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Workshop Manual
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Amarok 2011 ➤ , Beetle 2012 ➤ ,
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Caddy 1997 ➤ , Caddy 2004 ➤ ,
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Caddy 2011 ➤ ,
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Caddy Pickup 1997 ➤ ,
California 2004 ➤ , California 2010 ➤ ,
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Caravelle 2004 ➤ , Caravelle 2010 ➤ ,
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Golf 2004 ➤ , Golf 2009 ➤ ,
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Polo Classic 1996 ➤ ,
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Polo KH MY 2014 ➤ ,
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Polo KH MY 2015 ➤ ,
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Polo Lim IN 2011 ➤ ,
Polo Lim MY 2014 ➤ ,
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Polo Lim RUS 2011 ➤ ,
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Scirocco 2015 ➤ , Sharan 1996 ➤ ,
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Transporter 2004 ➤ ,
Prote AG.
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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
lk n
1.8 Comfort . . . . . . . . . . d. b.y .V . . . . . . . . . . . . . . . . . . . . . . . o.t g. u.a. . . . . . . . . . . . . . . . . . . . . . . . .
o
9
e ra
1.9 How air conditioning horisworks . . . . . . . . . . . . . . . . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . . . . . . . . 9
t o
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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un
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refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.12 Basics for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
erm
ab
ility
2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ot p
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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
rrectne
2.6 Pressures and temperatures in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ss o
2.8 Refrigerant circuit with restrictor and reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
cial p
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2.9 Test and measurement work that can be performed using a pressure gauge . . . . . . . . . . 36
form
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3.3 Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them
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(retrofitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
t. C rig
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3.4 Maintaining records on refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
cop Vo
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4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
46
AG.
Contents i
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
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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
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may cause damage or adversely influence the system.
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Only tools and materials approved by the manufacturer may
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void.
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est malfunctions.
♦ Workshop manual for service work specific to model ⇒ Heat‐
nform
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tio
cations
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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.
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1- Gas (invisible)
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2- Vapour
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3- Liquid
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4- Solid
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absorption, the visible vapour becomes invisible gas. This proc‐
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ess is reversible. If heat is extracted from gaseous water, it
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changes first to vapour, then to water and finally to ice. p by
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A - Heat absorption Prote AG.
B - Heat dissipation
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C - Vapour pressure curve for water le
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Vapour pressure curve for refrigerant R134a
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A - Liquid
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B - Gaseous
D - Vapour pressure curve for refrigerant R134a
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2 - Temperature in °C
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1.4 Vapour pressure table for refrigerant
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65 17.79
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70 20.05
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75 22.52
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80 25.21
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85 28.14
90 31.34
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1.5 Refrigerant R134a
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The refrigerant used is tetrafluoroethane R134a, which boils at
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Chemical formula CH2F–CF3 or CF3–CH2F t. Cop py
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Chemical designation Tetrafluoroethane
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Boiling point at 1 bar -26.5℃ Prote
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♦ R134a does not damage the ozone layer, the potential to re‐
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duce the amount of ozone is zero.
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♦ The contribution of R134a to the greenhouse effect is less by
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1.6 Characteristics of refrigerant R134a
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♦ H-FKW 134a
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♦ SUVA 134a
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♦ Other trade designations may be used in other countries.
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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.
water in the circuit, it will flow to the expansion valve jet or to the
pt
du
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restrictor and becomes ice.
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1.6.8 Combustibility
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ature will result in a very large increase in pressure, since the
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liquid is seeking to expand further but there is no space for it to
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do so. The resulting forces are sufficient to burst the container. p by
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To prevent containers from being overcharged, regulations gov‐
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erning the storage of compressed gases specify how many kilo‐
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since they are very hygroscopic (they readily absorb water).
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♦ Do not reuse used refrigerant machine oil.
♦ Disposing of used oil: Volkswagen InfoNet; Operation; Man‐
rrectness of i
uals and dealership documentation; Service handbook;
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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
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missible to mix such oils with other oils or materials. Proper
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storage and disposal must be performed according to guide‐
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lines in the country where the work is being performed. Ob‐ Cop py
serve, for example in the Federal Republic of Germany, the
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climate protective regulation concerning chemicals; closed cop Vo
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substance cycle waste management and ensuring environ‐ cted agen
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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).
