338/2- voir. C py
t. rig
gh ht
pyri by
Vo
o
Passat ♦ Adapter - – Remove reservoir – Restric‐
c by lksw
cted agen
1997 ► V.A.G and bridge refriger‐ tor re‐
Prote AG.

from 1785/7- ant pipes. moved


October and re‐
2000 ♦ Adapter - – Connect two adapt‐ friger‐
V.A.G ers - VAS 6338/10- ant line
1785/8- with hose - VAS recon‐
♦ Low-pres‐ 6338/31- together. nected.
sure side
adapter - – After flushing, in‐ – After
VAS stall a new reser‐ flush‐
6338/12- voir. ing, in‐
stall a
♦ High-pres‐ new re‐
sure side strictor.
adapter -
VAS 6338/2-

7. Clearing refrigerant circuit of contaminants 99


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 AG➤
. Vo, lkCC
swa2010
gen AG➤ , CC 2012 ➤ , ...
agen does
Air conditioning system with refrigerant
VolkswR134a - Edition 10.2014 not
g y ua
db ran
rise tee
Passat 2006; Passat CC 2009; CC u2010;
tho Passat 2011; CC FL or
s a ac
s
Vehicle Adapters re‐ Adapters required for Miscella‐

ce
e
nl

pt
quired for refrig‐ refrigerant pipes to re‐ neous

du

an
itte
erant pipes to air ceiver/reservoir

y li
erm

ab
conditioner com‐

ility
ot p
pressor

wit
, is n

Passat ♦ Low-pres‐ – Remove dryer car‐ – Install

h re
hole

2006 ►, sure side tridge and seal re‐ adapter

spec
Passat adapter - ceiver. - VAS
es, in part or in w

t to the co
CC VAS 6338/1
2009 ►, 6338/12- – After flushing, in‐ 8- in
CC stall a new dryer place of
2010 ►, ♦ High-pres‐

rrectness of i
cartridge. expan‐
Passat sure side sion
l purpos

2011 ►, adapter - – If a Showa con‐ valve


CC FL ► VAS 6338/3- denser is fitted, (or a
leave the receiver drilled

nform
ercia

fitted and purge the out ex‐


m

refrigerant circuit. pan‐

at
om

io
sion

n
c

in t
r

– After flushing, in‐ valve


o

his
e

stall a new receiver. ⇒


at

do
riv

pa
p

cum
or

ge 71 )
f

en
ng

t.
yi Co
op
– After
C py
t. rig
gh
purg‐
ht
pyri by
Vo
o
ing, in‐
c by lksw
cted agen
Prote
stall a
AG.
new ex‐
pan‐
sion
valve.
Passat 2015; Passat Estate 2015

Note

In the Passat 2015 and Passat Estate 2015 with BiTurbo engine,
the refrigerant circuit is not flushed. In these vehicles, it would
require too much effort to remove the expansion valve. If the air
conditioner compressor is defective, check whether filings have
entered the condenser or whether there are filings at the con‐
denser outlet. If there are only filings on the inlet side but not on
the outlet side, renew only the condenser and the air conditioner
compressor.

100 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
AG. Volkswagen AG d
agen oes
Vehicle Adapters re‐ Adapters required for Miscella‐ Volksw not
gu
quired for refrig‐ refrigerant pipes to re‐ neous db
y ara
ise nte
erant pipes to air ceiver tho
r eo
conditioner com‐ s au ra
c
pressor s

ce
e
nl

pt
du
Passat ♦ Low-pres‐ – Remove desiccant – Install

an
itte

y li
2015 ►; sure side bag/cartridge and adapter

erm

ab
Passat adapter - seal fluid receiver. - VAS

ility
ot p
Estate VAS 6338/1

wit
, is n
2015 ► 6338/12- – After purging, in‐ 8- in

h re
hole
stall a new desic‐ place of

spec
♦ High-pres‐ cant bag/cartridge. expan‐

es, in part or in w
sure side

t to the co
sion
adapter - valve
VAS 6338/3- (or a
drilled

rrectness of i
out ex‐
l purpos

pan‐
sion
valve

nf
ercia

orm
pa
m

atio
m

ge 71 )
o

n in
or c

thi
e

– After
t

sd
iva

purg‐

o
r
rp

cu
ing, in‐
o

m
f

en
ng

stall a
t.
yi Co
op
new ex‐ C py
t. rig
pan‐
gh ht
pyri by
sion
o Vo
by c lksw
cted
valve.
agen
Prote AG.

Sharan 1996

Note

On vehicles with a 2nd evaporator (Sharan), the front and rear


refrigerant circuit must be rinsed separately. The front refrigerant
circuit must be sealed with adapter - V.A.G 1785/1- , adapter -
1785/3- and sealing caps -VAS 6338/30-.

7. Clearing refrigerant circuit of contaminants 101


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and 2nd evapo‐
conditioner com‐ rator
pressor
Sharan ♦ Low-pressure – Remove receiver – Install
1996 ► side adapter - and connect refrig‐ adapt‐
up to VAS 6338/7- erant pipes to er -
May adapter - VAS VAS
2000 ♦ High-pressure 6338/37- . 6338/3
side adapter - – After purging, in‐ 5- in
VAS 6338/2- stall a new receiver place
♦ or adapter - (dryer). of front
VAS 6338/14- ♦ Low-pressure line and
for second evapo‐ rear
rator adapter - expan‐
V.A.G 1785/7- sion
valves
♦ High-pressure line (or a
for second
agen AGevapo‐
.Vo lkswagen AG
drilled
does
rator
yV
olks adapter -
w
out ex‐not
gu
ed b V.A.G 1785/5- pan‐
ara
nte
ris
utho
♦ Adapter - V.A.G sion eo
ra
ss
a
1785/3- with seal‐ valve c
⇒ page

ce
e

ing cap -VAS


nl

pt
du

71 )

an
6338/30- to seal
itte

y li
front refrigerant cir‐
erm

ab
cuit. – After

ility
ot p

purg‐
wit
, is n

♦ Adapter - V.A.G ing, in‐


stall a h re
hole

1785/1- with seal‐ spec


ing cap -VAS new
es, in part or in w

6338/30- to seal expan‐


t to the co

front refrigerant cir‐ sion


cuit. valve.
rrectness of i

Sharan ♦ Low-pressure – Remove dryer car‐ – Install


l purpos

1996 ► side adapter - tridge and seal re‐ adapt‐


from VAS 6338/7- ceiver. er -
June – After flushing, in‐ VAS
nf
ercia

2000 ♦ High-pressure stall a new dryer 6338/3


orm

side adapter - cartridge. 5- in


m

atio
m

VAS 6338/2- ♦ Low-pressure line place


o

n in
c

for second evapo‐ of front


or

thi
e

rator adapter - and


t

sd
iva

V.A.G 1785/7- rear


o
r
rp

cu

expan‐
o

m
f

en
ng

♦ High-pressure line sion


t.
yi Co
for second evapo‐
op
valves C py
. rig
rator adapter -
t
(or a
gh ht
yri by
V.A.G 1785/5-
p
drilled
co Vo
by lksw
cted agen
♦ Adapter - V.A.G out ex‐ Prote AG.

1785/3- with seal‐ pan‐


ing cap -VAS sion
6338/30- to seal valve
front refrigerant cir‐ ⇒ page
cuit. 71 )

♦ Adapter - V.A.G – After


1785/1- with seal‐ purg‐
ing cap -VAS ing, in‐
6338/30- to seal stall a
front refrigerant cir‐ new
cuit. expan‐
sion
valve.

102 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Sharan 2011

Note

On vehicles with a 2nd evaporator (Sharan), the front and rear


refrigerant circuit must be rinsed separately. The front refrigerant
circuit must be sealed with adapter - V.A.G 1785/1- , adapter -
1785/3- and sealing capse-VAS
n AG. V6338/30-.
olkswagen AG
wag does
olks not
byV gu
ara
Vehicle Adapters
ris
ed re‐ Adapters required for Miscella‐
nte
quired
utho for refrig‐ refrigerant pipes to re‐ neous eo
ra
ss erant pipes to air ceiver and 2nd evapo‐
a c
conditioner com‐ rator

ce
e
nl

pt
du

pressor

an
itte

y li
erm

Sharan ♦ Low-pressure – Remove dryer car‐ – Install

ab
ility
2011 ► side adapter - tridge and seal re‐ adapt‐
ot p

wit
VAS 6338/12- ceiver. er -
, is n

h re
– After flushing, in‐ VAS
hole

♦ High-pressure

spec
stall a new dryer 6338/1
side adapter -
es, in part or in w

cartridge. 8- in

t to the co
VAS 6338/3- ♦ Low-pressure line place
for second evapo‐ of front
rator adapter - VAS expan‐

rrectness of i
6338/3- sion
valve
l purpos

♦ High-pressure line (or a


for 2nd evaporator drilled
adapter - VAS out ex‐
nform
ercia

6338/4- pan‐
m

at

sion
om

♦ The refrigerant
io

valve
n
c

lines to the second


in t
r

⇒ page
o

evaporator must be
his
te

71 )
a

loosened sufficient‐
do
priv

ly so that the adapt‐


um
or

– Install
f

en
g

er can be fitted
n

t.
yi
adapt‐
Co
without deforming
op py
er -
. C rig
the refrigerant
t
gh ht
VAS
yri by
lines. cop Vo
6338/3
by lksw
cted agen
Prote
♦ Sealing adapter - 3- in
AG.

VAS 6338/5- for place


front refrigerant cir‐ of rear
cuit. expan‐
sion
♦ Sealing adapter - valve
VAS 6338/11- for (or a
front refrigerant cir‐ drilled
cuit. out ex‐
pan‐
sion
valve
⇒ page
71 )

– After
purg‐
ing, in‐
stall a
new
expan‐
sion
valve.

7. Clearing refrigerant circuit of contaminants 103


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Touareg 2003; Touareg 2010; Touareg 2015; Touareg Hybrid


2010

Note

On vehicles with a second evaporator (Touareg), the front and


rear refrigerant circuit must be purged separately. The front re‐
frigerant circuit must be sealed with sealing adapter - VAS
6338/5- and sealing adapter - VAS 6338/11- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

104 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and second
conditioner com‐ evaporator
pressor
Touar‐ ♦ Low-pressure – Remove dryer car‐ – Install
eg side adapter - tridge and seal re‐ adapt‐
2003 ► VAS 6338/12- ceiver. er -
to vehi‐ – After flushing, in‐ VAS
cle ♦ High-pressure stall a new dryer 6338/1
identifi‐ side adapter - cartridge. 7- in
cation VAS 6338/2- ♦ Low-pressure line place
number ♦ Engine code for second evapo‐ of front
50000 BJN 6.0
G. Vrator
olkswaadapter
gen AG - VAS expan‐
slwto
en A
ag does
vehicle
y Volkidenti‐ 6338/3- not
g sion
ntevalve
db ua
rification num‐ ♦ High-pressure line
s e ra
ho ber 20000 on (or
eo a
au
t
for second evapo‐ drilled
ra
ss high-pressure rator adapter - VAS
c
side adapter - out ex‐

ce
e

6338/4-
nl

pan‐

pt
du

VAS 6338/3-

an
sion
itte

y li
♦ Sealing adapter -
erm

valve

ab
VAS 6338/5- for

ility
⇒ page
ot p

front refrigerant cir‐

wit
71 )
, is n

cuit.

h re
hole

spec
♦ Sealing adapter - – After
es, in part or in w

VAS 6338/11- for purg‐


t to the co
front refrigerant cir‐ ing, in‐
cuit. stall a
new
rrectness of i

expan‐
sion
l purpos

valve.
nf
ercia

– Drill
o

out ex‐
rm
m

atio

pan‐
om

sion
n in
or c

valve
thi
te

sd
a

at sec‐
iv

o
r

ond
rp

cu
o

m
f

evapo‐
en
ng

t.
yi
rator
Co
op py
⇒ page
. C rig
ht ht
rig
71 .
py by
co Vo
by lksw
cted agen
Prote
– After
AG.

purg‐
ing, in‐
stall a
new
expan‐
sion
valve.

7. Clearing refrigerant circuit of contaminants 105


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for swMiscella‐


agen
AG. Volkswagen AG d
oes
quired for refrig‐ refrigerant pipes btoyVre‐
olk neous not
gu
erant pipes to air ceiver and second
rise
d ara
nte
conditioner com‐ evaporatorutho eo
r
pressor ss
a ac

ce
le
Touar‐ ♦ Low-pressure – Remove dryer car‐ – Install

un

pt
an
d
eg side adapter - tridge and seal re‐ adapt‐

itte

y li
2003 ► VAS 6338/12- ceiver. er -
rm

ab
pe

ility
as of – After flushing, in‐ VAS
ot

vehicle ♦ High-pressure stall a new dryer 6338/1

wit
, is n

side adapter -

h re
identifi‐ cartridge. 7- or
hole

cation VAS 6338/2- ♦ Low-pressure line adapt‐

spec
number or adapter - for second evapo‐ er -
es, in part or in w

t to the co
50001; VAS 6338/3- rator adapter - VAS VAS
Touar‐ ♦ Electrical air 6338/3- 6338/3
eg conditioner 3- in
♦ High-pressure line

rrectness of i
2010 ►; compressor, place
Touar‐ for second evapo‐ of front
adapter - VAS
l purpos

eg rator adapter - VAS and


6338/40- and 6338/4-
2015; adapter - VAS rear
Touar‐ expan‐

nform
ercia

6338/41- ♦ Sealing adapter -


eg Hy‐ VAS 6338/5- for sion
m

brid valves

a
front refrigerant cir‐
com

tio
2010 ► (or a

n in
cuit.
r

drilled
te o

thi
out ex‐

s
♦ Sealing adapter -
iva

do
r

VAS 6338/11- for pan‐


rp

cum
fo

front refrigerant cir‐ sion

en
ng

t.
valve
yi
cuit.
Co
op py
⇒ page t. C rig
gh ht
71 ) yri
p by
co Vo
by lksw
cted agen
– After
Prote AG.

purg‐
ing, in‐
stall
new
expan‐
sion
valves.
Transporter 1991

Note

On vehicles with a second evaporator, the front and rear refrig‐


erant circuit must be purged separately. The front refrigerant
circuit must be sealed with sealing adapter - VAS 6338/5- and
sealing adapter - VAS 6338/11- .

106 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ ,wBoraagen 1999 ➤ , CC
AG. Volkswagen AG2010
does ➤ , CC 2012 ➤ , ...
ks not
Air conditioning
by V system with refrigerant R134a
o l
g-uEdition 10.2014
a
ed ran
o ris tee
th
Vehicle Adapters re‐ Adapters required
au for Miscella‐ or
ac
quired for refrig‐ ss
refrigerant pipes to re‐ neous

ce
le
erant pipes to air ceiver and second

un

pt
an
d
conditioner com‐ evaporator

itte

y li
pressor

erm

ab
ility
ot p
Trans‐ ♦ Air condition‐ • If the receiver is at‐ – Install

wit
is n
porter er compres‐ tached beneath the adapt‐

h re
ole,
1991 ► sor 2D0 820 condenser, it can er -

spec
urposes, in part or in wh
to 805 B and be purged. VAS
12.1995 701 820 805 6338/5

t to the co
Q adapter - – For other versions, 5- in
VAS remove reservoir. place
6338/54- ♦ Adapter - VAS of front

rrectne
6338/20- for receiv‐ and
♦ Vehicle with a er. rear

s
additional expan‐

s
♦ Adapter - VAS

o
evaporator
cial p

f
sion

i
6338/29- for receiv‐

n
on the roof,

form
er. valves
mer

use adapter - (or a

atio
VAS
m

♦ Adapter - VAS drilled


o

n
6338/51- and
c

6338/26- with seal‐ out ex‐

i
or

n
adapter -

thi
pan‐
e

ing cap -VAS


t

sd
a

VAS
v

6338/30- to seal sion


i

o
pr

c
6338/52- .

um
valve
r

front refrigerant cir‐


fo

en
ng

cuit. ⇒ page
t.
yi Co
op
71 ) C py
♦ Adapter - VAS
t. rig
gh ht
yri by
6338/27- with seal‐ – After cop Vo
by lksw
ing cap -VAS purg‐
cted agen
Prote AG.
6338/30- to seal ing, in‐
front refrigerant cir‐ stall a
cuit. new
expan‐
♦ Adapter - VAS sion
6338/57- for refrig‐ valve.
erant line of second
evaporator.
♦ Adapter - VAS
6338/58- for refrig‐
erant line of second
evaporator.
– After flushing, in‐
stall a new receiver.

7. Clearing refrigerant circuit of contaminants 107


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and second
conditioner com‐ evaporator
pressor
Trans‐ ♦ Air condition‐ • If the receiver is at‐ – Install
porter er compres‐ tached beneath the adapt‐
1991 ► sor 7D0 820 condenser, it can er -
from 805 E adapt‐ be purged. VAS
Jan. er - VAS 6338/5
1996 6338/53- – For other versions, 5- in
remove reservoir. place
♦ Air condition‐ ♦ Adapter - VAS of front
er compres‐ 6338/20- for receiv‐ and
sor 7D0 820 er. rear
805 H low- expan‐
pressure side ♦ Adapter - VAS
sion
adapter - 6338/29- for receiv‐
er. valves
VAS 6338/7- (or a
♦ High-pres‐ ♦ Adapter - VAS drilled
sure side 6338/26- with seal‐ out ex‐
adapter - ing cap -VAS pan‐
VAS 6338/2- 6338/30- to seal sion
front refrigerant cir‐ valve
♦ Vehicle with a cuit. ⇒ page
additional 71 )
evaporator ♦ Adapter - VAS
on the roof, 6338/27- with seal‐ – After
use adapter - ing cap -VAS purg‐ . Volkswagen AG
6338/30- to seal gen AG
VAS ing,olkin‐
swa does
not
6338/51- and front refrigerant cir‐ d bstall
yV a gu
ara
adapter - cuit. o
e
ris new nte
eo
h
VAS ut
expan‐ ra
♦ Adapter - VAS ss a c
6338/52- . sion
6338/57- for refrig‐

ce
le

valve.
un

pt
erant line of second

an
d
itte

evaporator.

y li
rm

ab
pe

ility
♦ Adapter - VAS
ot

wit
6338/58- for refrig‐
, is n

h re
erant line of second
hole

spec
evaporator.
es, in part or in w

– After flushing, in‐ t to the co


stall a new receiver.
Transporter 2004
rrectness of i
l purpos

Note
nform
ercia

On vehicles with a second evaporator, the front and rear refrig‐


m

erant circuit must be purged separately. The front refrigerant


com

tio

circuit must be sealed with sealing adapter - VAS 6338/5- and


n in
r

sealing adapter - VAS 6338/11- .


te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

108 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and second
conditioner com‐ evaporator
pressor
Trans‐ ♦ Air condition‐ – Remove dryer car‐ – To ve‐
porter er compres‐ tridge and seal re‐ hicle
7H 2004 sor 7H0 820 ceiver. identi‐
► 805 E low- – After flushing, in‐ fica‐
pressure side stall a new dryer tion
adapter - cartridge. num‐ AG. Volkswagen AG d
VAS ♦ Sealing adapter - ber lkswagen oes
not
6338/12- , VAS 6338/5- for 20000
d by
Vo gu
ara
high-pres‐ front refrigerant cir‐ oris, drill
e nte
eo
sure side cuit. aut out
h
ra
adapter - ss ex‐ c
♦ Sealing adapter -

ce
le
VAS 6338/3- pan‐
un

pt
VAS 6338/11- for sion

an
d
itte
♦ Air condition‐ front refrigerant cir‐

y li
valve
rm

ab
er compres‐ cuit. ⇒
pe

ility
sor 7H0 820
ot

page

wit
♦ Low-pressure line
, is n

803 C low- 71

h re
pressure side for second evapo‐
hole

spec
adapter - rator adapter - VAS
– From
es, in part or in w

VAS 6338/7- , 6338/3-

t to the co
vehi‐
high-pres‐ ♦ High-pressure line cle
sure side for second evapo‐ identi‐
adapter - fica‐

rrectness of i
rator adapter - VAS
VAS 6338/2- 6338/4- tion
l purpos

num‐
ber
20001

nform
ercia

, in‐
stall
m

a
com

ti
adapt‐

on in
er -
r
te o

thi
VAS

s
iva

do
6338/
r
rp

cum
56- in
fo

en
g

place
n

t.
yi Co
op
of C py
t. rig
front
gh ht
pyri by
ex‐
o Vo
by c lksw
cted
pan‐
agen
Prote AG.
sion
valve

– After
purg‐
ing, in‐
stall a
new
ex‐
pan‐
sion
valve.

– Install
adapt‐
er -
VAS
6338/
33- in
place
of ex‐
pan‐
sion
valve
on

7. Clearing refrigerant circuit of contaminants 109


AG. Volkswagen AG d
agen oes
o lksw not
yV g
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ised ➤
b , CC 2010 ➤ , CC 2012 ➤ , ... uaran
r tee
Air conditioning system with refrigerant uR134a
tho - Edition 10.2014 or
a ac
ss

ce
e
Vehicle Adapters re‐ Adapters required for Miscella‐

nl

pt
du

an
quired for refrig‐ refrigerant pipes to re‐ neous

itte

y li
erant pipes to air ceiver and second

erm

ab
conditioner com‐ evaporator

ility
ot p
pressor

wit
, is n

h re
sec‐

hole

spec
ond

es, in part or in w
evap‐

t to the co
orator

– After

rrectness of i
purg‐
ing, in‐
l purpos

stall a
new

nf
ercia

ex‐

or
pan‐

m
m

atio
sion
om

n in
valve.
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

110 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and second
conditioner com‐ evaporator
pressor
Trans‐ ♦ Air condition‐ – Remove dryer car‐ – To ve‐
porter er compres‐ tridge and seal re‐ hicle
7J 2004 sor 7H0 820 ceiver. identi‐
► 805 E low- – After flushing, in‐ fica‐
pressure side stall a new dryer tion
adapter - cartridge. num‐
VAS ♦ Sealing adapter - ber
6338/12- , VAS 6338/5- for 5000,
high-pres‐ front refrigerant cir‐ drill
sure side cuit. out
adapter - ex‐
VAS 6338/3- ♦ Sealing adapter - pan‐
VAS 6338/11- for sion
♦ Air condition‐ front refrigerant cir‐ valve
er compres‐ cuit. ⇒
sor 7H0 820 page
803 C low- ♦ Low-pressure line
71
pressure sidelkswagfor
en Asecond evapo‐
G. Volkswage n AG do
es n
adapter - by V o rator adapter - VAS o t gu
6338/3- – From ara
VAS 6338/7-
orise
d
, vehi‐ nte
high-pres‐
aut
h
♦ High-pressure line cle
eo
ra
sure
ss side for second evapo‐ identi‐
c
adapter - ce
le

rator adapter - VAS fica‐


un

pt
VAS 6338/2- an
d

6338/4- tion
itte

y li
num‐
erm

ab
♦ Air condition‐
ber
ility
ot p

er compres‐
5001,
wit
is n

sor 7H0 820


install
h re

805 D low-
ole,

adapt‐
spec

pressure side
urposes, in part or in wh

adapter - er -
t to the co

VAS VAS
6338/52- , 6338/
high-pres‐ 56- in
rrectne

sure side place


adapter - of
front
s

VAS
s

ex‐
o

6338/51-
cial p

pan‐
inform

sion
mer

valve
atio
om

n
c

i
or

– After
thi
e

purg‐
t

sd
iva

ing, in‐
pr

cum
r
fo

stall a
en
ng

t.
new
yi Co
op
ex‐
C py
t. rig
gh
pan‐
ht
pyri by
Vo
o
by c sion
lksw
cted agen
Prote
valve.
AG.

– Install
adapt‐
er -
VAS
6338/
56- in
place
of ex‐
pan‐
sion
valve
on
sec‐

7. Clearing refrigerant circuit of contaminants 111


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and second
conditioner com‐ evaporator
pressor
ond
evap‐
orator

– After
purg‐
ing, in‐
stall a
new n AG. Volkswagen AG do
ex‐ olkswage es n
ot g
pan‐
d by
V ua
ran
orsion
ise
tee
au valve.
th or
a c
ss

ce
e

Transporter 2010; Multivan 2010; California 2010; Caravelle


nl

pt
du

2010;

an
itte

y li
erm

ab
ility
ot p

Note

wit
, is n

h re
hole

spec
On vehicles with a 2nd evaporator, the front and rear refrigerant
es, in part or in w

circuit must be rinsed separately. The front refrigerant circuit must

t to the co
be sealed with sealing adapter - VAS 6338/5- and sealing adapter
- VAS 6338/11- .

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

112 Rep. gr.00 - Technical data


AG. Volkswagen AG d
agen o
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora V1999
olks ➤ , CC 2010 ➤ , CC 2012
w es n
ot g ➤ , ...
by ua
Air conditioning system
rised with refrigerant R134a - Edition 10.2014
ran
t ee
tho or
au ac
Vehicle Adapters re‐ Adapters required for s Miscella‐
s

ce
e
quired for refrig‐ refrigerant pipes to re‐ neous

nl

pt
du
erant pipes to air ceiver and 2nd evapo‐

an
itte

y li
conditioner com‐ rator

erm

ab
pressor

ility
ot p

wit
, is n
Trans‐ ♦ Low-pres‐ – Remove dryer car‐ – Install

h re
porter sure side tridge and seal re‐ adapt‐

hole

spec
2010 ►, adapter - ceiver. er -

es, in part or in w
Multivan VAS – After flushing, in‐ VAS

t to the co
2010 ►, 6338/12- stall a new dryer 6338/
Califor‐ cartridge. 56- in
nia 2010 ♦ High-pres‐ ♦ Sealing adapter - place

rrectness of i
►, Cara‐ sure side VAS 6338/5- for of ex‐
velle adapter - front refrigerant cir‐ pan‐

l purpos
2010 ► VAS 6338/3- cuit. sion
valve
♦ Sealing adapter -

nf
ercia
(or a

o
VAS 6338/11- for

r
drilled

m
m

atio
front refrigerant cir‐ out
om

cuit.

n in
ex‐
or c

thi
pan‐
e

♦ Low-pressure line
t

sd
a

sion
iv

for second evapo‐

o
r
rp

cu
rator adapter - VAS valve
o

m
f

en

ng

6338/3-
t.
yi Co
pa Cop py
ge 71 )
t. rig
♦ High-pressure line yri
gh by
ht
for second evapo‐ cop Vo
by lksw
rator adapter - VAS – Re‐ cted agen
Prote AG.
6338/4- move
and
drill
open
ex‐
pan‐
sion
valve
for
rear
evap‐
orator

pa
ge 71 .

– After
purg‐
ing, in‐
stall a
new
ex‐
pan‐
sion
valve.
Crafter 2006; LT 2 as of 1997

Note

On vehicles with a 2nd evaporator, the front and rear refrigerant


circuit must be rinsed separately. The front refrigerant circuit must
be sealed with sealing adapter - VAS 6338/5- and sealing adapter
- VAS 6338/11- .

7. Clearing refrigerant circuit of contaminants 113


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver and 2nd evapo‐
conditioner com‐ rator
pressor
. Volkswagen AG
gen AG does
Crafter ♦ Air condition‐ Receiver – Drill Volkswa not
2006 ► er compres‐ – Can be flushed outdb
y gu
ara
sor 2E0 820 through. ise
rex‐ nte
tho eo
803 A low- – After flushing, in‐ s au pan‐ ra
c
pressure side stall a new receiver.s sion

ce
e
adapter - ♦ Sealing adapter - valve

nl

pt
du

an
VAS VAS 6338/5- for ⇒

itte

y li
6338/12- , front refrigerant cir‐ page
erm

ab
ility
high-pres‐ cuit. 71 ot p
sure side

wit
, is n

♦ Sealing adapter - – After

h re
adapter -
hole

VAS 6338/3- VAS 6338/11- for purg‐

spec
front refrigerant cir‐ ing, in‐
es, in part or in w

t to the co
♦ Air condition‐ cuit. stall a
er compres‐ new
sor 2E0 820 ♦ Low-pressure line ex‐
805 low-pres‐ for second evapo‐

rrectness of i
rator adapter - VAS pan‐
sure side sion
6338/3-
l purpos

adapter - valve.
VAS 6338/7- , ♦ High-pressure line
high-pres‐ for second evapo‐

nf
ercia

sure side

o
rator adapter - VAS

rm
adapter -
m

atio
6338/4-
m

VAS 6338/3-
o

n in
or c

thi
e

LT 2 ♦ Low-pres‐ – Remove receiver – Install


t

sd
iva

1997 ► sure side and bridge refriger‐ adapt‐

o
r
rp

cu
er -
o

adapter - ant pipes.

m
f

en
ng

VAS
t.
VAS 6338/7- op
yi Co
– Connect two adapt‐ 6338/
C py
ht. rig
♦ High-pres‐ ers - VAS 6338/29- 56- in rig ht
py by
sure side
Vo
place
o
with hose - VAS by c lksw
adapter -
cted agen
6338/31- together. of ex‐ Prote AG.
VAS 6338/2- pan‐
♦ Adapter - – After flushing, in‐ sion
VAS stall a new receiver. valve
6338/20- (or a
drilled
out
ex‐
pan‐
sion
valve

pa
ge 71 )

– After
purg‐
ing, in‐
stall a
new
ex‐
pan‐
sion
valve.

114 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Amarok 2011
Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor
Amarok ♦ Low-pres‐ – Remove dryer car‐ – Install
2011 ► sure side tridge and seal re‐ adapt‐
adapter - ceiver. er -
VAS VAS
6338/12- – After flushing, in‐ 6338/3
stall a new dryer 3- in
♦ High-pres‐ cartridge. place
sure side of ex‐
adapter - , pan‐
VAS 6338/3- sion
valve
(or a
drilled
out ex‐
pan‐
sion
valve
⇒ page
71 )

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw

115
cted agen
Prote
7. Clearing refrigerant circuit of contaminants
AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
n AG. Volkswagen AG do
wage es n
Golf 2009 blue e-Motion
yV
olks ot g
ua
db ran
ise
Vehicle Adapters ho re‐
r Adapters required for Miscella‐ tee
ut or
quired
ss
a for refrig‐ refrigerant pipes to re‐ neous ac
erant pipes to air ceiver

ce
le
un

conditioner com‐

pt
an
d

pressor and for


itte

y li
erm

air conditioner

ab
ility
compressor itself
ot p

wit
is n

Golf ♦ Low-pres‐ – Remove dryer car‐ – Install

h re
ole,

2009 sure side tridge and seal re‐ adapter

spec
urposes, in part or in wh

blue e- adapter - ceiver. - VAS

t to the co
Motion VAS – After flushing, in‐ 6338/3
► 6338/12- stall a new dryer 4- in
cartridge. place of
♦ High-pres‐

rrectne
♦ Shut-off tap - VAS expan‐
sure side 6338/42- sion
adapter - valve

s
VAS 6338/3-

s
(or a

o
cial p

f
drilled

in
♦ Purging elec‐

form
out ex‐
mer

trical air con‐


pan‐

atio
ditioner com‐
m

sion
o

pressor,

n
c

i
valve
or

n
adapter -

thi
e


t

sd
a

VAS
v

pa
i

o
r

6338/40- and
p

cum
r

ge 71 )
fo

Adapter -
en
ng

t.
yi
VAS
Co
op
– After
py
6338/41- ,
t. C rig
gh
purg‐
ht
yri
Observe p by
ing, in‐
o Vo
by c
notes:
lksw
cted agen
Prote
⇒ page 82
AG.
stall a
new ex‐
pan‐
sion
valve.

– Re‐
move
refrig‐
erant
shut-off
valve
for
high-
voltage
battery
heat
ex‐
chang‐
er -
N542-
and in‐
stall
shut-off
tap -
VAS
6338/4
2- .

– Re‐
move
refrig‐
erant
shut-off
valve
for
heater
and air
condi‐

116 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐ Adapters required for Miscella‐


quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor and for
air conditioner
compressor itself
tioner
unit -
N541-
and in‐
stall
shut-off
agen AG. Volkswagen AG do
es n
tap -
guVAS
olksw ot
yV
sedb 6338/4
ara
nte
ri
tho 2- . eo
ss au
Comply ra
c
with

ce
le
un

notes

pt
an
d


itte

y li
rm

pa

ab
pe

ility
ge
ot

wit
121 .
, is n

h re
hole

spec
– If no
es, in part or in w

shut-off

t to the co
tap -
VAS
6338/4
2- is rrectness of i
availa‐
l purpos

ble, a
voltage
nform
ercia

of 12 V
may be
m

applied
com

tio

to shut-
n in
r
te o

off
thi
s
iva

valves -
do
r

N541-
rp

cum
fo

and -
en
ng

t.
yi
N542-
Co
op py
as an
t. C rig
gh ht
yri
alterna‐
p by
co Vo
tive.
by lksw
cted agen
Prote AG.

7. Clearing refrigerant circuit of contaminants 117


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

e-Golf 2014 and e-Golf 2014 with heat pump


Vehicle Adapters re‐ Adapters required for Miscella‐
quired for refrig‐ refrigerant pipes to re‐ neous
erant pipes to air ceiver
conditioner com‐
pressor and for
air conditioner
compressor itself
e-Golf ♦ Low-pres‐ – Remove dryer car‐ – Install
2014 ► sure side tridge and seal re‐ adapter
adapter - ceiver. - VAS
VAS 6338/3
6338/12- – After flushing, in‐ 4- in
stall a new dryer place of
♦ High-pres‐ cartridge. expan‐
sure side sion
adapter - valve
VAS 6338/3- (or a
♦ Purging elec‐ drilled
trical air con‐ out ex‐
ditioner com‐ pan‐
pressor, sion
adapter - valve
VAS ⇒
6338/40- and lksw
pa
o
Adapter - s wa gen AG
.V agen AG
doege
s
71 )
k not
VAS Vol gu
by
6338/41-ori,se
d – After arante
Observe ut
h purg‐ eo
ra
notes:
ssa ing, in‐ c
stall a
ce
e

⇒ page 82
nl

pt

new ex‐
du

an
itte

pan‐
y li
erm

ab

sion
ility
ot p

valve.
wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

118 Rep. gr.00 - Technical data


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut Amarok 2011 ➤ , Beetle 2012 ➤ , Bora r a 1999
➤ , CC 2010 ➤ , CC 2012 ➤ , ...
c
s
s Air conditioning system with refrigerant R134a - Edition 10.2014

ce
e
nl

pt
du

an
Vehicle Adapters re‐ itte
Adapters required for Miscella‐

y li
erm

ab
quired for refrig‐ refrigerant pipes to re‐ neous

ility
ot p

erant pipes to air ceiver

wit
, is n

conditioner com‐

h re
pressor and for
hole

spec
air conditioner
es, in part or in w

compressor itself

t to the co
e-Golf ♦ Low-pres‐ – Remove reservoir – Start
2014 ► sure side (dryer), and bridge “Basic

rrectness of i
with adapter - refrigerant pipes. setting”
heat VAS in ⇒ Ve‐
l purpos

pump 6338/12- – Join two adapters - hicle di‐


VAS 6338/6- and agnos‐
♦ High-pres‐ connect to hose - tic test‐

nf
ercia

o
sure side VAS 6338/31- . er, and

rm
adapter -
m

atio
start
m

VAS 6338/3-
o

– After flushing, in‐ the

n in
or c

stall a new reser‐ func‐

thi
♦ Purging elec‐
te

sd
voir. tion
a

trical air con‐


iv

o
r

“Charg
rp

cu
ditioner com‐
o

m
e refrig‐
f

en
ng

pressor,
t.
yi
erant
Co
adapter -
op py
circuit”.
t. C rig
VAS gh ht
♦ This will
yri by
6338/40- and
op Vo
by c
open
lksw
Adapter -
cted agen
Prote
the
AG.
VAS
6338/41- , electri‐
Observe cal
notes: valves
⇒ page 82 in the
refrig‐
erant
circuit.
♦ Leave
vehicle
diag‐
nostic
tester
con‐
nected
to keep
the
valves
open.