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
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
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Head region 23℃ 42℃
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1.9 How air conditioning works
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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‐
maintained.
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WARNING
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• How high the temperature is. “This is because the higher the
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The refrigerant will draw its latent heat of evaporation from its
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surroundings. That can be your skin. This can result in very low
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temperatures. The result is local frostbite (boiling point of R134a
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1.10.6 Do not breath in refrigerant vapour
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Note
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In high concentrations, emerging refrigerant vapours can mix with
the air and displace the oxygen necessary for breathing.
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substances are poisonous and must not be breathed in.
on
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Before welding and brazing on vehicles (in the vicinity of the air
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conditioning system components), extract the refrigerant and
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then purge the system by blowing through with compressed air py by
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and using nitrogen.
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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.
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ately, releasing violent forces. Flying fragments of cylinders can
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cause severe injuries.
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Bottle valves can brake during improper transport. To protect cyl‐
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inder valves, bottles may be transported only with protective
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covers screwed on.
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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
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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
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Do not heat with an open flame under any circumstance. The local
te
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overheating that will result can change the structure of the con‐
i
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c
tainer's materials, thereby reducing the safe maximum pressure
um
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limit of the container. In addition, the danger arises that the re‐
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frigerant decomposes due to localised overheating. Cop py
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1.10.14 Seal empty containers
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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.
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pt
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vehicles with air conditioning and when
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handling refrigerant R134a
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⇒ Workshop equipment
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WARNING
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♦ It is recommended that a bottle containing water be kept
l purpos
nf
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purge the eyes with water for about 15 minutes. Then ad‐
orm
minister eye drops and visit a doctor immediately even if
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or c
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♦ The doctor must be informed that the frostbite has been
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measures, refrigerant comes into contact with other body
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or vessels containing air.
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Precautions:
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– Evacuate systems and containers before charging with refrig‐
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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
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• When handling refrigerants and nitrogen, wear protective
m
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t
clothing, protective glasses and protective gloves.
ion in
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• Switch on exhaust gas fume extractor (if there is one).
thi
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service station, and only then loosen the threaded joints and
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renew the defective components.
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• Protect units and hoses against moisture and dirt using sealing
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caps.
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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:
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
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
spec
activated when the refrigerant circuit is empty and the air con‐
t to the co
cuit:
l purpos
ion
c
in t
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).
Note
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
wit
, is n
vated).
h re
hole
spec
the air conditioner compressor and allow the engine to idle for
t to the co
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.
Caution
pt
an
itte
ab
Excessive pressure results if the circuit is filled with too much re‐
wit
, is n
h re
t to the co
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.
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
thi
te
sd
a
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).
Note
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.
ce
e
nl
pt
du
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
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
atio
m
pressor.
o
n in
or c
thi
te
sd
iva
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.
WARNING
WARNING
Note
pt
an
itte
ab
ility
h re
pressor.
t to the co
2.1.6 Condenser
l purpos
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.
2.1.7 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
y li
erm
compressor. wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Do not remove sealing plugs -A- and -B- until just before in‐
stallation.
nf
ercia
orm
atio
m
n in
or c
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.
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
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
nform
ercia
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
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
spec
es, in part or in w
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
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.
ce
e
1- Evaporator
nl
pt
du
an
itte
y li
2- Expansion valve
erm
ab
ility
ot p
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
nform
mercia
at
om
ion
reservoir
c
in t
or
his
ate
do
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
WARNING
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
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.
Note
Note
Note
pt
an
d
system - F23-
itte
y li
erm
ab
ility
ot p
Function:
wit
is n
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.
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
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
at
om
his
ate
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.
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
an
itte
y li
erm
ab
ility
This high-pressure sender - G65- is fitted in place of the air con‐
ot p
wit
, is n
h re
hole
spec
a square wave signal, or data telegram. This signal changes when
es, in part or in w
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
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.
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.
Note
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.
Note
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.
pt
perature between the cooling fins of the evaporator. It prevents
an
d
itte
ab
ility
netic clutch if the temperature at the fins falls to the freezing point
ot
wit
, is n
spec
Note
rrectness of i
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
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
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
nform
ercia
at
om
ion
c
in t
r
his
te
do
riv
cum
or
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.