7. Clearing refrigerant circuit of contaminants 119


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Golf Hybrid 2014


Vehicle Adapters re‐ Adapters Arequired
G. Volkswafor
gen Miscella‐
agen pipes to re‐ AG
quired for refrig‐ refrigerant neous
does
olksw not
erant pipes to eaird b ceiver
yV gu
ara
conditionerhcom‐
oris nte
eo
pressor sand
au for
t ra
c
air conditioner
s

ce
e

compressor itself
nl

pt
du

an
itte

Golf Hy‐ ♦ Low-pres‐ There are two versions ♦ Install

y li
erm

ab
brid sure side of the fluid receiver: adapter -

ility
ot p

2014 ► adapter - See vehicle specific re‐ VAS

wit
, is n

VAS pair manual. 6338/38-

h re
6338/12- ♦ Fluid receiver with in place of
hole

spec
permanently fitted expan‐
es, in part or in w

♦ High-pres‐ dryer sion valve

t to the co
sure side (or a dril‐
adapter - – Can be flushed led out ex‐
VAS 6338/3- through. pansion

rrectness of i
– After flushing, in‐ valve
♦ Purging elec‐ stall a new receiver. ⇒
l purpos

trical air con‐ ♦ Receiver with des‐


ditioner com‐ page 71 )
iccant bag or car‐
pressor,

nform
ercia

tridge ♦ Replace
adapter - shut-off
m

VAS – Remove desiccant

at
valves -
om

io
6338/40- and bag/cartridge and N541-

n
c

in t
r

Adapter - seal fluid receiver.


o

and -
his
e

VAS
at

N542- do
riv

6338/41- , – After purging, in‐ with two


p

cum
or

Observe stall a new desic‐


f

shut-off
en
ng

t.
notes: cant bag/cartridge.
yi
taps -
Co
op
⇒ page 82
py
VAS
. C rig
ht ht
rig
6338/42- .
py by
co Vo
Comply
by lksw
cted agen
Prote
with notes
AG.


page
121 .
♦ Remove
restrictor
in refriger‐
ant line to
heat ex‐
changer
for high-
voltage
battery,
and drill it
out (see
notes be‐
low)

page
121 .

120 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

In the Golf Hybrid 2014, the refrigerant circuit is flushed in 2 cy‐


cles. For the first cycle, the adapter for the shut-off valve -N541-
is open, and the adapter for shut-off valve -N542- is closed. This
will cause the refrigerant circuit with the evaporator in the heater
and air conditioning unit to be flushed. For the second cycle, the
adapter for the shut-off valve agen
-N541-
AG. Volkswis
ageclosed,
n AG d and the adapter
for shut-off valve -N542- Volksw is open. This will cause
oes
nthe
ot refrigerant
circuit with thesevaporator
ed by
in the heat exchanger forguhigh-voltage
ara
battery to be thoflushed
ri ⇒ Heating, air conditioning; Rep. Gr.
nte
e o87;
Refrigerant
s a circuit; System overview - refrigerant circuit (repair
u ra
c
manual for the specific vehicle).
s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
Note
ot

wit
, is n

h re
hole

♦ The illustration shows a refrigerant line -A- with a permanently

spec
installed restrictor -B- (without strainer). This refrigerant line
es, in part or in w

t to the co
must be drilled open with a suitable 5 mm drill bit (remove the
restrictor if it is removable), and it must be cleaned before it is
installed in the purging circuit. Renew the refrigerant line which

rrectness of i
has been drilled open after purging has been completed ⇒
Electronic Parts Catalogue .
l purpos

♦ The diameter of the shown restrictor hole -B- is


approx. 0.7 mm. Depending on the refrigerant line version, this nform
ercia

restrictor is permanently installed or it can be removed. For the


removable version a strainer may be fitted to prevent the re‐
m

a
com

strictor hole from being blocked by suspended particles.


ion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Clearing refrigerant circuit of contaminants 121


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

8 Complaints

8.1 Possible complaints about refrigerant


circuit

Note
AG. Volkswagen AG d
agen oes
lksw not
♦ The air conditioning by system is operating correctly ifguthe
Vo
ara air
emerging from is the vent on the dashboard is at a temperature
ed
r nte
ho
of 7oC or aless.
eo
ut ra
ss c
♦ Set the Climatronic to: “LO”.

ce
le
un

pt
an
d

♦ Set the air conditioning system: “AC” on; “max”; “cold”.


itte

y li
rm

ab
pe

ility
8.1.1 Test prerequisites:
ot

wit
, is n

h re
hole

• Self-diagnosis of the air conditioning system with the Vehicle

spec
diagnosis, testing and information system - VAS 5051A- using
es, in part or in w

t to the co
“Guided Fault Finding” cannot detect any faults; no switch-off
conditions for the air conditioner compressor are set in the
measured value block (only when the vehicle “air conditioning
rrectness of i
system” is fitted with self-diagnosis).
⇒ Rep. gr. 87
l purpos

8.1.2 Possible complaints


nform
mercia

a
com

ti

Note
on in
r
te o

thi

For all complaints marked with a * ⇒ page 127 .


s
iva

do
r
rp

cum
fo

en
g

♦ The cooling has failed completely. *


n

t.
yi Co
op py
♦ Insufficient cooling at all vehicle speeds and engine speeds.*
t. C rig
gh ht
pyri by
Vo
o
♦ No cooling or insufficient cooling after a distance of several
by c lksw
cted agen
kilometres has been driven. * Prote AG.

♦ The air conditioner compressor, the air conditioning system


magnetic clutch - N25- or the air conditioner compressor reg‐
ulating valve - N280- have been switched off by low-pressure
switch for magnetic clutch - F73- , high-pressure switch for
magnetic clutch - F118- , air conditioning system pressure
switch - F129- or by operating and display unit for Climatronic
air conditioning system - E87- or Climatronic control unit -
J255- because pressure was too high or too low.* *
♦ No fresh air flow, or very much reduced fresh air flow after
driving some distance (evaporator iced up). *
In addition the following complaints may also arise:
The air conditioner compressor is noisy
– Tighten the securing screws for the air conditioner compressor
and the air conditioner compressor bracket using a torque
wrench.
– Check routing of refrigerant pipes; they must not touch other
components and must be installed without tension (adjust if
necessary).

122 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Noises (refrigerant hammering) occur immediately after the air


conditioning is switched on and/or in a curve or when the brakes
are applied:
– Discharge refrigerant circuit, evacuate and charge again (too
much refrigerant in circuit).

Note

♦ Excess refrigerant oil in the circuit may also cause this problem
(e.g. if the refrigerant oil level AwasG. Vonot
lkswchecked
agen AG after the air
conditioner compressor lkswas
wagenrenewed). In case doof
es nthis com‐
plaint, the refrigerant by circuit
Vo must be purged with R134a
ot g
ua re‐
frigerant ⇒ page i 67 .
ed ran
r s tee
o h
ut or
♦ The refrigerant
ss
a must be drained from the air conditioning com‐ac
pressor. To facilitate this process, turn the air conditioner

ce
e
nl

pt
compressor over by hand at the poly V-belt pulley or coupling
du

an
itte

disc of the magnetic coupling. Then fill refrigerant circuit with

y li
erm

ab
total amount of refrigerant oil (50 g direct into air conditioner

ility
ot p

compressor) according to ⇒ vehicle-specific workshop man‐

wit
, is n

ual .

h re
hole

spec
Water sprays out of the air vents (dash panel or footwell) although
es, in part or in w

t to the co
the air conditioning system otherwise works properly:
– Check that the condensation water drain is properly routed; it
must not be pinched or kinked.

rrectness of i
– The condensed water drain valve must not be hindered in its
l purpos

operation by wax or underbody sealant and must open and


close properly. nform
ercia

– Check the plenum chamber cover; it must be undamaged and


m

be installed correctly (no water must flow into the evaporator).


at
om

ion
c

– Check water drains in plenum chamber; they must not be


in t
or

blocked (e.g. by leaves).


his
ate

do
priv

8.2 Smells from heater and air conditioner


um
for

en
ng

unit
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
8.2.1 Is the smell coming from evaporator or
cted agen
Prote AG.

the heat exchanger?


♦ Fishy smell
– Due to leak in engine's cooling system or in heat exchanger of
heater and air conditioner unit.

Note

If the fishy smell is weaker when the temperature is set to “cold”


or stronger when the temperature is set to “warm”, check the heat
exchanger for leaks.

♦ Smell of a burnt clutch


♦ Vapours from foot mats, retrospectively installed seat covers
etc.
♦ Putrid, mouldy smell
– Due to accumulation of leaves, pine needles etc. in plenum
chamber.

8. Complaints 123
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

Clean plenum chamber.


n AG. Volkswagen AG do
lkswage es n
Vo ot g
– Use water so that it cannot flow out d of plenum chamber.
by ua
ran
ir se tee
tho
u or
a ac
ss
Note

ce
le
un

pt
an
d
itte

Check water runoff points in plenum chamber.

y li
erm

ab
ility
ot p

♦ Smell from heater and air conditioner unit

wit
is n

h re
ole,

spec
urposes, in part or in wh

Note

t to the co
Smells that can originate in heater and air conditioner unit can be
detected in fresh air mode and in recirculation mode.

rrectne
– Due to too much condensation water in heater and air condi‐

s
tioner unit

s o
cial p

f inform
mer

Note

atio
om

n
c

i
or

n
Check the runoff points of condensation water ⇒ Rep. gr. 87 as

thi
e

indicated in the vehicle-specific repair manual.


t

sd
iva

o
pr

cum
r
fo

– Due to an old or very dirty dust and pollen filter en


ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
Check the dust and pollen filter ⇒ Rep. gr. 80 as indicated in the
vehicle-specific repair manual.

– Due to deposits on the fins of the evaporator

Note

Clean the evaporator, using the ultrasonic air conditioner cleaning


unit - VAS 6189A- ⇒ page 124 or the suction feed spray-gun -
V.A.G 1538- and corresponding spray lance ⇒ page 125 .

8.2.2 Ultrasonic air conditioner cleaning unit -


VAS 6189A-
– The ultrasonic air conditioner cleaning unit - VAS 6189A- must
be placed in the front-passenger footwell and sprays the agent
Aero-Clean. Aero-Clean neutralises microbes and bacteria in
the heater and air conditioner unit.
The device is provided with instructions for use.
Current equipment ⇒ ServiceNet; Workshop Equipment; Cata‐
logue; Workshop equipment; Air conditioning/heating; Service
equipment

124 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

8.2.3 Spraying the evaporator with the suction


feed spray-gun - V.A.G 1538- and spray
lance
Spray the evaporator with Contra Sept directly using a spray
lance (approx. 10 bar). Contra Sept neutralises microbes and
bacteria directly at the evaporator.
In order to enable access to the evaporator, some preliminary
work and different spray lances are necessary, e.g. V.A.G 1538/5;
V.A.G 1538/6 or V.A.G 1538/7.
Vehicle-specific instructions for user are provided with the evap‐
orator cleaning solution D 600 100 A2.
Current equipment and spray lances ⇒ ServiceNet Function
“Search”

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

8. Complaints 125
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

9 Connecting air conditioner sservice


wage
n AG. Volkswagen AG do
es n
station olk ot g
byV ua
ed ra nte
ris
utho eo
ra
a c
ss
9.1 For vehicles that have connections on

ce
e
nl

pt
du
both low-pressure and high-pressure

an
itte

y li
erm

ab
sides of refrigerant circuit

ility
ot p

wit
, is n

h re
hole

9.1.1 Connecting air conditioner service sta‐

spec
es, in part or in w

tion for measuring and checking

t to the co
– Switch off ignition.

rrectness of i
– Connect air conditioner service station to power supply.
l purpos

– Connect quick-release coupling adapters to charging hoses


for air conditioner service station (handwheels not turned in‐
wards, i.e. hand shut-off valves not open).

nform
ercia

– Switch on air conditioner service station and evacuate charg‐


m

at
om

i
ing hoses (necessary only if there is air in the charging hoses).

on
c

in t
or

– Switch off air conditioner service station.

his
ate

do
riv

– Unscrew sealing caps from service connections (with valve).


p

cum
for

en
ng

– Connect air conditioner service station via service connections


t.
yi Co
op
to the vehicle refrigerant circuit using quick-release coupling
C py
t. rig
gh
adapter.
ht
pyri by
Vo
co lksw
by
– Turn handwheel of quick-release coupling adapter inwards
cted agen
Prote AG.
only far enough to ensure that valves on service connections
are open (check using a pressure gauge; do not overstress
valves).
– Perform the intended measuring and checking work.

126 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

10 Checking pressures on vehicles

10.1 Checking pressures in refrigerant circuit


(using air conditioner service station)olkswagen AG.
Volkswagen AG
does
no t gu
yV
db ara
rise nte
tho eo
Note s au ra
c
s

ce
le
♦ Check the cooling performance. The air conditioning system

un

pt
an
d
is operating correctly if the air emerging from the vent on the

itte

y li
rm
dashboard is at a temperature of 7oC or less.

ab
pe

ility
ot
♦ Set the Climatronic to: “LO”.

wit
, is n

h re
hole

♦ Set the air conditioning system: “AC” on; “max”; “cold”.

spec
es, in part or in w

♦ Connections with valve and service connections for measuring

t to the co
and testing.

rrectness of i
10.1.1 Test prerequisites
l purpos

• Radiator and condenser must be clean (clean them if neces‐


sary).

nform
ercia

• The heat insulation on expansion valve is OK and properly


installed. See vehicle-specific repair manual ⇒ Rep. gr. 87 .
m

a
com

tion in
• The poly V-belt is OK and properly tensioned. The V-belt for
r
te o

thi
air conditioner compressor and alternator is in good condition

s
iva

and correctly tensioned. See vehicle-specific repair manual ⇒

do
r
rp

c
Rep. gr. 87

um
fo

en
ng

t.
yi
• All air ducts, covers and seals are OK and properly installed.
Co
Cop py
t. rig
gh
• Fault-finding on the electrical systems and vacuum system
ht
pyri by
has found no faults. See vehicle-specific repair manual ⇒ Rep.
co Vo
by lksw
cted agen
gr. 87 Prote AG.

• Self-diagnosis of the air conditioning system with the vehicle


diagnosis, testing and information system - VAS 5051A- using
“guided fault finding” cannot detect any faults; no switch-off
conditions for the air conditioner compressor are set in the
measured value block (only when the vehicle “air conditioning
system” is fitted with self-diagnosis).
• The passage of air through the dust and pollen filter is not im‐
paired by dirt. See vehicle-specific repair manual ⇒ Rep. gr.
87
• The heater and air conditioner does not draw any secondary
air at highest fresh air blower speed. The evaporator and heat‐
ing do not draw any uncooled air at highest fresh air blower
speed. See vehicle-specific repair manual ⇒ Rep. gr. 87
• The air duct flaps in the heater and air conditioner reach their
stop positions. See vehicle-specific repair manual ⇒ Rep. gr.
87
• The fresh air intake ducts under the bonnet and in the pas‐
senger compartment and their water drain valves are in good
condition. See vehicle-specific repair manual ⇒ Rep. gr. 87
• The engine is at operating temperature.
• The vehicle is not exposed to direct sunlight.
• The ambient temperature is higher than 15°C.
• All dash panel air vents are open.

10. Checking pressures on vehicles 127


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

• With engine running and air conditioning set for maximum


cooling output:
⇒ Rep. gr. 87
Setting maximum cooling output
Settings on operating and display unit for Climatronic air condi‐
tioning system - E87-
– Select “Auto” mode (air conditioner compressor switched on).
– Select temperature setting “LO” for driver and front passenger.
Settings on heater controls:
– A/C button and Rec or recirculate
en AG. V
olbuttons
kswagen Ashould
G
be pressed.
ag does
ksw not
Vol switch to “Cold” stop.
– Set rotary temperature gu
by d ara
ise nte
– Set rotary fresh
ut
ho air blower switch to “4”.
r eo
ra
sa c
• The radiator
s fan(s) should be running radiator fan - V7- (at

ce
e

least at speed 1).*


nl

pt
du

an
itte

y li
erm

ab
ility
Note
ot p

wit
, is n

h re
In some versions, the fan is not switched on until the pressure in
hole

spec
the refrigerant circuit has exceeded a specified value.
es, in part or in w

t to the co
• The fresh air blower - V2- should be running at maximum
speed.
rrectness of i

• The air flap for fresh air and air recirculation moves to the “re‐
circulation” position or the air flow flap closes and the recircu‐
l purpos

lation flap opens (within 1 minute of starting the vehicle).