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
-1- evaporator, from inlet to Vapour approx. 1.2 bar1) approx. -7°C2)
m
outlet
com
tion in
thi
-2- Air conditioning system Gas approx. 1.2 bar1) approx. -1℃
s
iva
do
r
compressor A-side
rp
cum
fo
en
g
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
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
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
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
nform
ercia
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.
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
Note
ce
e
nl
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
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
atio
n in
thi
sd
iva
o
r
cu
o
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
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
wit
, is n
h re
equipment
hole
spec
es, in part or in w
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
n in
or c
thi
te
sd
a
o
r
rp
cu
device is then permanently attached to the pressure vessel. In
o
m
f
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
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.
ce
le
un
pt
an
d
itte
y li
erm
ab
Caution
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
void.
ss o
f inform
system:
atio
om
n
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⇒ page 165 .
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sd
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ferred to ⇒ page 58 .
ng
t.
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• Expert knowledge is necessary. t. C rig
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Prote
Note
AG.
AG. Volkswagen AG d
Note lksw
agen oes
not
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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
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nl
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du
an
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sible authorities.
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, is n
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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
nform
ercia
at
2008 the climate protective regulation concerning chemicals
om
ion
comes into force.
c
in t
or
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te
do
priv
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or
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t.
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♦ Regulation (EU) No. 842/2006 ht. Cop py
rig
rig ht
♦ Regulation (EU) No. 706/2007 py by
co Vo
by lksw
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♦ 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‐
Note
pt
du
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sure).
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substances).
h re
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spec
ary containers).
t to the co
ing).
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ion
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for
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t.
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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
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nical Rules for Operational Safety (TRBS)rised
reflect the state of nte
technology, occupational safety and ut health, occupational hy‐
ho eo
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giene as well as other definite knowledge relating to provision
s a c
s
and use of work equipment, operation of facilities requiring
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un
pt
supervision and activities involving hazardous substances.
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♦ The technical rules stated here are valid in Germany and do
ab
pe
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not necessarily reflect the rules and regulations valid in other
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countries.
, is n
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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.
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♦ Filling stations – general provisions.
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Filling stations
tion in
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thi
s
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♦ Filling stations are systems for charging non-stationary com‐
r
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pressed gas containers. A filling station comprises its corre‐
fo
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le
pt
an
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pressure for charging at 15°C in the compressed gas container
rm
ab
pe
ility
is not exceeded. To determine possible overcharging, the
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charged containers must be checked through random pres‐
, is n
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sure tests.
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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
nform
ercia
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
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r
cum
fo
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ng
Note
ce
e
pt
du
an
found in the ⇒ Repair manual for air conditioning systems with
itte
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refrigerant R12 parts 2 and 3 . This workshop manual is only
erm
ab
available as a hard copy.
ility
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, is n
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Maintaining records on refrigerant
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spec
es, in part or in w
at
om
in t
upon request.
or
his
ate
do
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or
Note
f
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t.
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op py
A record sheet need no longer be kept within the EU due to re‐
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spective European parliament legislation from 2005. Other legis‐ py by
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lation may apply in countries not belonging to the EU.
by lksw
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Prote AG.
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.
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nl
an
drocarbons (at least one hydrogen atom has been replaced by
itte
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e.g the halogens flourine, chlorine, bromine or iodine) must be
erm
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disposed of as waste requiring particular care. It is impermissible
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to mix such oils with other oils or materials. Proper storage and
, is n
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or c
thi
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
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3.3 Converting R12 refrigerant circuits to
un
pt
an
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ab
them (retrofitting)
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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
atio
m
for R12.
o
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or
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sd
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o
pr
cum
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ng
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.
4 Refrigerant circuit
Note
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ab
copy.
wit
is n
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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
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pr
cum
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fo
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ng
t.
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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
Caution
Note
ce
have differing physical and chemical characteristics that may
le
un
pt
subsequently affect the function of the air conditioning system
an
d
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and air conditioner service station or even cause a total failure.
rm
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♦ Volkswagen rejects the use of chemical substances for pur‐
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, is n
cuits often react with the surrounding air and the humidity
t to the co
a
com
ti
thi
ces (to seal leaks). Since Volkswagen rejects the use of these
um
fo
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g
t.
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the effectiveness and separation rate of these filters. Cop py
t. rig
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Prote AG.
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• If there is damage to the air conditioner compressor, such that
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decomposition of the refrigerant due to overheating might
pe
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have occurred.
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• If there are dark sticky deposits in the refrigerant circuit (these
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spec
es, in part or in w
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
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com
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tries other or additional regulations may apply).
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Commercially available air conditioner service stations can be
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divided into 2 groups:
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t.
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frigerant for reuse (so-called evacuating and recycling sta‐ t. Cop py
tions) e.g. air conditioner service station - VAS 6007A- .
rig
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co
♦ B. Air conditioner service stations, called extraction stations,
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that charge the extracted refrigerant into recycling bottles (for
AG.
reprocessing in bulk).
Note
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du
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Caution
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Do not open the valves in the low- or high-pressure sides when
, is n
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the engine is running. Otherwise, if the air conditioning is
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spec
switched on, the air conditioner compressor or the air condi‐
es, in part or in w
t to the co
between the high- and low-pressure sides of the refrigerant
circuit.
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– Turn hand wheel into quick-release coupling adapter until the
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– Start the engine and perform the planned tests and measure‐
m
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ments.
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turning out the handwheel.
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5.3 Draining refrigerant circuit using air con‐ Cop py
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WARNING
Note
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un
pt
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erm
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conditioner service station
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is n
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spec
urposes, in part or in wh
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
cuit.
mer
atio
m
Evacuating:
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Caution
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cedure and as long as there is a vacuum present in the Cop py
refrigerant circuit.
t. rig
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co
♦ The air conditioner compressor may be damaged if the
by lksw
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engine is started when a vacuum is present in the refrig‐
Prote AG.
erant circuit.
♦ Only start engine when refrigerant circuits are charged.
Note
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pt
– Initiate the vacuum phase on the air conditioner service station
du
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ab
(observe preset evacuation period). Observe vacuum gauge
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is maintained.
, is n
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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.
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– Search for the leak in the refrigerant circuit as follows:
l purpos
⇒ page 55
nform
ercia
at
om
ion
c
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r
WARNING
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ate
do
priv
t.
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Models with a high-voltage system: now de-energise the high-
C py
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voltage system ⇒ Electric drive; Rep. gr. 93 ; De-energising
ht
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the high-voltage system .
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Note
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es, in part or in w
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Note
rrectness of i
system is switched on for the first time. If there is oil in the cylinder
o
atio
tation.
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n in
or c
thi
te
sd
iva
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o
m
f
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
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Prote AG.
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nl
pt
du
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– Turn out handwheel on quick-release coupling adapter.
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– Detach the charging hose from the refrigerant circuit.
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, is n
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es, in part or in w
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service station with refrigerant
• Always follow the procedure described in the user's manual
rrectness of i
for your air conditioner service station.
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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
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t.
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Note C py
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♦ If it becomes necessary to drain the air conditioner service
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station (e.g. because contaminated refrigerant was extracted),
Prote AG.
WARNING
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un
pt
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the recycling bottle).
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is n
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
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iva
o
pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
Note
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♦ A wide range of processes are offered on the open market for
erm
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finding leaks in refrigerant circuits. These processes do not
ility
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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.
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nf
ercia
o
⇒ page 50 .
rm
m
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om
n in
or c
thi
Caution
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sd
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♦ If there is evidence to suggest that chemical substances
o
m
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ng
Note
pt
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d
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rm
ab
pe
ility
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, is n
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mercia
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s
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t.
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Cop py
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by lksw
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Prote AG.
Note
AG. Volkswagen AG d
WARNING
agen oes
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♦ 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.
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nl
pt
du
an
itte
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erm
ab
of sounds.
h re
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spec
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.
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at
ion
in t
or
off, this indicates there may be a very small ingress of air and
do
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t.
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– 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
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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
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circuit using leak detector system VAS 6201 or later model and
AG.
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nl
detector.
pt
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– Evacuate refrigerant circuit using an air conditioner service
ility
ot p
station ⇒ page 50 .
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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 .
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♦ If during the evacuation process no leak is detected or a very
l purpos
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om
io
♦ If the refrigerant circuit is completely empty, charge with about
n
c
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workshop manual).
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do
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cum
for
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Leak detection:
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t.
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– Prepare leak detector for operation according to its operating
t. C rig
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instructions. p by
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– Always hold probe tip under location of suspected leak. Prote AG.
Note
Note
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1- Hand pump with low-pressure service hose, service cou‐
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7- Tube
VAS 6201/8
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t.
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Cop py
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by
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Prote AG.