• The coolant shut-off valve is closed. *
nf
ercia

orm
m

• The valves for the pump valve unit are closed (and the coolant
atio
m

circulation pump is not pumping).*


o

n in
or c

thi

10.1.2 Checking pressures


te

sd
iva

o
r
rp

cu

– Switch off ignition.


o

m
f

en
ng

t.
yi Co
– Connecting air conditioner service station ⇒ page 126 . ht. Cop py
rig
rig ht
– Read pressure from pressure gauges; two results may be dis‐ py by
co Vo
played.
by lksw
cted agen
Prote AG.

Ambient temperature (in de‐ Pressure in the refrigerant cir‐


grees centigrade) cuit in bar positive pressure
+15℃ 3.9
+20 ℃ 4.7
+25℃ 5.6
+30 ℃ 6.7
+35℃ 7.8
+40 ℃ 9.1
+45℃ 10.5

128 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ The temperature of the components of the refrigerant circuit


should be the same as the ambient temperature.
♦ If individual components of the refrigerant circuit are warmer
or colder, then the pressure will deviate from the values shown
in the tables.
♦ Absolute pressure means that 0 bar corresponds to an abso‐
lute vacuum. The normal ambient pressure (positive pressure)
corresponds to 1 bar absolute pressure. On most pressure
gauges, a reading of 0 bar corresponds to an absolute pres‐
sure of one bar (which is confirmed by the existence of - 1 bar
marking beneath the 0 scale marking).
♦ Where vehicles have a high-pressure sender - G65- which in‐
dicates the measured pressure in the measured values block,
. Volkswagen AG
the measured pressure kswashould
gen AG agree with the
doevalues
s no in the
tables. by Vol t gu
a
ed ran
oris tee
th
⇒ Rep. gr. s87
au
or
ac
s

ce
The pressure in the refrigerant circuit is lower than indicated in
e
nl

pt
du

the table

an
itte

y li
erm

ab
Insufficient refrigerant in circuit.
ility
ot p

wit
– Check for leaks in the refrigerant circuit ⇒ page 58 .
, is n

h re
hole

– Check the high-pressure safety valve. spec


es, in part or in w

If the high-pressure safety valve has blown off:


t to the co

– Check activation of radiator fan.


rrectness of i

– Check refrigerant pipes and refrigerant hoses for restrictions


in cross-section at bends that have too tight radius.
l purpos

– Check refrigerant pipes and refrigerant hoses for external


damage.
nform
ercia

– If no defects are found, blow through refrigerant circuit with


m

at

compressed air and nitrogen.


om

ion
c

in t
r

The pressure in the refrigerant circuit is equal to or greater than


o

his
e

that in the table


at

do
priv

cum
or

– Start engine.
f

en
ng

t.
yi Co
– On vehicles with electrical air conditioner compressor, switch Cop py
off ignition.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING
Prote AG.

High voltage on high-voltage system of hybrid vehicle. Danger


of electric shock! Before starting work, carry out a visual check
of high-voltage components in area of work. Comply with gen‐
eral warnings ⇒ Hybrid electrical system; Rep. gr. 93 ; General
warnings for working on the high-voltage onboard power sup‐
ply system .

– Set air conditioning system for maximum cooling output.

10. Checking pressures on vehicles 129


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

If the low-pressure switch had been removed in order to connect


the air conditioner service station, bridge the electrical connec‐
tions in the respective connector for pressure measurement.

• The air conditioner compressor is driven by the engine via the


air conditioning system magnetic clutch - N25- .
• The air conditioner compressor regulating valve - N280- is ac‐
tivated by the Climatronic control unit - J255- .
⇒ Rep. gr. 87
n AG. Volkswagen A
If the air conditioner compressor is notodriven
lksw
age or the regulating
G do
es n
ot g
valve not activated when the engine d byis running:
V ua
r e an
ris tee
– Determine the cause, e.g.utby ho reading the event memory for or
the air conditioning system,
ss a
and rectify it. ac

ce
e
nl

– Observe the test prerequisites.

pt
du

an
itte

y li
– Check power supply for air conditioning system magnetic
erm

ab
clutch - N25- . If this is OK, repair magnetic clutch.

ility
ot p

wit
, is n

– Check actuation of air conditioner compressor regulating valve

h re
- N280- .
hole

spec
es, in part or in w

⇒ Rep. gr. 87 .

t to the co
10.1.3 Continuation of checking pressures

rrectness of i
♦ Where vehicles have a restrictor and reservoir, check these
(with internally regulated air conditioning system compressor)
l purpos

⇒ page 130 .
♦ Where vehicles have an expansion valve and receiver, check
nform
ercia

these (with internally regulated air conditioner compressor)


m

⇒ page 135 .
at
om

ion
c

♦ Where vehicles have an expansion valve and receiver, check


in t
or

these (without internally regulated air conditioner compressor)


his
ate

do
riv

⇒ page 141 .
p

cum
for

♦ Where vehicles have a restrictor and reservoir and air condi‐


en
ng

t.
yi
tioning system compressor regulating valve - N280- (external‐
Co
Cop py
ly regulated air conditioning system compressor) ht. rig
rig ht
⇒ page 143 . py by
co Vo
by lksw
cted agen
10.2 Checking systems with a restrictor and
Prote AG.

collector (with internally regulated air


conditioner compressor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .


♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.


– Observe air conditioner service station pressure gauge.

130 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Switch pressures for switches in refrigerant circuit are vehicle-


specific.
♦ The connection with a valve for the low-pressure switch or on
the evaporator should only be used where the vehicle does
not have a service connection on the low-pressure side and
access to the connection on the air conditioner compressor or
reservoir is not possible (measurement accuracy). This only
applies to certain vehicles.

⇒ Rep. gr. 87

10.2.1 Specifications:
High-pressure side:
Rising from starting pressure (when pressure gauge is connec‐
ted) to maximum 20 bar.
Low-pressure side: n AG. Volkswagen AG do
lkswage es n
Falling from starting pressure (whend bpressure
yV
o
gauge is connec‐ ot g
ua
ted) to diagram value. o
ir se
ran
tee
th or
u
A - High pressure (measured ss at the service connection) in bar
a ac
positive pressure.

ce
le
un

pt
an
d

B - Low pressure (measured at the connection with the valve at


itte

y li
the air conditioner compressor or at the reservoir) in bar positive
erm

ab
ility
pressure.
ot p

wit
is n

C - Permitted tolerance range.

h re
ole,

spec
D - Low pressure (measured at the connection with the valve for
urposes, in part or in wh

the low-pressure switch or at the service connection) in bar pos‐

t to the co
itive pressure.
E - Permitted tolerance range. rrectness o
cial p

f inform
mer

atio
om

n
c

Possible deviation from specification Possible cause of fault Rectifying fault


i
or

n thi
te

sd

• High pressure remains constant or in‐ Insufficient refrigerant in cir‐ – Look for leaks and rectify them.
iva

o
r

creases only slightly (above the pres‐ cuit.


p

cum
r
fo

sure measured when the engine is – Recharge refrigerant circuit.


en
ng

t.
yi
stopped),
Co
Cop py
t. rig
gh
• Low pressure falls quickly to the dia‐
ht
pyri by
Vo
gram value or lower,
co lksw
by
cted agen
Prote AG.
• The required cooling output is not de‐
livered.

• High pressure is normal,


• Low pressure matches the diagram
value,
• The required cooling output is not de‐
livered.

10. Checking pressures on vehicles 131


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a -AEdition
G. Volksw10.2014
agen A
n G do
wage es n
Volks ot g
y
Possible deviation from specification ised bPossible cause of fault ua
ranRectifying fault
or tee
• High pressure is normal, au
th or
ac
ss
• Low pressure is too low (see dia‐

ce
e
nl

pt
du
gram),

an
itte

y li
erm
• The required cooling output is not de‐

ab
ility
livered.
ot p

wit
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
If no fault can be found for this complaint, purge (clean) refrigerant
circuit with refrigerant R134a ⇒ page 67 . If this is not possible in

rrectness of i
your workshop, blow through refrigerant circuit with compressed
air and dry with nitrogen ⇒ page 65 .
l purpos

nform
mercia

at
Possible deviation from specification Possible cause of fault Rectifying fault
om

ion
c

in t
• High pressure increases only slightly The air conditioner compressor is de‐ – Purge (clean) refriger‐
or

his
e

above the pressure measured when fective. ant circuit ⇒ page 67 .


at

do
riv

the engine is stopped,


p

cum
or

– Renew air conditioner


f

en
g

• Low pressure falls only slightly,


n

compressor.
t.
yi Co
op py
• The required cooling output is not
. C rig
ht ht
rig
delivered. py by
co Vo
by lksw
cted agen
Prote AG.

Possible deviation from specification Possible cause of fault Rectifying fault


• High pressure rises above specifica‐ Restriction or obstruction in the refrigerant – Feel the refrigerant
tion, circuit. circuit with the hand
to sense the tem‐
• Low pressure falls quickly to the di‐ perature gradient.
agram value or lower,
• The required cooling output is not • At one component a
delivered. temperature gradi‐
ent will be detected:
– If a hose or pipe is
kinked or crushed,
renew it.

– In case of an ob‐
struction, blow
through refrigerant
circuit with com‐
pressed air and ni‐
trogen.

– Repeat the check; if


the system does not
operate correctly

– Purge (clean) refrig‐


erant circuit
⇒ page 67 .

132 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specification Possible cause of fault Rectifying fault


• High pressure and low pressure are Moisture in the refrigerant circuit. – Blow through refrig‐
normal at first, but after a time, erant circuit with
compressed air and
• The high pressure increases beyond nitrogen.
the specified value, AG. Volkswagen AG d
agen oes
lksw no–t Renew receiver.
• The low pressure falls to the diagram d by
Vo gu
ara
value or lower, rise nte
ut
ho – Repeat
e o the check; if
ra
• The cooling power called for is not ss a the systemc does not
delivered. operate correctly

ce
e
nl

pt
du

an
itte
– Purge (clean) refrig‐

y li
erm

ab
erant circuit

ility
ot p
⇒ page 67 .

wit
, is n

h re
– Recharge refriger‐
hole

spec
ant circuit.
es, in part or in w

t to the co
– Repeat check.
• High pressure is normal, The air conditioner compressor is defec‐ – Purge (clean) refrig‐
tive. erant circuit

rrectness of i
• Low pressure is too low (see dia‐ ⇒ page 67 .
gram),
l purpos

• The cooling power required is deliv‐ – Renew air condi‐


tioner compressor.

nf
ered.
ercia

orm
m

atio
om

n in
or c

Note

thi
te

sd
iva

o
r
rp

cu
♦ If the fault is “high pressure normal, low pressure too low ”
o

m
f

en
ng

please note the following:


t.
yi Co
op py
♦ In this case, the evaporator may be iced up or the low-pressure
t. C rig
gh ht
yri
switch for air conditioning system - F73- has switched off the p by
o Vo
by c
air conditioning system compressor, although the correct
lksw
cted agen
Prote
quantity of refrigerant is present in the refrigerant circuit.
AG.

10. Checking pressures on vehicles 133


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying


from specification fault
• High pressure nor‐ Too much refrigerant in – Extract
mal or too high, circuit. some re‐
frigerant
• Low pressure too from the
high (see dia‐ refriger‐
gram), ant cir‐
• The air conditioner cuit.
compressor is
noisy (especially • The
immediately after quantity
being switched of refrig‐
on), erant ex‐
tracted is
• The required cool‐ about
ing output is not equal to
delivered. the pre‐
scribed
charge
quantity.
– Renew
the air
condition‐
er com‐
pressor.

• The
quantity
of refrig‐
erant ex‐
tracted is
signifi‐
n AG. Volkswagcantly
en AG
lkswage greaterdoes
n
by Vo than the ot gua
ris
ed
prescri‐ ran
tee
tho bed or
au ac
ss charge
quantity.
ce
le
un

pt
an
d
itte

– Recharge
y li
erm

ab

refriger‐
ility
ot p

ant cir‐
wit
is n

cuit.
h re
ole,

spec

– Repeat
urposes, in part or in wh

check.
t to the co

Possible deviation from specification Possible cause of fault Rectifying fault


rrectne

• High-pressure and low-pressure Too much refrigerant oil in circuit. – Drain refrigerant cir‐
are normal, cuit.
ss

• The required cooling output is not – Purge (clean) refrig‐


o
cial p

delivered.
i

erant circuit
nform

⇒ page 67 .
mer

atio
m

• High-pressure and low-pressure


o

n
c

are normal,
i
or

n thi
te

sd
a

• The air conditioner compressor is


iv

o
r

noisy (especially immediately af‐


p

cum
r
fo

ter being switched on),


en
ng

t.
yi Co
op
• The cooling power required is de‐
C py
t. rig
gh
livered.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

134 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Overfilling with refrigerant oil can occur if the refrigerant oil


level was not checked after the air conditioner compressor
was renewed.
♦ If the air conditioner compressor is not to be replaced, drain
refrigerant oil from air conditioner compressor via the drain
plug. From the total amount of refrigerant oil, fill 50 g direct into
air conditioner compressor and fill remainder in refrigerant cir‐
cuit according to ⇒ vehicle-specific workshop manual .

10.3 Checking systems with an expansion


valve and reservoir (with internally regu‐
lated air conditioner compressor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .


♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.


– Observe manifold gauge.

Note

The switch pressures and the versions of switches in the refrig‐


erant circuit are vehicle-specific.

Pressures must be measured at the service nconnections;


AG. Volkswagenthe
AG dfit‐
wage oes
ting locations of these connectionsyare
Volksvehicle-specific. not
g b ua
ed ran
⇒ Rep. gr. 87 horis tee
t or
au ac
10.3.1 Specifications:
ss
ce
le
un

pt

High-pressure side:
an
d
itte

y li
erm

ab

Rising from starting pressure (when pressure gauge is connec‐


ility
ot p

ted) to maximum 20 bar.


wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
135
by c lksw
cted
10. Checking pressures on vehicles
agen
Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Low-pressure side:
Falling from starting pressure (when pressure gauge is connec‐
ted) to diagram value.
A - High pressure in bar positive pressure.
B - Low pressure in bar positive pressure.
C - Permitted tolerance range.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

136 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying


from specification fault
• High pressure re‐ Too little refrigerant in cir‐ – Extract
mains constant or cuit or expansion valve some re‐
increases only defective. frigerant
slightly (above the from the
pressure meas‐ refriger‐
ured when the en‐ ant cir‐
gine is stopped), cuit.
• Low pressure falls • The
quickly to the dia‐ quantity
gram value or low‐ of refrig‐
er, erant ex‐
• The required cool‐ tracted is
ing output is not about
delivered. equal to
the pre‐
scribed
charge
quantity.
– Renew
expan‐
sion
valve.

– Recharge
refriger‐
ant cir‐
cuit.

– Repeat
check.
• High pressure is • The
normal, quantity
of refrig‐
• Low pressure erant ex‐ olkswagen AG
matches the dia‐ en AG. V
tracted isolkswag does
not
gram value, signifi‐ byV gu
ara
ed
• The required cool‐ cantly
oris nte
eo
th
uless
ing output is not s a than ra
c
s the pre‐
delivered. ce
e

scribed
nl

pt
du

an
charge
itte

y li
quantity.
erm

ab
ility
ot p

– Look for
wit
, is n

leaks us‐
h re
hole

ing leak
spec

detector
es, in part or in w

and recti‐
t to the co

fy them.

– Recharge
rrectness of i

refriger‐
l purpos

ant cir‐
cuit.
nform
ercia

– Repeat
check.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen

137
Prote AG.
10. Checking pressures on vehicles
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

If no fault can be determined and the function of the air condi‐


tioning system is not OK when the test is repeated, purge refrig‐
erant circuit with refrigerant R134a (clean) ⇒ page 67n A. G
If. this
Volksis
wagen AG
not possible in your workshop, blow through refrigerant
lksw
age circuit with does
not
compressed air and dry with nitrogen ⇒ paged b 65 .
Vo gu
y ar
e an
ris tee
tho or
Possible deviation Possible cause of fault au Rectifying ac
ss
from specification fault

ce
e
nl

pt
du

an
• High pressure ♦ Restriction or obstruc‐ – Feel the
itte

y li
rises above speci‐ tion in the refrigerant refriger‐
erm

ab
ility
fication, circuit. ant circuit
ot p

with the

wit
, is n

• Low pressure falls ♦ Expansion valve de‐

h re
hand to
hole

quickly to the dia‐ fective. sense the

spec
gram value or low‐ tempera‐
es, in part or in w

t to the co
er, ture gra‐
• The required cool‐ dient.
ing output is not

rrectness of i
delivered. • At one
compo‐
l purpos

nent a
tempera‐
ture gra‐

nform
ercia

dient will
m

be detec‐

at
om

io
ted:

n
c

in t
or

his
e

– If a hose
at

do
riv

or pipe is
p

cum
or

kinked or
f

en
g

crushed,
n

t.
yi Co
op
renew it.
C py
t. rig
gh ht
pyri by
– In case of
o Vo
by c lksw
cted
an ob‐
agen
Prote AG.
struction,
purge re‐
frigerant
circuit
with com‐
pressed
air and ni‐
trogen
and re‐
new ex‐
pansion
valve.
• If no
faults are
found:
– Purge
(clean)
refriger‐
ant circuit

page 67 .

– Repeat
check.

138 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

If the air conditioning system is still not operating correctly after


the refrigerant circuit has been purged with compressed air and
nitrogen, the expansion valve must be renewed.
AG. Volkswagen AG d
agen oes
ksw
Possible deviation
by
Vol
from specification not
gu Possible cause of fault
ara
Rectifying fault
ed
is nte
• High hopressure
r and low pressure ♦ Expansion valve
eo defective. – Examine the expan‐
are autnormal at first, ra sion valve for dirt or
c
ss
♦ Moisture in the refrigerant circuit. corrosion; renew if

ce
le

• After a while, the high pressure necessary.


un

pt
increases beyond the specifica‐

an
d
itte

y li
tion, and the low pressure falls to
erm

– Blow through refrig‐

ab
the diagram value or lower,

ility
erant circuit with
ot p

wit
compressed air and
is n

• The cooling power called for is

h re
nitrogen.
ole,

not delivered.

spec
urposes, in part or in wh

– Renew receiver.

t to the co
– Repeat the check; if
the system does not

rrectne
operate correctly

– Purge (clean) refrig‐


ss o erant circuit
cial p

f i
⇒ page 67 .
nform
mer

atio

– Recharge refriger‐
om

ant circuit.
n
c

i
or

n thi
te

sd

– Repeat check.
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
When this fault occurs, always renew receiver.
o Vo
by c lksw
cted agen
Prote AG.

10. Checking pressures on vehicles 139


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specification Possible cause of fault Rectifying fault


• High pressure normal or too high ♦ Too much refrigerant in circuit. – Extract some refrig‐
(see diagram), erant from the re‐
♦ Expansion valve or air conditioner com‐ frigerant circuit.
• The required cooling output is not pressor defective.
delivered. • The quantity of re‐
• The air conditioner compressor is frigerant extracted
noisy (especially immediately af‐ is about equal to the
ter being switched on), prescribed charge
quantity.
– Renew expansion
valve.

– Recharge refriger‐
ant circuit.

– Repeat test.
AG. Volkswagen AG d
agen • oeThe
s no quantity of re‐
olksw t gu
ed by V
frigerantara extracted
horis is significantly
nte
e
s aut
greater thanortheac
s prescribed charge

ce
e

quantity.
nl

pt
du

an
itte

y li
– Recharge refriger‐
erm

ab
ant circuit.

ility
ot p

wit
, is n

– Repeat check.

h re
hole

spec
es, in part or in w

t to the co
Note

If the air conditioning system is still not operating correctly when

rrectness of i
the test is repeated, refit the expansion valve and purge the re‐
frigerant circuit with compressed air and nitrogen. Then renew the
l purpos

air conditioner compressor and receiver.

nf
ercia

orm
m

atio
m

Possible deviation from specification Possible cause of fault Rectifying fault


o

n in
or c

thi
• High pressure increases only ♦ The air conditioner compressor is defec‐ – Purge (clean) refrig‐
te

sd
a

slightly above the pressure tive. erant circuit


iv

o
r
rp

cu

measured when the engine is ⇒ page 67 .


o

m
f

en
ng

stopped,
t.
yi Co
– Renew the air condi‐
op py
• Low pressure falls only slightly,
t. C rig
yri
gh bytioner compressor ht
and receiver.
op Vo
• The required cooling power is not
c by lksw
cted agen
delivered. Prote AG.

Possible deviation Possible cause of fault Rectifying


from specification fault
• High pressure is ♦ Expansion valve or air – Renew
normal, conditioner compres‐ expansion
sor defective. valve.
• Low pressure is
too low (see dia‐ – Recharge
gram), refrigerant
• The cooling pow‐ circuit.
er required is de‐
livered. – Repeat
check.

140 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If repeated check results in air conditioning system still not


operating correctly, purge (clean) the refrigerant circuit
⇒ page 67 . Then renew the air conditioner compressor and
receiver.
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.

Possible deviation from specification Possible cause of fault Rectifying fault


• High-pressure and low-pressure Too much refrigerant oil in circuit. – Drain refrigerant cir‐
are normal, cuit.
• The required cooling output is not – Purge (clean) refrig‐
delivered. erant circuit
⇒ page 67 .
• High-pressure and low-pressure
are normal,
• The air conditioner compressor is
noisy (especially immediately af‐
ter being switched on),
• The cooling power required is de‐
livered.

Note

♦ Overfilling with refrigerant oil can occur if the refrigerant oil


level was not checked after the air conditioner compressor
was renewed.
♦ If the air conditioner compressor is not to be replaced, drain
refrigerant oil from air conditioner compressor via the drain
plug. From the total amount of refrigerant oil, fill 50 g direct into AG. Volkswagen AG d
agen
air conditioner compressor and fill remainder in refrigerant olksw cir‐
oes
not
cuit according to ⇒ vehicle-specific workshop manual .
V gu
d by ara
e nte
ris
ho eo
aut ra
ss c
ce
le
un

pt

10.4 Checking systems with an expansion


an
d
itte

y li

valve and reservoir (without regulated


erm

ab
ility
ot p

air conditioner compressor)


wit
is n

h re
ole,

spec
urposes, in part or in wh

10.4.1 Test prerequisites


t to the co

• Radiator and condenser must be clean (clean them if neces‐


sary).
rrectne

• The V-belt for air conditioner compressor and alternator is


correctly tensioned.
ss o
cial p

• All air ducts, covers and seals are OK and properly installed.
inform
mer

• The flaps reach their end positions.


atio
m

• The engine is at operating temperature.


o

n
c

i
or

n thi
e

• The evaporator and heating do not draw any uncooled air at


t

sd
va

highest fresh air blower speed.


i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

141
op Vo
by c lksw
Prote
cted 10. Checking pressures on vehicles
AG.
agen
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

With the engine running and the air conditioning system set to full
power, check the following points:
• The fresh air blower is running
• The radiator fan is running or is switched on.
• The fresh air and air recirculation flap is set to “recirculate”.
• The ambient temperature is more than 15oC.
• The temperature switch for evaporator - E33- is correctly fitted
and its switching temperatures are correct.

10.4.2 Checking
– Switch off ignition.
– Connect manifold gauge (air conditioner service station).
– Read pressure gauge. It may display two results, A and B.
Ambient temperature in de‐ waPressure
gen AG
. Volin the refrigerant
kswagen AG
does cir‐
grees centigrade y V olks
cuit in bar positive pressurenot
gu b ara
ed
+15℃ thoris 3.9 nte
e or
au
+20 ℃
ss 4.7 ac

ce
le

+30 ℃ 6.7
un

pt
an
d
itte

+40 ℃ 9.1
y li
rm

ab
pe

ility
♦ A- The pressure in the refrigerant circuit is less than shown in
ot

wit
, is n

the table, (insufficient refrigerant in the circuit). h re


hole

- Check for leaks using leak detector.


spec
es, in part or in w

t to the co

- The high-pressure safety valve has opened; check the activation


for the radiator fan referring to the current flow diagram.
Check refrigerant pipes and refrigerant hoses for bends that have
rrectness of i

too tight radius (restrictions in cross-section) and for external


damage. If no faults are found, purge the refrigerant circuit.
l purpos

♦ B- The pressure in the refrigerant circuit is greater than or


equal to the value in the table.
nform
ercia

– Start engine.
m

a
com

tion in

– Set air conditioning system to maximum cooling power.


r
te o

thi
s
iva

– Open doors.
do
r
rp

cum
fo

– Open vents in dash panel.


en
ng

t.
yi Co
op
The air conditioner compressor is driven by the engine, via the V- C py
t. rig
belt and magnetic clutch. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

♦ If the air conditioner compressor is not being driven, check the


power supply for the air conditioning system magnetic clutch
- N25- in accordance with the current flow diagram.
♦ If power supply is OK, repair magnetic clutch.

If the air conditioner compressor is not being driven, check the


refrigerant circuit:
– Raise engine speed to 2,000 rpm.
– Observe the manifold gauge.

142 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

10.4.3 Specifications
High-pressure side:
Increasing from the pressure when the engine is stopped to a
maximum of 20 bar positive pressure.
Low-pressure side:
Decreasing from the pressure when the engine is stopped to 1.3
bar positive pressure.

10.5 Checking systems with a restrictor and


reservoir and air conditioner compres‐
sor regulating valve - N280- (with exter‐
nally regulated air conditioner compres‐
sor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .


AG. Volkswagen AG d
agen
♦ Observe the test
Vol prerequisites ⇒ page 127 .ot g
ksw
oes
n
y ua
db ran
rise tee
– Raiseuthengine
o speed to 2,000 rpm. or
s a ac
s
– Observe air conditioner service station pressure gauge.
ce
le
un

pt
an
d
itte

y li
erm

ab

Note
ility
ot p

wit
is n

Switching pressures for the air conditioner compressor regulating


h re
ole,

valve - N280- and the radiator fan - V7- are vehicle-specific.


spec
urposes, in part or in wh

t to the co

⇒ Rep. gr. 87

10.5.1 Specifications:
rrectne

High-pressure side:
s

Rising from starting pressure (when pressure gauge is connec‐


s o
cial p

ted) to 20 bar.
inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

10. Checking pressures on vehicles 143


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Low-pressure side:
Falling from starting pressure (when pressure gauge is connec‐
ted) to diagram value.
A - Low pressure (measured at the service connection) in bar ab‐
solute pressure.
B - Control current for the air conditioner compressor regulating
valve - N280- .
C - Permitted tolerance range.

Note

♦ Under unfavourable conditions (very high ambient tempera‐


tures, high atmospheric humidity), the pressure on the high-
pressure side can increase to a maximum of 29 bar.
♦ The control current -B- is indicated in the measured values
block.
♦ The high pressure is indicated in the measured values block
⇒ Rep. gr. 87 . AG. Volkswagen AG d
agen oes
ksw
♦ The low pressure is adjusted by Vto within tolerances within the t gua
ol no
output range for the air conditioner
ised compressor depending on rante
or air conditioner compressor regulat‐
the control current foruththe eo
ra
ing valve - N280- .ss a c
ce
le

♦ Under unfavourable conditions (very high ambient tempera‐


un

pt
an
d

tures, high atmospheric humidity), the output may be insuffi‐


itte

y li
erm

cient to achieve the specification in every case.


ab
ility
ot p

♦ The set working current for the regulating valve must be great‐
wit
is n

er than 0.3 A to ensure that the regulating valve is reliably


h re
ole,

activated.
spec
urposes, in part or in wh

♦ At the setting for “maximum cooling power”, the control current


t to the co

should be approx. 0.8 A (indicated in the measured values


block) ⇒ Rep. gr. 87 .
rrectne

♦ Absolute pressure means that 0 bar corresponds to an abso‐


lute vacuum. The normal ambient pressure corresponds to 1
bar absolute pressure. On most pressure gauges, a reading
ss o

of 0 bar corresponds to an absolute pressure of one bar (which


cial p

f in

is confirmed by the existence of - 1 bar marking beneath the


form
mer

0 scale marking).
atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

144 Rep. gr.00 - Technical data


Amarok 2011 ➤ge,nBeetle
AG. Volks2012
wagen➤
AG, dBora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
wa oes
y Volks Air conditioning system nwith
ot g refrigerant R134a - Edition 10.2014
b ua
ed ran
oris tee
Possible deviation auPossible
th cause of fault Rectifying fault or
ac
from specification ss

ce
e
nl

pt
• High pressure ♦ Actuation of air con‐ – Check ac‐

du

an
itte
remains con‐ ditioner compressor tuation of air

y li
erm

ab
stant or increa‐ regulating valve - conditioner

ility
ot p

ses only slightly N280- is defective. compressor

wit
, is n

(above the pres‐ regulating

h re
sure measured ♦ Insufficient refriger‐ valve -
hole

ant in circuit.

spec
when the engine N280- .
es, in part or in w

is stopped),

t to the co
– Look for
• Low pressure leaks using
falls quickly to leak detector

rrectness of i
the diagram val‐ and rectify
ue or lower, them.
l purpos

• The required
cooling output is – Recharge re‐

nf
ercia

not delivered. frigerant cir‐

or
cuit.

m
m

atio
m

• High pressure is
o

n in
c

normal,
or

thi
te

sd
a

• Low pressure
iv

o
r
rp

cu
matches the dia‐
o

m
f

en
ng

gram value,
t.
yi Co
op py
• The required
t. C rig
gh ht
yri
cooling output is p by
co Vo
not delivered.
by lksw
cted agen
Prote AG.

• High pressure is
normal,
• Low pressure is
too low (see dia‐
gram),
• The required
cooling output is
not delivered.
• High pressure is
normal,
• Low pressure is
too low (see dia‐
gram),
• The required
cooling output is
not delivered.

Note

If no fault can be found for this complaint, purge (clean) refrigerant


circuit with refrigerant R134a ⇒ page 67 . If this is not possible in
your workshop, blow through refrigerant circuit with compressed
air and dry with nitrogen ⇒ page 65 .

10. Checking pressures on vehicles 145


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifica‐ Possible cause of fault Rectifying fault


tion agen
AG. Volkswagen AG d
oes
olksw not
V
• High pressure increases only ed
by ♦ Actuation of air conditioner
gu
acompressor
ran reg‐ – Check actuation of
slightly above the pressure
horis ulating valve - N280- is defective.
tee air conditioner com‐
ut
measured when thes aengine is
or
ac pressor regulating
stopped, s ♦ The air conditioner compressor is defective. valve - N280- .

ce
le
un

pt
• Low pressure falls only slightly,

an
d

– Purge (clean) refrig‐


itte

y li
erant circuit
erm

ab
• The required cooling output is

ility
⇒ page 67 .
ot p

not delivered.

wit
is n

h re
– Renew air condi‐
ole,

tioner compressor.

spec
urposes, in part or in wh

• High pressure rises above spec‐ ♦ Restriction or obstruction in the refrigerant – Feel the refrigerant

t to the co
ification, circuit. circuit with the hand
to sense the tem‐
• Low pressure falls only slightly, perature gradient.

rrectne
• The required cooling output is
not delivered. • At one component a

s
temperature gradi‐

s o
ent will be detected:
cial p

f inform
mer

– If a hose or pipe is

atio
kinked or crushed,
om

renew it.

n
c

i
or

n thi
te

sd
a

– In case of an ob‐
iv

o
r

struction, blow
p

cum
r
fo

through refrigerant
en
ng

t.
yi
circuit with com‐
Co
op py
pressed air and ni‐
. C rig
ht ht
rig
trogen.
py by
co Vo
by lksw
cted agen
Prote
• If no faults are
AG.

found:
– Purge (clean) refrig‐
erant circuit
⇒ page 67 .
• High pressure and low pressure ♦ Moisture in the refrigerant circuit. – Blow through refrig‐
are normal at first, but after a erant circuit with
while, the high pressure increa‐ compressed air and
ses beyond the specification, nitrogen.
• The low pressure falls to the di‐ – Renew reservoir.
agram value or lower,
• The cooling power called for is – Repeat the check; if
not delivered. the system does not
operate correctly

– Purge (clean) refrig‐


erant circuit
⇒ page 67 .

– Recharge refriger‐
ant circuit.

– Repeat check.

146 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifica‐ Possible cause of fault Rectifying fault


tion
G. Volkswagen
• High pressure is normal, lkswage♦ n A Actuation ofAG
airdoconditioner
es n compressor reg‐ – Check actuation of
y Vo ulating valve - N280-ot g
is
u defective. air conditioner com‐
• Low pressure is toorislow
ed (see di‐
b ara
nte pressor regulating
agram), utho ♦ The air conditioner compressor eo
r
is defective. valve - N280- .
a ac
• ss
The cooling power required is
– Purge (clean) refrig‐

ce
e

delivered.
nl

pt
du

erant circuit

an
itte

y li
⇒ page 67 .
erm

ab
ility
ot p

– Renew air condi‐

wit
, is n

tioner compressor.

h re
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ If the fault is “high pressure normal, low pressure too low ” note
l purpos

the following: if faulty the evaporator could ice up or the re‐


quired cooling output is not delivered.

nf
ercia

o
♦ In this case, the evaporator may ice up although the correct

rm
m

quantity of refrigerant is present in the refrigerant circuit.

atio
om

n in
c

♦ Check the measured value of the evaporator output tempera‐


or

thi
ture sender - G263- or evaporator temperature sensor -
te

sd
iva

G308- .
o
r
rp

cu
o

m
f

♦ Check the actuation of the air conditioner compressor regu‐


en
ng

t.
yi
lating valve - N280-
Co
Cop py
t. rig
gh ht
pyri by
⇒ Rep. gr. 87
co Vo
by lksw
cted agen
Prote AG.
Possible deviation from specifi‐ Possible cause of fault Rectifying fault
cation
• High pressure normal or too ♦ Too much refrigerant in circuit. – Extract some refrig‐
high, erant from the refrig‐
erant circuit.
• Low pressure too high (see di‐
agram), • The quantity of re‐
• The air conditioner compres‐ frigerant extracted is
sor is noisy (especially imme‐ about equal to the
diately after being switched prescribed charge
on), quantity:

• The required cooling output is – Renew the air condi‐


not delivered. tioner compressor.
• The quantity of re‐
frigerant extracted is
significantly greater
than the prescribed
charge quantity:
– Recharge refrigerant
circuit.

– Repeat check.
• High-pressure and low-pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
sure are normal, cuit.
• The required cooling output is – Purge (clean) refrig‐
not delivered. erant circuit
⇒ page 67 .