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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
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pump.
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mercia
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or
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for
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Cop py
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rig ht
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by lksw
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Prote AG.
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
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placed. If only some of the refrigerant machine
orise oil was replaced nte
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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
an
itte
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erm
ab
ility
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, is n
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– Reassemble refrigerant circuit again.
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spec
– Attach a label, close to the service connection, which has in‐
es, in part or in w
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 .
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Note
rm
m
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thi
sd
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compressor must run). The leak may become visible after a short
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t.
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Cop py
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– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
ht
pyri by
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erant circuit ⇒ page 63 .
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AG. Volkswagen AG d
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Note
nform
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Ensure the hose of the hand pump is completely filled with leak
detecting additive.
m
at
om
ion
c
in t
or
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.
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ng
t.
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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
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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.
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le
un
pt
an
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erm
ab
Note
ility
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is n
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ole,
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.
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pr
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Note
pt
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ab
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spec
refrigerant oil and leak detecting additive can leak out, light-up
t to the co
Note
l purpos
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atio
n in
thi
repair work.
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t.
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Cop py
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Prote AG.
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Note
spec
urposes, in part or in wh
t to the co
atio
om
n
c
i
or
WARNING
thi
te
sd
iva
o
r
cum
r
fo
way.
en
ng
t.
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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.
ce
e
nl
pt
du
an
itte
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erm
ab
nection, use adapter from adapter case for VW/Audi passen‐
ility
ot p
wit
, is n
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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
atio
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.
Note
ce
le
pt
an
d
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new the dryer cartridge or dryer.
erm
ab
ility
ot p
wit
is n
h re
ole,
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
n
c
i
or
n thi
sd
a
o
pr
compartment.
um
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
WARNING
co Vo
by lksw
cted agen
Prote AG.
DANGER!
an
itte
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erm
ab
ility
ot p
spec
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.
Caution
Note
ce
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nl
pt
du
an
valves to malfunction and defects in other components with
itte
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erm
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
atio
n in
or c
sd
iva
cu
o
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
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
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nl
pt
du
replacement of certain components.
an
itte
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erm
ab
♦ a different air conditioner compressor with other refrigerant oil
ility
ot p
is to be fitted.
wit
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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
at
om
io
♦ Adapter case commercial vehicle set - VAS 6338/50-
n
c
in t
or
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
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.
Note
Caution
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
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 .
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.
Note
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-.
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wit
, is n
♦ Reinstall the solenoid valve -B- with the respective seal -E- to
h re
hole
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
n in
or c
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).
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
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
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
atio
m
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
– 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).
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
nf
ercia
or
fore starting second purging cycle.
m
m
atio
om
n in
c
thi
e
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.
– 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
pt
an
d
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
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
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
thi
s
iva
do
r
rp
cum
en
g
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.
Note
are joined together with two adapters and the charging hose -
itte
y li
erm
ab
- 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.
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
5 - Connection to reservoir
❑ Different versions depending on vehicle ⇒ page 86 .
rrectness of i
a
com
ti
❑ 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
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
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
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
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
n in
or c
thi
e
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
ce
le
un
pt
- VAS 6337- .
an
d
itte
y li
rm
ab
❑ If an air conditioner
pe
ility
ot
wit
, is n
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
nform
ercia
a
cuits - VAS 6337/1- be‐
com
tion in
tween air conditioner
r
te o
thi
service station and re‐ s
iva
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.
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
tion in
thi
s
do
r
rp
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).
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
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
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
do
r
cum
fo
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.
DANGER!
ce
le
un
pt
the high-voltage cables and the maintenance connector
an
d
itte
y li
erm
ab
ility
♦ Carry out a visual check on all potential equalisation lines.
ot p
wit
is n
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
sd
iva
cum
r
fo
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
Note
pt
new air conditioner compressor is not sufficient, the new air con‐
du
an
itte
ab
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.
Note
– Extract refrigerant, if
there is any in the sys‐
tem.
Note
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
❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of
h re
hole
❑ 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
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
sd
iva
o
r
rp
cu
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.
ce
e
nl
pt
du
connected directly to the air condi‐
an
itte
y li
tioner compressor. erm
ab
ility
ot p
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
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
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.
Note
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.
ce
le
un
Fox 2005
pt
an
d
itte
y li
rm
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
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.