10. Checking pressures on vehicles 147


AG. Volkswagen AG d
agen oes
olksw not
V
Amarok 2011 ➤ , Beetle 2012 ➤ d ,
b Bora 1999 ➤ , CC 2010 ➤ , CC 2012
y gu
ara ➤ , ...
ise nte
Air conditioning system with threfrigerant
or R134a - Edition 10.2014 eo
au ra
ss c
Possible deviation from specifi‐ Possible cause of fault Rectifying fault

ce
e
nl

pt
du
cation

an
itte

y li
erm
• High-pressure and low-pres‐

ab
ility
sure are normal,

ot p

wit
, is n
• The air conditioner compres‐

h re
hole
sor is noisy (especially imme‐

spec
diately after being switched
es, in part or in w

t to the co
on),
• The cooling power required is
delivered.

rrectness of i
l purpos

Note

nform
mercia

♦ Overfilling with refrigerant oil can occur if the refrigerant oil

at
om

io
level was not checked after the air conditioner compressor

n
c

in t
was renewed.
or

his
ate

do
riv

♦ If the air conditioner compressor is not to be replaced, drain


p

cum
refrigerant oil from air conditioner compressor via the drain
for

en
g

plug. From the total amount of refrigerant oil, fill 50 g direct into
n

t.
yi Co
op
air conditioner compressor and fill remainder in refrigerant cir‐ C py
t. rig
cuit according to ⇒ vehicle-specific workshop manual . gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10.6 Checking systems with an expansion


valve, receiver and air conditioner com‐
pressor regulating valve - N280- (with
externally regulated air conditioner com‐
pressor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .


♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.


– Observe air conditioner service station pressure gauge.

Note

♦ Switching pressures for the air conditioner compressor regu‐


lating valve - N280- and the radiator fan - V7- are vehicle-
specific.
♦ Pressures should be measured at the service connections; the
location of these connections is vehicle-specific ⇒ Rep. gr.
87 .

10.6.1 Specifications:
High-pressure side:
Rising from starting pressure (when pressure gauge is connec‐
ted) to 20 bar.

148 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Low-pressure side:
Falling from starting pressure (when pressure gauge is connec‐
ted) to diagram value.
A - Low pressure (measured at the service connection) in bar ab‐
solute pressure.
B - Control current for the air conditioner compressor regulating
valve - N280- .
C - Permitted tolerance range.

Note

♦ Under unfavourable conditions (very high ambient tempera‐


tures, high atmospheric humidity), the pressure on the high-
pressure side can increase to a maximum of 29 bar.
♦ The control current -B- is indicated in the measured values
block. n AG. Volkswagen AG do
lkswage es n
o ot g
♦ The high-pressure ed
b value
yV measured by the high-pressure
ua
ran
sender - G65- or is indicated in the measured values block
is te⇒
eo
Rep. gr. s87
au .
th
ra
s c
♦ The low pressure is adjusted to within tolerances within the
ce
e
nl

pt
du

output range for the air conditioner compressor depending on


an
itte

the control current for the air conditioner compressor regulat‐ y li


erm

ing valve - N280- . ab


ility
ot p

wit
♦ Under unfavourable conditions (very high ambient tempera‐
, is n

h re
tures, high atmospheric humidity), the output may be insuffi‐
hole

spec

cient to achieve the specification in every case.


es, in part or in w

t to the co

♦ The set working current for the regulating valve must be great‐
er than 0.3 A to ensure that the regulating valve is reliably
activated.
rrectness of i

♦ At the setting “maximum cooling power”, the control current


l purpos

should be approx. 0.65 A to 0.8 A (vehicle-specific, indicated


in the measured values block) ⇒ Rep. gr. 87 .
nf
ercia

♦ Absolute pressure means that 0 bar corresponds to an abso‐


or

lute vacuum. The normal ambient pressure corresponds to 1


m
m

atio

bar absolute pressure. On most pressure gauges, a reading


om

n in

of 0 bar corresponds to an absolute pressure of one bar (which


or c

is confirmed by the existence of - 1 bar marking beneath the


thi
te

sd
a

0 scale marking).
iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Checking pressures on vehicles 149


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying fault


from specification
• High pressure ♦ Actuation of air con‐ –n AG Check
. Volkswac‐
agen
remains con‐ ditioner compressor swage tuation of airAG does
olk not
stant or increa‐ regulating valved by -
V conditioner gu
ara
ses only slightly N280- isordefective.
ise compressor nte
eo
(above the pres‐ uth
regulating ra
sure measured ♦ Insufficient
ss a
refriger‐ valve - c
ant in circuit.

ce
e

when the engine N280- .


nl

pt
du

is stopped).

an
itte

y li
– Look for
erm

ab
• Low pressure leaks using

ility
ot p

falls quickly to leak detector

wit
, is n

the diagram val‐ and rectify

h re
ue or lower.
hole

them.

spec
es, in part or in w

• The required

t to the co
cooling output is – Recharge re‐
not delivered. frigerant cir‐
cuit.

rrectness of i
• High pressure is
normal.
l purpos

• Low pressure
matches the di‐

nf
ercia

o
agram value.

rm
m

atio
m

• The required
o

n in
c

cooling output is
or

thi
e

not delivered.
t

sd
iva

o
r
rp

cu
o

m
• High pressure is • Insufficient refriger‐ – Extract some
f

en
ng

t.
normal. ant in circuit. refrigerant
yi Co
op
from the re‐
C py
t. rig
• Low pressure
gh
frigerant cir‐
ht
yri by
too low (see dia‐
op Vo
cuit.
c by lksw
cted
gram).
agen
Prote AG.

• The required • The quantity


cooling output is of refrigerant
not delivered. extracted is
significantly
less than the
prescribed
charge
quantity.
– Look for
leaks using
leak detector
and rectify
them.

– Recharge re‐
frigerant cir‐
cuit.

– Repeat
check.

• The quantity
of refrigerant
extracted is
about equal
to the pre‐
scribed
charge
quantity.

150 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying fault


from specification
• Expansion valve de‐ – Renew ex‐
fective pansion
valve.

– Recharge re‐
frigerant cir‐
cuit.

– Repeat
check.

Note

♦ If no fault can be found for this complaint, purge (clean) re‐


frigerant circuit with refrigerant R134a ⇒ page 67 . If this is not
possible in your workshop, blow through refrigerant circuit with
compressed air and dry with nitrogen ⇒ page 65 .
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- or evaporator temperature sensor -
G308- and actuation of the air conditioner compressor
regulating valve - N280- . If the measured value of the evap‐
orator output temperature sender - G263- or the evaporator
temperature sender - G308- is faulty, the evaporator may ice
up or the cooling output will not be achieved.
♦ If a repeat test after the expansion valve has been renewed
indicates that the air conditioning system is still not operating
correctly, refit the expansion valve and purge the refrigerant
circuit with compressed air and nitrogen. Then renew the air
AG. Volkswagen AG d
conditioner compressor and receiver. lksw
agen oes
no
Vo t gu
by
♦ In this case, the evaporator may ice up although
ris
ed the correct ara
nte
quantity of refrigerant is present in theuthrefrigerant
o circuit. eo
ra
sa c
♦ If the expansion valve is defective (always
s
closed or not open‐ ce
e

ing wide enough) the air conditioner compressor regulating


nl

pt
du

an
valve - N280- will be set to maximum power and the low-pres‐
itte

y li

sure value will fall to the diagram value or less (the air condi‐
erm

ab
ility

tioner compressor is drawing the refrigerant out of the low-


ot p

pressure side). However, since no refrigerant can flow through


wit
, is n

h re

the expansion valve, the required cooling power is not deliv‐


hole

ered, and it can be that the high-pressure value does not rise
spec

at all or not enough, since no energy exchange is occurring.


es, in part or in w

t to the co

Possible deviation from specifica‐ Possible cause of fault Rectifying fault


rrectness of i

tion
l purpos

• High pressure increases only ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
slightly above the pressure ulating valve - N280- is defective. air conditioner com‐
measured when the engine is pressor regulating
nform
ercia

stopped. valve - N280- .


m

at
om

• Low pressure falls only slightly.


on
c

in t
or

• The required cooling output is


his
ate

not delivered.
do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

10. Checking pressures on vehicles 151


n AG. Volkswagen AG do
wage es n
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 yV
o ➤ , CC 2012 ➤ , ...
lks ot g
b ua
Air conditioning system with refrigerant R134a - Edition
ir se
d 10.2014 ran
tee
tho
u or
s a ac
Possible deviation from specifica‐ Possible cause of fault
s Rectifying fault

ce
e
tion

nl

pt
du

an
itte
♦ The air conditioner compressor is defective. – Extract refrigerant.

y li
erm

ab
ility
ot p
– Purge (clean) refrig‐

wit
, is n
erant circuit

h re
⇒ page 67 .

hole

spec
es, in part or in w
– Renew air condi‐

t to the co
tioner compressor.

– Recharge refriger‐

rrectness of i
ant circuit.
• High pressure increases be‐ l purpos
♦ Actuation of air conditioner compressor reg‐ – Check actuation of
yond the specification. ulating valve - N280- is defective. air conditioner com‐
pressor regulating

nf
ercia

• Low pressure falls quickly to the

o
valve - N280- .

rm
diagram value or lower.
m

atio
om

n in
• The required cooling output is
or c

not delivered.

thi
te

sd
iva

o
r
rp

cu
♦ Restriction or obstruction in the refrigerant – Feel the refrigerant
o

m
f

en
ng

circuit. circuit with the hand


t.
yi Co
to sense the tem‐
Cop py
t. rig
opyri
gh
perature gradient.
by
Vo
ht
c by lksw
• At one component a
cted agen
Prote AG.
temperature gradi‐
ent will be detected:
– If a hose or pipe is
kinked or crushed,
renew it.

– In case of an ob‐
struction, blow
through refrigerant
circuit with com‐
pressed air and ni‐
trogen.
– Recharge refriger‐
ant circuit.

– Repeat check.

• If no faults are
found:
– Purge (clean) refrig‐
erant circuit
⇒ page 67 .

– Recharge refriger‐
ant circuit.

– Repeat the check; if


the system does not
operate correctly
♦ Expansion valve defective. – Extract refrigerant.

– Renew the expan‐


sion valve and re‐
ceiver.

– Recharge refriger‐
ant circuit.

152 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ In this case, the evaporator may ice up although the correct


quantity of refrigerant is present in the refrigerant circuit.
♦ If the expansion valve is defective w(always
agen
AG.closed
Volkswagor
ennot
AG dopen‐
oes
ing wide enough) the air conditionerby
Vol
ks compressor regulatingnot gu
valve - N280- will be set rto isedmaximum power and the low-pres‐ arant
sure value will fall to the
ut diagram value or less (the air condi‐
ho ee
or
tioner compressor is ss adrawing the refrigerant out of the low- ac
pressure side). However, since no refrigerant can flow through

ce
le
un

pt
the expansion valve, the required cooling power is not deliv‐

an
d
itte

ered, and it can be that the high-pressure value does not rise

y li
erm

ab
at all or not enough, since no energy exchange is occurring.

ility
ot p

wit
is n

h re
Possible deviation from specifica‐ Possible cause of fault Rectifying fault
ole,

tion

spec
urposes, in part or in wh

• High pressure and low pressure ♦ Actuation of air conditioner compressor reg‐ – Check actuation of

t to the co
are normal at first, but after a ulating valve - N280- is defective. air conditioner com‐
time the high pressure increa‐ pressor regulating
ses beyond the specification. valve - N280- .

rrectne
• After a time, the low pressure

s
falls to the diagram value or low‐

s o
er.
cial p

f inform
• The cooling power called for is
mer

not delivered.

atio
om

n
c

i
or

n
• High pressure and low pressure ♦ Moisture in the refrigerant circuit. – Extract refrigerant.
thi
te

sd
a

are normal at first, but after a


iv

o
r

longer drive, the low pressure – Blow through refrig‐


p

cum
r
fo

falls to below the specification erant circuit with


en
ng

t.
yi
(evaporator iced up). compressed air and
Co
op py
nitrogen.
. C rig
ht ht
rig by
copy Vo
– Renew receiver to‐
by lksw
cted agen
Prote
gether with dryer.
AG.

– Evacuate refriger‐
ant circuit for at
least 3 hours.

– Recharge refriger‐
ant circuit.

– Repeat the check; if


the function is not
OK

– Purge (clean) refrig‐


erant circuit
⇒ page 67 .

– Recharge refriger‐
ant circuit.

– Repeat check.

10. Checking pressures on vehicles 153


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If this complaint occurs after a longer period of operation or


only occasionally (the low pressure falls below the specifica‐
tion and the evaporator ices up) it is sufficient only to renew
the dryer (fitted within the receiver). Check the quantity of re‐
frigerant oil. Then evacuate the refrigerant circuit for at least 3
hours.
♦ In case of this complaint, it is not initially necessary to purge
the refrigerant circuit with compressed air and nitrogen, since
as a rule only a small quantity of moisture will have accumu‐swa
gen AG
. Volkswagen AG
does
lated in the system, which can be removed by a longer yV
olk evac‐ not
gu
uation period. ris
ed b ara
nt ee
tho or
♦ In this case, the evaporator may ice up although
sa
u the correct ac
quantity of refrigerant is present in the refrigerant
s
circuit.

ce
e
nl

pt
du

an
itte

y li
Possible deviation from specifica‐ Possible cause of fault Rectifying fault
erm

ab
tion

ility
ot p

wit
, is n

• High pressure normal, low pres‐ ♦ Actuation of air conditioner compressor reg‐ – Check actuation of

h re
sure too low (see diagram), the ulating valve - N280- is defective. air conditioner com‐
hole

spec
required cooling power is deliv‐ pressor regulating
es, in part or in w

ered. valve - N280- .

t to the co
♦ Expansion valve defective. – Extract refrigerant.

rrectness of i
– Purge (clean) refrig‐
erant circuit
l purpos

⇒ page 67 .

nform
ercia

– Renew the expan‐


sion valve and re‐
m

at
om

ceiver.

ion
c

in t
or

– Recharge refriger‐

his
ate

ant circuit.
do
priv

cum
for

en
g

– Repeat the check; if


n

t.
yi Co
the system does not
Cop py
. rig
operate correctly
ht ht
rig by
copy Vo
by lksw
– Renew the air con‐
cted agen
Prote AG.
ditioner compres‐
sor.
♦ The air conditioner compressor is defective. – Extract refrigerant.

– Purge (clean) refrig‐


erant circuit
⇒ page 67 .

– Renew the air con‐


ditioner compres‐
sor.

– Recharge refriger‐
ant circuit.

– Repeat check.

154 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If the fault is “high pressure normal, low pressure too low ” note
the following: if faulty the evaporator could ice up or the re‐
quired cooling output is not delivered.
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.
olkswagen AG
en AG. V
♦ Check the measured valuesolkofswthe
ag evaporator output temper‐
does
no
ature sender - G263- or ed
bevaporator
yV temperature sensor - t guara
G308- and actuation ho
rof the air conditioner compressor
is nte
eo
regulating valve s-aN280-
ut . If the measured value at the high- ra
pressure senders - G65- is faulty, the evaporator can ice up or
c

ce
e

the required cooling power is not delivered.


nl

pt
du

an
itte

♦ If the defect is in the air conditioner compressor regulating

y li
erm

ab
valve - N280- (the regulating valve is not activated, but the air

ility
ot p

conditioner compressor still runs), it is not necessary to blow

wit
, is n

through the refrigerant circuit. If this fault occurs, it is sufficient

h re
to renew the air conditioner compressor (check the refrigerant
hole

spec
oil quantity in the air conditioner compressor).
es, in part or in w

t to the co
♦ If the expansion valve is defective (always closed or not open‐
ing wide enough) the air conditioner compressor regulating
valve - N280- will be set to maximum power and the low-pres‐

rrectness of i
sure value will fall to the diagram value or less (the air condi‐
tioner compressor is drawing the refrigerant out of the low-
l purpos

pressure side). However, since no refrigerant can flow through


the expansion valve, the required cooling power is not deliv‐

nf
ercia

ered, and it can be that the high-pressure value does not rise

o
at all or not enough, since no energy exchange is occurring.
rm
m

atio
om

n in
c

⇒ Rep. gr. 87
or

thi
te

sd
iva

Possible deviation from specifi‐ Possible cause of fault Rectifying fault


o
r
rp

cu

cation
o

m
f

en
ng

t.
yi
• High pressure normal or too ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
Co
op py
high. ulating valve - N280- is defective. air conditioner com‐
. C rig
ht ht
rig
pressor regulating
py by
o Vo
• Low pressure too low (see di‐ ♦ Too much refrigerant in circuit.
c
valve - N280- .
by lksw
cted agen
agram). Prote AG.

• The air conditioner compres‐ – Extract some refrig‐


sor is noisy (especially imme‐ erant from the refrig‐
diately after being switched erant circuit.
on).
• The quantity of re‐
• The required cooling output is frigerant extracted is
not delivered. about equal to the
prescribed charge
quantity:
– Renew the air condi‐
tioner compressor.
• The quantity of re‐
frigerant extracted is
significantly greater
than the prescribed
charge quantity:
– Recharge refrigerant
circuit.

– Repeat check.

10. Checking pressures on vehicles 155


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Amarok 2011th➤ o , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010
ris
e➤
or
, CC 2012 ➤ , ...
u
Air conditioning
ss a system with refrigerant R134a - Edition 10.2014 ac

ce
le
un

pt
Possible deviation from specifi‐ Possible cause of fault Rectifying fault

an
d
itte

y li
cation rm

ab
pe

ility
♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
ot

wit
, is n

cuit.

h re
hole

spec
• The quantity of re‐
es, in part or in w

frigerant extracted is

t to the co
about equal to the
prescribed charge
quantity.

rrectness of i
– Purge (clean) refrig‐
l purpos

erant circuit
⇒ page 67 .

nform
ercia

– Recharge refrigerant
m

circuit.

a
com

tion in
r

– Repeat check.
te o

thi
s
iva

♦ Expansion valve defective. – Drain refrigerant cir‐

do
r
rp

c
cuit.

um
fo

en
ng

t.
yi Co
– Renew the expan‐
Cop py
t. rig
yri
gh by
ht
sion valve and re‐
ceiver.
op Vo
by c lksw
cted agen
Prote AG.
– Recharge refrigerant
circuit.

– Repeat the check; if


the system does not
operate correctly

– Renew the air condi‐


tioner compressor.
♦ The air conditioner compressor is defective. – Drain refrigerant cir‐
cuit.

– Purge (clean) refrig‐


erant circuit
⇒ page 67 .
– Renew the air condi‐
tioner compressor.

• The quantity of re‐


frigerant extracted is
significantly greater
than the prescribed
charge quantity.
– Recharge refrigerant
circuit.

– Repeat check.

156 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If the defect is in the air conditioner compressor regulating


valve - N280- (the regulating valve is not activated, but the air
conditioner compressor still runs), it is not necessary to blow
through the refrigerant circuit. If this fault occurs, it is sufficient
to renew the air conditioner compressor (check the refrigerant
oil quantity in the air conditioner compressor).
♦ Overfilling with refrigerant oil can occur if the refrigerant oil
level was not checked after the air conditioner compressor
was renewed.
♦ If the air conditioner compressor is not to be replaced, drain
refrigerant oil from air conditioner compressor via the drain
plug. From the total amount of refrigerant oil, fill 50 g direct into
air conditioner compressor and fill remainder in refrigerant cir‐
cuit according to ⇒ vehicle-specific workshop manual .
♦ If the expansion valve is defective (always closed or not open‐
ing wide enough) the air conditioner compressor regulating
valve - N280- will be set to maximum power and the low-pres‐
sure value will fall to the diagram value or less (the air condi‐
tioner compressor is drawing the refrigerant out of the low-
pressure side). However, since no refrigerant can flow through
the expansion valve, the required cooling power is not deliv‐
ered, and it can be that the high-pressure value does not rise
at all or not enough, since no energy exchange is occurring.

Possible deviation from specifi‐ Possible cause of fault Rectifying fault


cation
• High pressure and low pres‐ ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
sure are normal. ulating valve - N280- is defective.
. Volkswagen AG
air conditioner com‐
agen AG doe pressor regulating
• The required coolingy Voutput
olks
w
is ♦ Too much refrigerant
s no
t gu oil in circuit. valve - N280- .
not delivered. ised b ara
n
r tee
ut
ho or – Purge (clean) refrig‐
ss
a ac
erant circuit
⇒ page 67 .
ce
le
un

pt
an
d

• High pressure and low pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
itte

y li

sure are normal. cuit.


erm

ab
ility
ot p

• The air conditioner compres‐ – Purge (clean) refrig‐


wit
is n

sor is noisy (especially imme‐


h re

erant circuit
ole,

diately after being switched ⇒ page 67 .


spec
urposes, in part or in wh

on).
t to the co

• The cooling power required is – Recharge refrigerant


delivered. circuit.
rrectne

– Repeat check.
♦ Expansion valve defective. – Renew expansion
s

valve.
s o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Checking pressures on vehicles 157


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Overfilling with refrigerant oil can occur if the refrigerant oil


level was not checked after the air conditioner compressor
was renewed.
♦ If the air conditioner compressor is not to be replaced, drain
refrigerant oil from air conditioner compressor via the drain
plug. From the total amount of refrigerant oil, fill 50 g direct into
air conditioner compressor and fill remainder in refrigerant cir‐
cuit according to ⇒ vehicle-specific workshop manual .
♦ If the expansion valve is defective (always open) the evapo‐
rator temperature will no longer be regulated so that only
gaseous refrigerant exits the evaporator. It is then possible
that under certain operating conditions, drops of liquid will be
drawn into the air conditioner compressor, which will hen
cause noise (because liquid is incompressible).

10.7 With expansion valve, receiver and


electrical airlksconditioner
wage
n AG. Volkswacompressor
gen AG
does
n
o ot g
yV ua
edb ran
ris tee
ho
Note aut or
ac
ss
ce
le

The electrical air conditioner compressor does not have an air


un

pt
an
d

conditioner compressor regulating valve - N280- . Regulation


itte

y li

takes place via the speed of the air conditioner compressor. The
rm

ab
pe

ility

air conditioner compressor contains the control electronics and a


ot

G-supercharger that impels the refrigerant.


wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

158 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

11 Renewing components
• All components of the refrigerant circuit submitted for quality
monitoring must always be sealed (use the original sealing
caps from the genuine part).
• The genuine parts (air conditioner compressor, reservoir, re‐
ceiver, evaporator and condenser) are charged with nitrogen
before shipment. This filling is being gradually discontinued,
the pressure of the nitrogen filling is so low that escaping gas
is no longer perceptible when the part is initially opened.
• Where vehicles are fitted with an air conditioner compressor
without a magnetic clutch, the engine should be started only
when the refrigerant circuit has been fully assembled (since
the air conditioner compressor will always run when the engine
is running) ⇒ page 14 .
. Volkswagen AG
does gen AG
• The air conditioner compressor with Vol
kair
swaconditioner compres‐ not
sor regulating valve - N280- (without edb
y magnetic clutch) has an gu
ara
internal oil circuit to ensure that
horis the air conditioner compressor nte
eo
is not damaged when the s aurefrigerant
t
circuit is empty. This ra
c
means that approx. 40 to s
50 cm3 of refrigerant oil remains in

ce
e
nl

the air conditioner compressor ⇒ page 14 .

pt
du

an
itte

y li
erm

ab
ility
ot p

Note

wit
, is n

h re
♦ Since genuine parts are sometimes stored for long periods in
hole

spec
various places, it can well be that gas will escape from some
es, in part or in w

parts when first opened but not from others (even among those

t to the co
having the same part number). Therefore, be careful when
unscrewing the sealing plugs from the genuine part connec‐
tions and allow the nitrogen gas to escape slowly.

rrectness of i
♦ Either a restrictor with a reservoir or an expansion valve with
l purpos

a receiver is built into the refrigerant circuit.


♦ Seal open connections and lines to prevent moisture from en‐
nform
ercia

tering.
m

at
om

♦ Always renew restrictor.


ion
c

in t
or

his
te

The reservoir or receiver or cartridge of the dryer bag need not


a

do
riv

be renewed under the following circumstances:


p

cum
for

en
g

• After an accident in which there was no damage to the reser‐


n

t.
yi Co
op
voir or receiver. C py
t. rig
gh ht
yri by
• Repairs are performed quickly (no more delay than during a op Vo
by c lksw
normal repair time) and there was no moisture intrusion. The cted agen
Prote AG.
vehicle is no more than 5 years old.
The reservoir or receiver or dryer cartridge should be renewed
under the following circumstances:
• The refrigerant circuit was opened and the vehicle is more than
5 years old.
• The refrigerant circuit has been opened for in indeterminate
period (seepage leak).
• Repairs take longer than a normal repair time and there has
been moisture intrusion.
• Always renew collector/reservoir or dryer cartridge after blow‐
ing through with compressed air or purging with refrigerant
R134a. Keep genuine parts sealed for as long as possible to
keep the ingress of moisture as low as possible.
• The air conditioner compressor seizes.

11. Renewing components 159


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

• The reservoir or receiver is damaged (e.g. in an accident).

Caution

♦ Handling refrigerant ⇒ Volkswagen ServiceNet; Service


handbook; Environmental protection; Waste disposal;
Current situation; Disposal channels; Disposal of used
oils; Refrigerant oils .

11.1 In the event of leakingolor kswdamaged com‐ es not


AG n AG d . Volkswage
agen o

ponents (apart from d the air conditioner


y V gu
b ara
rise nte
compressor, receiver
au
tho
or reservoir) eo
ra
c ss

ce
e
nl

pt
du

an
11.1.1 If the refrigerant circuit was completely
itte

y li
erm

ab
empty

ility
ot p

wit
, is n

– Remove defective part.

h re
hole

spec
– Remove air conditioner compressor.
es, in part or in w

t to the co
– Remove oil drain screw from air conditioner compressor.

rrectness of i
Note
l purpos

♦ To speed up the draining of the refrigerant oil, rotate the shaft


of the air conditioner compressor by hand using the poly V-

nf
ercia

belt pulley or the magnetic clutch.

orm
m

atio
♦ Pour old refrigerant oil out of air conditioner compressor, han‐
om

dling refrigerant oil ⇒ Volkswagen ServiceNet; Service hand‐


n in
or c

book; Environmental protection; Waste disposal; Current


thi
te

sd

situation; Disposal channels; Disposal of used oils; Refrigerant


iva

o
r

oils .
rp

cu
o

m
f

en
ng

t.
♦ Then fill the air conditioner compressor with the quantity of
yi Co
op
new refrigerant oil corresponding to the quantity in a genuine
C py
ht. rig
air conditioner compressor ⇒ Rep. gr. 87 .
rig ht
py by
co Vo
by lksw
♦ Different types and quantities of refrigerant oils are required
cted agen
Prote AG.
for different air conditioner compressors ⇒ Rep. gr. 87 .
♦ To ensure proper lubrication of the air conditioner compressor
when it runs for the first time, the air conditioner compressor
must be filled with at least 80 cm3 of refrigerant oil; the re‐
mainder can be poured into the new reservoir or receiver ⇒
Rep. gr. 87 .
♦ If dirt enters the air conditioner compressor whilst the refrig‐
erant circuit is open (e.g. after an accident), the air conditioner
compressor should be renewed.
♦ Blow through refrigerant circuit with compressed air and re‐
move moisture with nitrogen ⇒ page 65 .

– Renew receiver or reservoir and restrictor.


– Assemble the refrigerant circuit, evacuate it and charge it.

11.1.2 If there is still refrigerant in the refriger‐


ant circuit
– Drain refrigerant circuit.

160 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

– Remove defective part, purge with compressed air and collect


escaping refrigerant oil.
– A quantity of fresh refrigerant oil equal to the quantity of re‐
frigerant oil that has been blown out (plus 20 cm3 for the
evaporator, plus 10 cm3 for the condenser, refrigerant pipes
and refrigerant hoses) should be poured into the new compo‐
nent.
– Renew restrictor. Depending on vehicle
– Assemble refrigerant circuit, evacuate and charge.

11.2 Renewing air conditioner compressor

Note

On vehicles equipped with an electrical air conditioner compres‐


sor, de-energise the high-voltage system before removing the air
conditioner compressor. ⇒ Electric drive; Rep. gr. 93 ; Electric
drive; De-energising high-voltage system

11.2.1 Without needing to purge refrigerant cir‐


cuit of contaminants (cleaning), e.g. in
cases of external damage after an acci‐
dent
– Drain refrigerant circuit.
– Remove air conditioner compressor.

Note

If a different air conditioner compressor with other refrigerant oil


is fitted, purge the refrigerant circuit with R134a refrigerant
⇒ page 67 . gen AG
. Volkswagen AG
d
wa oes
olks not
byV gu
Electrical air conditioner
rised compressor: ara
nte
tho eo
If an electrical
s au air conditioner compressor is renewed withoutr ahav‐
c
ing a mechanical fault (e.g. defective printed circuit board), the
s
ce
le

amount of refrigerant oil from this electrical air conditioner com‐


un

pt
an
d

pressor must be determined.


itte

y li
erm

ab
ility
ot p

wit

Note
is n

h re
ole,

spec

♦ The air conditioner compressor must be purged in order to


urposes, in part or in wh

extract the refrigerant oil which needs to be determined.


t to the co

♦ Purge the air conditioner compressor in normal direction of


flow (from low-pressure inlet to high-pressure outlet).
rrectne

♦ In order to purge as much refrigerant oil from the air condi‐


tioner compressor as possible make sure that the high-pres‐
ss

sure outlet of the air conditioner compressor is in the lowest


o
cial p

position possible.
inform
mer

♦ If an air conditioner service station without purging programme


atio
m

is used, the sequence has to be carried out manually (evacu‐


o

n
c

ate, purge 3 times with at least 2 kg of refrigerant each time


i
or

n thi

and extract refrigerant again, evacuate).


te

sd
iva

o
pr

cum
r
fo

Determined amount e.g. 50 cm³


en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

161
co Vo
by lksw
cted
11. Renewing components
agen
Prote AG.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Then, remove as much refrigerant oil from the new air conditioner
compressor as is necessary to ensure that only the same amount
of refrigerant oil which has been purged from the old air condi‐
tioner compressor remains in the new one (plus 10 cm 3). If, for
example, the new original air conditioner compressor is filled with
e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
– Pour old refrigerant oil out of air conditioner compressor. Han‐
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐
book; Environmental protection; Waste disposal; Current
situation; Disposal channels; Disposal of used oils; Refrigerant
oils .

Note

If the amount of refrigerant oil which can be removed from the


new air conditioner compressor is not sufficient, the new air con‐
ditioner compressor must be purged. After the new air conditioner
compressor has been purged, fill the amount of refrigerant oil
which has been determined when purging the old air conditioner
compressor. gen AG
. Volkswagen AG
d
a oes
ksw not
y Vol gu
b
Mechanical air conditioner compressor: ris
ed
ara
nte
tho eo
– Remove oil drain screw from air conditioner
au compressor. ra
c
ss

ce
e

– To speed up the draining of the refrigerant oil, rotate the shaft


nl

pt
du

of the air conditioner compressor using the magnetic clutch

an
itte

y li
poly V-belt pulley. Not applicable for electrical air conditioner
erm

ab
compressor.

ility
ot p

wit
, is n

– Pour old refrigerant oil out of air conditioner compressor. Han‐

h re
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐
hole

spec
book; Environmental protection; Waste disposal; Current
es, in part or in w

situation; Disposal channels; Disposal of used oils; Refrigerant

t to the co
oils .
– Remove oil drain screw from genuine air conditioner com‐

rrectness of i
pressor, pour out refrigerant oil and replace it with only the
quantity of fresh refrigerant oil equal to the amount of refrig‐
l purpos

erant oil poured out of the defective air conditioner compres‐


sor.
nform
mercia

at

Note
om

ion
c

in t
or

♦ If for instance 70 cm3 refrigerant oil was poured out of the de‐
his
ate

do
riv

fective air conditioner compressor, and 220 cm3 oil was pour‐
p

cum
or

ed out of the genuine air conditioner compressor (a small


f

en
ng

quantity of refrigerant oil remains in the air conditioner com‐


t.
yi Co
op
pressor), Pour 70 cm3 refrigerant oil into the genuine air con‐
C py
t. rig
gh ht
ditioner compressor (the refrigerant oil previously poured out yri
p by
o Vo
of the genuine air conditioner compressor part may be used).
c by lksw
cted agen
Prote AG.
♦ Different air conditioner compressors require different types
and quantities of refrigerant oils ⇒ Rep. gr. 87 .
♦ If a large quantity of refrigerant oil (more than about 80 cm3)
was poured from the defective air conditioner compressor, the
remaining refrigerant oil can also be poured into the evapora‐
tor or the reservoir or receiver ⇒ Rep. gr. 87 .

– Renew restrictor. Depending on vehicle


– Assemble refrigerant circuit, evacuate and charge.

162 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

11.2.2 Leaks or internal damage (e.g. noises or


lack of power)
– Drain refrigerant circuit.
– Remove air conditioner compressor.

Note
. Volkswagen AG
gen AG does
swa
♦ In the event of internal damage (to air conditioner
by
Vol
k compres‐ not
gu
sor), purge with R134a refrigerant ⇒ page rise 67 .
d ara
nte
tho eo
♦ If a different air conditioner compressor
s au with other refrigerant ra
c
oil is fitted, purge the refrigerant circuit with R134a refrigerant
s

ce
le

⇒ page 67 .
un

pt
an
d
itte

y li
erm

ab
– Renew receiver / dryer cartridge and expansion valve or res‐

ility
ot p

ervoir and restrictor. Only if there was no more refrigerant in

wit
is n

the circuit.

h re
ole,

spec
– If leaking, examine the expansion valve for dirt or corrosion;
urposes, in part or in wh

renew if necessary.

t to the co
– Assemble refrigerant circuit, evacuate and charge.

11.3 Renewing receiver or reservoir, and re‐

rrectne
strictor

ss o
cial p

f inform
11.3.1 After purging refrigerant circuit of con‐
mer

atio
taminants, e.g. due to moisture intrusion
om

n
c

i
(because refrigerant circuit has stood
or

n thi
te

sd
a

open for a length of time) or due to dirt


iv

o
pr

cum
r
fo

en
ng

The reservoir or receiver or cartridge of the dryer bag need not


t.
yi Co
be renewed under the following circumstances: t. Cop py
rig
gh ht
yri
• After an accident in which there was no damage to the reser‐ p by
co Vo
voir or receiver.
by lksw
cted agen
Prote AG.
• Repairs are performed quickly (no more delay than during a
normal repair time) and there was no moisture intrusion. The
vehicle is no more than 5 years old.
The reservoir or receiver or dryer cartridge should be renewed
under the following circumstances:
• The refrigerant circuit was opened and the vehicle is more than
5 years old.
• The refrigerant circuit has been opened for in indeterminate
period (seepage leak).
• Repairs take longer than a normal repair time and there has
been moisture intrusion.
• Always renew collector/reservoir or dryer cartridge after blow‐
ing through with compressed air or purging with refrigerant
R134a. Keep genuine parts sealed for as long as possible to
keep the ingress of moisture as low as possible.
• The air conditioner compressor seizes.
• The reservoir or receiver is damaged (e.g. in an accident).
– Drain refrigerant circuit.
– Remove air conditioner compressor.