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
wit
, is n
h re
hole
spec
cation stall a new receiver. place of
es, in part or in w
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.
ce
e
nl
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
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.
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
a
com
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.
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.
ce
e
erant pipes to air ceiver
nl
pt
du
an
conditioner com‐
itte
y li
pressor erm
ab
ility
ot p
wit
, is n
h re
hole
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
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-
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
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.
– 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
y li
erm
ab
2004 ►; VAS pair manual. 6338/1
ility
ot p
wit
is n
h re
2005 ►; ♦ High-pres‐ dryer expan‐
ole,
sure side
spec
Golf sion
urposes, in part or in wh
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
n
Sciroc‐ – After
c
i
or
n
co 2009 purg‐
thi
e
bag/cartridge.
t
sd
a
o
pr
c
occo stall a
um
r
fo
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 ►
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
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.
– After
purg‐
ing, in‐
stall a
new ex‐
pan‐
sion
valve.
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
h re
ole,
spec
VAS 6338/6- and ant pipe
urposes, in part or in wh
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.
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
nf
ercia
adapter - VAG
o
sure side
rm
1785/8- or adapter - – After
m
atio
adapter -
m
VAS
n in
c
6338/12-
thi
e
6338/31- . stall a
t
sd
iva
o
r
rp
cu
sure side – After flushing, in‐ strictor.
o
m
f
en
ng
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
h re
hole
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
nform
ercia
at
om
io
sion
n
c
in t
r
his
e
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.
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
ce
e
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
atio
m
n in
c
thi
e
sd
iva
cu
expan‐
o
m
f
en
ng
Sharan 2011
Note
ce
e
nl
pt
du
pressor
an
itte
y li
erm
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
6338/4- pan‐
m
at
sion
om
♦ The refrigerant
io
valve
n
c
⇒ page
o
evaporator must be
his
te
71 )
a
loosened sufficient‐
do
priv
– 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.
– After
purg‐
ing, in‐
stall a
new
expan‐
sion
valve.
Note
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.
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
wit
71 )
, is n
cuit.
h re
hole
spec
♦ Sealing adapter - – After
es, in part or in w
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.
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
wit
, is n
side adapter -
h re
identifi‐ cartridge. 7- or
hole
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
nform
ercia
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
cum
fo
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
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
atio
VAS
m
n
6338/51- and
c
i
or
n
adapter -
thi
pan‐
e
sd
a
VAS
v
o
pr
c
6338/52- .
um
valve
r
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.
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
Note
nform
ercia
tio
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.
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
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
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.
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
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
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‐
– 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
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
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.
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
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
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
h re
adapter -
hole
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
sd
iva
o
r
rp
cu
er -
o
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.
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
y li
erm
air conditioner
ab
ility
compressor itself
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
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‐
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.
⇒ 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.
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
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
nf
ercia
o
sure side VAS 6338/31- . er, and
rm
adapter -
m
atio
start
m
VAS 6338/3-
o
n in
or c
thi
♦ Purging elec‐
te
sd
voir. tion
a
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.
ce
e
compressor itself
nl
pt
du
an
itte
y li
erm
ab
brid sure side of the fluid receiver: adapter -
ility
ot p
wit
, is n
h re
6338/12- ♦ Fluid receiver with in place of
hole
spec
permanently fitted expan‐
es, in part or in w
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
nform
ercia
tridge ♦ Replace
adapter - shut-off
m
at
valves -
om
io
6338/40- and bag/cartridge and N541-
n
c
in t
r
and -
his
e
VAS
at
N542- do
riv
cum
or
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 .
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
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
a
com
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.
8 Complaints
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
y li
rm
ab
pe
ility
8.1.1 Test prerequisites:
ot
wit
, is n
h re
hole
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
a
com
ti
Note
on in
r
te o
thi
do
r
rp
cum
fo
en
g
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.
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
y li
erm
ab
total amount of refrigerant oil (50 g direct into air conditioner
ility
ot p
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
ion
c
do
priv
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.
Note
8. Complaints 123
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
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
sd
iva
o
pr
cum
r
fo
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.