11. Renewing components 163


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora .1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
AG Volkswagen AG d
swagen R134a - Edition
Air conditioning system with refrigerant oe10.2014
s no
olk t gu
yV
db ara
– Rectify cause of fault. rise nte
tho eo
au ra
– Examine the expansions valve for dirt
s or corrosion; renew if c
necessary.

ce
e
nl

pt
du

an
– Remove oil drain screw from air conditioner compressor. itte

y li
erm

ab
ility
– To speed up the draining of the refrigerant oil, rotate the shaft
ot p

wit
of the air conditioner compressor using the magnetic clutch
, is n

h re
poly V-belt pulley.
hole

spec
– Pour old refrigerant oil out of air conditioner compressor. Han‐
es, in part or in w

t to the co
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐
book; Environmental protection; Waste disposal; Current
situation; Disposal channels; Disposal of used oils; Refrigerant
oils .

rrectness of i
– Then fill the air conditioner compressor with a quantity of new
l purpos

refrigerant oil equal to the quantity in a genuine air conditioner


compressor ⇒ Rep. gr. 87 .

nf
ercia

orm
m

atio
m

Note
o

n in
or c

thi
e

♦ Types and quantities of refrigerant oils which should be used


t

sd
iva

for different air conditioner compressors ⇒ Rep. gr. 87 .

o
r
rp

cu
o

m
f

en
ng

♦ To ensure proper lubrication of the air conditioner compressor


t.
yi Co
when it runs for the first time, the air conditioner compressor Cop py
t. rig
must be filled with at least 80 cm3 of refrigerant oil; the re‐
gh ht
yri by
mainder can be poured into the new reservoir or receiver ⇒
cop Vo
by lksw
cted
Rep. gr. 87 .
agen
Prote AG.

♦ If dirt enters the air conditioner compressor whilst the refrig‐


erant circuit is open (e.g. after an accident), the air conditioner
compressor should be renewed.

– Renew receiver or reservoir and restrictor.


– Assemble refrigerant circuit, evacuate and charge.

11.3.2 Without needing to purge refrigerant cir‐


cuit of contaminants (e.g. damage in an
accident); no refrigerant has escaped
and no moisture or dirt has entered re‐
frigerant circuit
– Drain refrigerant circuit.
– Renew restrictor. Depending on vehicle
– Remove receiver or reservoir.
– Clean any dirt out of receiver or reservoir.
– Weigh receiver or reservoir that was removed.

Note

♦ Fill enough refrigerant oil into the new reservoir or collector so


that it has the same weight as the container which was re‐
moved.
♦ Install new receiver or reservoir.

– Assemble refrigerant circuit, evacuate and charge.

164 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

12 Testing equipment and tools

12.1 List of test equipment, tools and materi‐


als

Note

This list is an overview of the test equipment, tools and materials


necessary for professional repairs to the refrigerant circuit.

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)


may cause damage or adversely influence the system.
Only tools and materials approved by the manufacturer may
be used.
Use of non-approved tools ornmaterials will render the warranty
AG. Volkswagen AG d
void. olkswage oes
no
yV t gu
db ara
rise nte
tho eo
12.1.1 ss Tools and materials available from dis‐
au ra
c
tribution centre or importer
ce
le
un

pt
an
d
itte

y li

Overview page
rm

ab
pe

ility

Air conditioner service station - VAS 6007A- , ⇒ page 168


ot

wit
, is n

other air conditioner service stations ⇒


h re

V.A.G workshop equipment catalogue .


hole

spec

Leak detector - V.A.G 1796- ⇒ page 169


es, in part or in w

t to the co

Leak detecting system - VAS 6196- ⇒ page 169


Leak detection additive - VAS 6196/1- not illustrated
rrectness of i

Leak detecting system - VAS 6201- or later ⇒ page 170


model
l purpos

Air conditioner service station - VAS 6380- not illustrated


with purging device or air conditioner service
nform
ercia

station with purging device - VAS 6337- (lat‐


m

est available air conditioner service stations


a
com

tio

⇒ V.A.G workshop equipment catalogue ).


n in

♦ With integrated program for purging re‐


r
te o

thi

frigerant circuit using refrigerant R134a.


s
iva

do
r
rp

cum
fo

Purging device for refrigerant circuits - VAS ⇒ page 169


en
ng

t.
yi
6337/1- , (other available refrigerant circuit
Co
op py
purging devices ⇒ V.A.G workshop equip‐ t. C rig
gh ht
ment catalogue . yri
p by
o Vo
♦ For purging refrigerant circuit using re‐
by c lksw
cted agen
frigerant R134a. To use also on older air
Prote AG.

conditioner service stations (purging de‐


vice must then be carried out manually)
with a reservoir volume of at least 10 kg
refrigerant R134a.

12. Testing equipment and tools 165


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Overview page
Purging device for refrigerant circuits - VAS ⇒ page 169
6336/1- , (other available refrigerant circuit
purging devices ⇒ V.A.G workshop equip‐
ment catalogue .
♦ For purging refrigerant circuit using re‐
frigerant R134a. To use also on older air
conditioner service stations (purging de‐
vice must then be carried out manually)
with a reservoir volume of at least 10 kg
refrigerant R134a.

Adapter case VW/Audi passenger vehicle not illustrated


set -VAS 6338/1- for refrigerant circuits with
refrigerant R134a.
♦ For connection of air conditioner service
station to refrigerant circuit and to bridge
certain components during purging with
refrigerant R134a or blowing through with
compressed air or nitrogen.

Adapter case commercial vehicle set - not illustrated


VAS 6338/50- for refrigerant circuits with re‐
frigerant R134a.
♦ For connection of air conditioner service
station to refrigerant circuit and to bridge
certain components during purging or
G. Volkswagen AG d
blowing through. lkswagen A oes
n
o ot g
yV ua
db ran
Ultrasonic air conditioner
ris
e cleaning unit - VAS not illustrated
tee
ho
6189A- aut or
ac
♦ To remove
ss unpleasant odours originating
ce
e

from air conditioning system.


nl

pt
du

an
itte

y li

Suction feed spray-gun - V.A.G 1538- not illustrated


erm

ab

♦ V.A.G 1538/5, probe for evaporator


ility
ot p

cleaning, short
wit
, is n

h re
hole

♦ V.A.G 1538/6, probe for evaporator


spec

cleaning, long
es, in part or in w

t to the co

♦ V.A.G 1538/7, probe for evaporator


cleaning, 700 mm (CV)
rrectness of i

♦ Cleaner D 600 100 A1


l purpos

♦ Cleaning solution for evaporator D 600


100 A2
nform
ercia

♦ To remove unpleasant odours from evap‐


orator
m

at
om

ion
c

Release tools case - VAS 6127- ⇒ page 170


in t
or

his

♦ To open refrigerant pipes.


ate

do
priv

cum
or

Release tools - VAS 6127/1-3- ⇒ page 170


f

en
ng

♦ To open refrigerant pipes.


t.
yi Co
Cop py
ht. rig
Counterhold - V.A.G 1616- ⇒ page 171
rig ht
py by
o Vo
♦ For coupling plate (air conditioner com‐ by c lksw
cted agen
pressor made by “Sanden”). Prote AG.

Puller - V.A.G 1616/1- for magnetic clutch ⇒ page 171


(Sanden air conditioner compressor).
Magnetic clutch puller - V.A.G 1719- (Zexel ⇒ page 171
air conditioner compressor).
Adapter set for refrigerant circuit - V.A.G ⇒ page 171
1785/1-10- R134a.

166 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Overview page
Combination fine filter unit for compressed not illustrated
air systems; oil, dirt and water separator as
used for paint gun systems ⇒ Workshop
equipment catalogue .
O-ring ⇒ Parts catalogue . not illustrated
Refrigerant oil ⇒ Parts catalogue . not illustrated
Socket insert - T10364- for valves of service ⇒ page 172
connections on HP/LP side of refrigerant cir‐
cuit.

12.1.2 Tools and materials commercially avail‐


able

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)


may cause damage or adversely influence the system.
Only tools and materials approved by the manufacturer may
be used.
Use of non-approved tools or materials will render the warranty
void.

Overview page
Fin comb ⇒ page 172
Charging hoses 5/8"-18 UNF with valve opener ⇒ page 173
Connector piece for pressure bottles for refrigerant and sealing ring with quick- ⇒ page 173
release coupling or threaded sconnector agen
AG. Vo5/8"-18 UNF
lkswagen AG
does
olk w not
Valve caps 5/8" -18 UNF d by V gu
ara ⇒ page 173
ise nte
r
Manifold gauge with ut
h pressure limiter for nitrogen
o eo
ra
⇒ page 173
a
Quick-release coupling
ss
adapter for service connections, 2 included cin items ⇒ page 174
ce
le

supplied with air conditioner service station


un

pt
an
d
itte

Open ring spanners of widths matching those of the threaded connections on not illustrated
y li
erm

ab

the refrigerant pipes.


ility
ot p

Valve opener for charging hoses not illustrated


wit
is n

h re

Connection nipple for tapered seal 5/8"-18 UNF not illustrated


ole,

spec
urposes, in part or in wh

Compressed air gun with rubber nozzle not illustrated


t to the co

Hand shut-off valve 5/8" - 18 UNF not illustrated


Recycling bottle for refrigerant R134a not illustrated
rrectne

Digital thermometer not illustrated


Protective gloves not illustrated
ss

Protective goggles not illustrated


o
cial p

f in

Refrigerant R134a with pressure bottle (contents as required) not illustrated


form
mer

Nitrogen in pressure bottle not illustrated


atio
om

n
c

Strap wrench (oil filter) as counterhold for poly V-belt pulley not illustrated
i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

12. Testing equipment and tools 167


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

12.1.3 Tools to be made locally


Overview page
Charging hose with connector to the work‐ ⇒ page 174
shop's compressed air system

12.1.4 Tools and materials available from dis‐


tribution centre or importer

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)


may cause damage or adversely influence the system.
Only tools and materials approved by the manufacturer may
be used.
Use of non-approved tools or materials will render the warranty
void.

Air conditioning service station - VAS 6007A- (and further service


stations currently available)
⇒ Workshop equipment
♦ The procedures for testing, extracting (recycling), evacuating
and charging should be carried out in accordance with the re‐
spective user's manual.
♦ The installed filter and dryer must be renewed at the latest at
G. Volkswagen AG d
the end of the period of use specified wa gen Ain the operating oinstruc‐
es n
tions and every time that the olks
y V station is emptied (keep replace‐
ot g
b ua
ment filter on hand. theyir secan be ordered from the manufacturer ante
d r
of the device, see auser's
utho
manual. eo
ra
ss c
♦ Air conditioner service stations or purging devices approved
ce
e
nl

by VW but not shown here may also be used.


pt
du

an
itte

y li

⇒ Workshop equipment
erm

ab
ility
ot p

wit
, is n

h re

Note
hole

spec
es, in part or in w

♦ This air conditioner service station incorporates the following


t to the co

common individual devices: charging cylinder, manifold


gauge, vacuum pump, shut-off valves and charging hoses.
rrectness of i

♦ This air conditioner service station includes one of each type


of quick-release coupling (for high-pressure and low-pressure
l purpos

side service connections).


nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

168 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Purging device for refrigerant circuits - VAS 6337/1- from “Behr”


or later model.

Note

♦ With filter -1- and two large cylindrical sight glasses


♦ The filter in the purging device for refrigerant circuits should
be changed after about 2 purging cycles (depending on the
level of contamination from the purged refrigerant circuits). If
a heavily contaminated refrigerant circuit is purged (the refrig‐
erant oil from the refrigerant circuit is black and viscous or
there are large amounts of shavings in the refrigerant circuit)
renew filter after purging refrigerant circuit.

Purging device for refrigerant circuits - VAS 6336/1- from “Waeco”


or later model.

Note

♦ With filter -1- and one sight glass


♦ The filter in the purging device for refrigerant circuits should
be changed after about 2 purging cycles (depending on the
level of contamination from the purged refrigerant wage
n AGcircuits).
. VolkswageIfn AG
does
a heavily contaminated refrigerant circuit y V is purged (the refrig‐
olks not
gu
erant oil from the refrigerant circuitris
eis black and viscous or
d b ara
nte
there are large amounts of shavings
utho in the refrigerant circuit) eo
ra
renew filter after purging refrigerant
ss
a circuit. c

ce
e
nl

pt
du

an
itte

Leak detector - V.A.G 1796-


y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Leak detecting system - VAS 6196-


m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

12. Testing equipment and tools 169


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Leak detecting system VAS 6201 or later model

Release tool - VAS 6127- case comprising release tool - VAS


6127/1- release tool - VAS 6127/2- and release tool - VAS 6127/3-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Release tool - VAS 6127/1- release tool - VAS 6127/2- s

ce
le
un

pt
♦ Blue 1/2 inch

an
d
itte

y li
erm

ab
♦ Black 5/8 inch

ility
ot p

wit
♦ Red 3/8 inch
is n

h re
ole,

♦ White 3/4 inch

spec
urposes, in part or in wh

t to the co
rrectness
Release tool - VAS 6127/3-

o
cial p

f inform
♦ Green NW 8 for high-pressure line
mer

atio

♦ Black NW 13 for low-pressure line


om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

170 Rep. gr.00 - Technical data


olkswagen AG
wag en AG. V
Amarok 2011 ➤ , Beetle 2012 ➤ , Boraolks1999 ➤ , CC 2010 ➤ , CC
does
not2012 ➤ , ...
yV gu
Air conditioning system
sed b with refrigerant R134a - Edition a10.2014
ran
ri tee
ho
ut or
Counterhold - V.A.G 1616- for clutch pulley (for “Sanden”
ss
a air con‐ ac
ditioner compressors)

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos
Puller - V.A.G 1616/1- for clutch pulley (for “Sanden” air condi‐
tioner compressors)

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Magnetic clutch puller - V.A.G 1719- (for “Zexel” air conditioner


compressors)

Adapter set for refrigerant circuit - V.A.G 1785/1-10-


♦ Adapter to clean refrigerant circuit (flushing with refrigerant
R134a) ⇒ page 67 or blowing through with compressed air or
nitrogen ⇒ page 65
A - 5/8"-18 UNF thread for conical surface seal
B - Cap nuts (for connection with O-ring) with thread
♦ M 18x1.5 V.A.G 1785/1
♦ M 20x1.5 V.A.G 1785/2
♦ M 24x1.5 V.A.G 1785/3
♦ M 28x1.5 V.A.G 1785/4
A - 5/8"-18 UNF thread for conical surface seal
B - Threaded union for O-ring

12. Testing equipment and tools 171


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

♦ M 18x1.5 V.A.G 1785/5


♦ M 20x1.5 V.A.G 1785/6
♦ M 24x1.5 V.A.G 1785/7
♦ M 28x1.5 V.A.G 1785/8

Valve adapters
A - 5/8"-18 UNF thread for conical surface seal
B - Internal thread with valve opener M 10x1.25 V.A.G 1785/9 (for
connections with valves on the high-pressure side) M 12x1.5
V.A.G 1785/10 (for connections on the low-pressure side)

Note
AG. Volkswagen AG d
♦ There is a Schrader valve screwed into connection -A-. ksw
agen oes
not
ol
yV gu
♦ A valve opener must be fitted into the charging hose isedconnec‐
b ara
nte
tion. ut
hor eo
a ra
ss c

ce
e
nl

pt
Socket insert - T10364- for valves of service connections on HP/
du

an
itte

LP side of refrigerant circuit

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

12.1.5 Tools and materials commercially avail‐


orm
m

able
atio
om

n in
or c

Fin comb
thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

172 Rep. gr.00 - Technical data


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Charging hoses
5/8"-18 UNF valve

Note

♦ Various colours of charging hose can be used, 1,800 mm long.


♦ Maintain a stock of valve openers and spare seals.

Connector piece for pressure bottles for refrigerant with sealing


ring, quick-release coupling or threaded connector 5/8"-18 UNF

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Valve caps with replacement seals (for 5/8''-18 UNFris threads)
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Manifold gauge with pressure reducer for nitrogen (maximum re‐
duction pressure: 15 bar)
l purpos

1- Manifold gauge with pressure reducer


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2- Pressure hose (internal diameter 5 mm, length 2 m) with


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3- Nitrogen bottle
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4- Hose fitting
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Hose junctions for connection to the adapter set for refrigerant co Vo
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circuit - V.A.G 1785- with 5/8"-18 UNF threads or quick-release
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Prote AG.
coupling adapter for service connections to refrigerant circuit.

12. Testing equipment and tools 173


Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014

Quick-release coupling adapter for service connection


♦ High-pressure side with nominal diameter of 16 mm
♦ Low-pressure side with nominal diameter of 13 mm

Note

These quick-release couplings are supplied with the air condi‐


tioner service station.

12.1.6 Tools to be made locally


Charging hose with connector to the workshop's compressed air
system
A - Charging hose 5/8" - 18 UNF** (version with large internal
diameter)
B - Connector for workshop compressed air system** (use only
with filter and dryer for compressed air)
** Tools and materials which are commercially available

AG. Volkswagen AG d
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cted agen
Prote AG.

174 Rep. gr.00 - Technical data

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