Note
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
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
spec
es, in part or in w
t to the co
– Switch off ignition.
rrectness of i
– Connect air conditioner service station to power supply.
l purpos
nform
ercia
at
om
i
ing hoses (necessary only if there is air in the charging hoses).
on
c
in t
or
his
ate
do
riv
cum
for
en
ng
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
spec
es, in part or in w
t to the co
and testing.
rrectness of i
10.1.1 Test prerequisites
l purpos
nform
ercia
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
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.
ce
e
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
orm
m
• The valves for the pump valve unit are closed (and the coolant
atio
m
n in
or c
thi
sd
iva
o
r
rp
cu
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.
Note
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
at
ion
c
in t
r
his
e
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.
Note
ce
e
nl
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
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
⇒ page 135 .
at
om
ion
c
do
riv
⇒ page 141 .
p
cum
for
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.
Note
Note
⇒ 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
y li
the air conditioner compressor or at the reservoir) in bar positive
erm
ab
ility
pressure.
ot p
wit
is n
h re
ole,
spec
D - Low pressure (measured at the connection with the valve for
urposes, in part or in wh
t to the co
itive pressure.
E - Permitted tolerance range. rrectness o
cial p
f inform
mer
atio
om
n
c
n thi
te
sd
• High pressure remains constant or in‐ Insufficient refrigerant in cir‐ – Look for leaks and rectify them.
iva
o
r
cum
r
fo
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.
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
do
riv
cum
or
en
g
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.
– In case of an ob‐
struction, blow
through refrigerant
circuit with com‐
pressed air and ni‐
trogen.
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
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
• 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
• High-pressure and low-pressure Too much refrigerant oil in circuit. – Drain refrigerant cir‐
are normal, cuit.
ss
delivered.
i
erant circuit
nform
⇒ page 67 .
mer
atio
m
n
c
are normal,
i
or
n thi
te
sd
a
o
r
cum
r
fo
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.
Note
Note
Note
pt
High-pressure side:
an
d
itte
y li
erm
ab
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.
– 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
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
h re
hand to
hole
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.
Note
ce
le
pt
increases beyond the specifica‐
an
d
itte
y li
tion, and the low pressure falls to
erm
ab
the diagram value or lower,
ility
erant circuit with
ot p
wit
compressed air and
is n
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
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.
– 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
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
nf
ercia
orm
m
atio
m
n in
or c
thi
• High pressure increases only ♦ The air conditioner compressor is defec‐ – Purge (clean) refrig‐
te
sd
a
o
r
rp
cu
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.
Note
Note
pt
y li
ab
ility
ot p
h re
ole,
spec
urposes, in part or in wh
• All air ducts, covers and seals are OK and properly installed.
inform
mer
n
c
i
or
n thi
e
sd
va
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
t to the co
– Start engine.
m
a
com
tion in
thi
s
iva
– Open doors.
do
r
rp
cum
fo
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
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.
Note
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
t to the co
⇒ Rep. gr. 87
10.5.1 Specifications:
rrectne
High-pressure side:
s
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.
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
pt
an
d
y li
erm
♦ The set working current for the regulating valve must be great‐
wit
is n
activated.
spec
urposes, in part or in wh
f in
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.
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
wit
, is n
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
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
ce
le
un
pt
• Low pressure falls only slightly,
an
d
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
– Recharge refriger‐
ant circuit.
– Repeat check.
ce
e
delivered.
nl
pt
du
erant circuit
an
itte
y li
⇒ page 67 .
erm
ab
ility
ot p
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
nf
ercia
o
♦ In this case, the evaporator may ice up although the correct
rm
m
atio
om
n in
c
thi
ture sender - G263- or evaporator temperature sensor -
te
sd
iva
G308- .
o
r
rp
cu
o
m
f
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:
– 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 .
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
at
om
io
level was not checked after the air conditioner compressor
n
c
in t
was renewed.
or
his
ate
do
riv
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.
Note
Note
10.6.1 Specifications:
High-pressure side:
Rising from starting pressure (when pressure gauge is connec‐
ted) to 20 bar.
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
pt
du
wit
♦ Under unfavourable conditions (very high ambient tempera‐
, is n
h re
tures, high atmospheric humidity), the output may be insuffi‐
hole
spec
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
atio
n in
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.
ce
e
pt
du
is stopped).
an
itte
y li
– Look for
erm
ab
• Low pressure leaks using
ility
ot p
wit
, is n
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.
– Recharge re‐
frigerant cir‐
cuit.
– Repeat
check.
• The quantity
of refrigerant
extracted is
about equal
to the pre‐
scribed
charge
quantity.
– Recharge re‐
frigerant cir‐
cuit.
– Repeat
check.
Note
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
h re
ered, and it can be that the high-pressure value does not rise
spec
t to the co
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
at
om
in t
or
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.
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
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
– 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.
– Recharge refriger‐
ant circuit.
Note
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
o
r
cum
r
fo
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.
– Recharge refriger‐
ant circuit.
– Repeat check.
Note
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
t to the co
♦ Expansion valve defective. – Extract refrigerant.
rrectness of i
– Purge (clean) refrig‐
erant circuit
l purpos
⇒ page 67 .
nform
ercia
at
om
ceiver.
ion
c
in t
or
– Recharge refriger‐
his
ate
ant circuit.
do
priv
cum
for
en
g
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.
– Recharge refriger‐
ant circuit.
– Repeat check.
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
pt
du
an
itte
y li
erm
ab
valve - N280- (the regulating valve is not activated, but the air
ility
ot p
wit
, is n
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
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
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.
– Repeat check.
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
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 check.
Note
pt
an
d
• High pressure and low pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
itte
y li
ab
ility
ot p
erant circuit
ole,
on).
t to the co
– 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.
Note
pt
an
d
y li
takes place via the speed of the air conditioner compressor. The
rm
ab
pe
ility
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.
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
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
tering.
m
at
om
in t
or
his
te
do
riv
cum
for
en
g
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.
Caution
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
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
nf
ercia
orm
m
atio
♦ Pour old refrigerant oil out of air conditioner compressor, han‐
om
sd
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 .
Note
Note
pt
an
d
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
position possible.
inform
mer
n
c
n thi
sd
iva
o
pr
cum
r
fo
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
ce
e
pt
du
an
itte
y li
poly V-belt pulley. Not applicable for electrical air conditioner
erm
ab
compressor.
ility
ot p
wit
, is n
h re
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐
hole
spec
book; Environmental protection; Waste disposal; Current
es, in part or in w
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
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
en
ng
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
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.
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
o
pr
cum
r
fo
en
ng
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
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
Note
Caution
pt
an
d
itte
y li
Overview page
rm
ab
pe
ility
wit
, is n
spec
t to the co
tio
thi
do
r
rp
cum
fo
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.
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.
pt
du
an
itte
y li
ab
cleaning, short
wit
, is n
h re
hole
cleaning, long
es, in part or in w
t to the co
at
om
ion
c
his
do
priv
cum
or
en
ng
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.
Caution
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
pt
an
d
itte
Open ring spanners of widths matching those of the threaded connections on not illustrated
y li
erm
ab
h re
spec
urposes, in part or in wh
f in
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.
Caution
an
itte
y li
⇒ Workshop equipment
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Note
hole
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orm
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Cop py
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Prote AG.
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ility
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nform
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om
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c
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or
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ate
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priv
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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Release tool - VAS 6127/1- release tool - VAS 6127/2- s
ce
le
un
pt
♦ Blue 1/2 inch
an
d
itte
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erm
ab
♦ Black 5/8 inch
ility
ot p
wit
♦ Red 3/8 inch
is n
h re
ole,
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
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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
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♦ A valve opener must be fitted into the charging hose isedconnec‐
b ara
nte
tion. ut
hor eo
a ra
ss c
ce
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nl
pt
Socket insert - T10364- for valves of service connections on HP/
du
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
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nf
ercia
able
atio
om
n in
or c
Fin comb
thi
te
sd
iva
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rp
cu
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m
f
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Charging hoses
5/8"-18 UNF valve
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Valve caps with replacement seals (for 5/8''-18 UNFris threads)
ed
nte
ho eo
ut
Seals can also be used for charging hoses. ss a ra
c
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
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Manifold gauge with pressure reducer for nitrogen (maximum re‐
duction pressure: 15 bar)
l purpos
hose junctions
m
atio
om
n in
c
3- Nitrogen bottle
or
thi
te
sd
a
4- Hose fitting
iv
o
r
rp
cu
o
m
f
en
ng
t.
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Note . Cop py
rig
ht ht
rig by
py
Hose junctions for connection to the adapter set for refrigerant co Vo
by lksw
circuit - V.A.G 1785- with 5/8"-18 UNF threads or quick-release
cted agen
Prote AG.
coupling adapter for service connections to refrigerant circuit.
Note
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.