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Workshop Manual
Amarok 2011 ➤ , Amarok 2017 ➤ ,
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Atlas 2017 ➤ , Beetle 2012 ➤ ,
Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ ,
Caddy 1997 ➤ , Caddy 2004 ➤ ,
Caddy 2011 ➤ , Caddy 2016 ➤ ,
Caddy Kasten/Kombi 1996 ➤ ,
Caddy Pickup 1997 ➤ ,
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New Beetle Cabrio 2003 ➤ ,
Passat 1994 ➤ , Passat 1997 ➤ ,
Passat 2006 ➤ , Passat 2011 ➤ ,
Passat 2015 ➤ ,
Passat (NMS - US) 2012 ➤ ,
Passat (NMS - US) 2016 ➤ ,
Passat CC 2009 ➤ ,
Passat Variant 1997 ➤ ,
Passat Variant 2011 ➤ ,
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Air conditioning systems with refrigerant R134a -
General information
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Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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All rights reserved.

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B8027068B

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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Safety precautions when working on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Safety precautions when working on a high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 2
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1.4 Safety precautions when tow-starting or towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.1 Rules for cleanliness when working on high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Hazard classification of high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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4 General information on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4.2 Basics of air conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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4.3 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.4 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.5 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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4.6 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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4.7 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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4.8 How air conditioning works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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4.9 General work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.11 Basics for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Evacuation and charging valves for quick-release couplings of air conditioner service station
on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Switches and senders in refrigerant circuit and related connections . . . . . . . . . . . . . . . . . . 32
5.5 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.6 Pressures and temperatures in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.8 Refrigerant circuit with restrictor and reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.9 Test and measurement work that can be performed using a pressure gauge . . . . . . . . . . 40
5.10 Air conditioner service and recycling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.11 Notes to repairs on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Legal texts and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Recycling and refuse law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3 Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them
(retrofitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.4 Maintaining records on refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.1 Important repair notes on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2 Converting refrigerant circuits from R12 refrigerant to R134a . . . . . . . . . . . . . . . . . . . . . . 50
8 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Important instructions for working with the air conditioner service station . . . . . . . . . . . . 51
8.2 Connecting a air conditioner service station for measuring and testing . . . . . . . . . . . . . . . . 52
8.3 Drain the refrigerant circuit using the air conditioner service station . . . . . . . . . . . . . . . . . 53
8.4 Evacuating refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . 53
8.5 Filling refrigerant circuit with air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.6 Bringing air conditioning system into service after charging . . . . . . . . . . . . . . . . . . . . . . . . 55
8.7 Charging the container in the air conditioning service station with refrigerant . . . . . . . . . . 56
Contents i
Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2 ...
Air conditioning systems with refrigerant R134a - General information - Edition 11.2019
8.8 Emptying air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

9 Detecting leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.1 Leak detection in refrigerant circuit using compressed air or nitrogen . . . . . . . . . . . . . . . . 58
9.2 Searching for leaks in refrigerant circuits using leak detector V.A.G 1796 . . . . . . . . . . . . 60
9.3 Detecting leaks in refrigerant circuit using leak detecting system VAS 6196 or leak detecting
system VAS 6201 or a later model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10 Clearing refrigerant circuit of contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1 Vehicles with high-voltage system (hybrid vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2 Blowing through refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . 68
10.3 Flushing refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11 Clearing refrigerant circuit of contaminants, commercial vehicles . . . . . . . . . . . . . . . . . . . . 100
11.1 Vehicles with high-voltage system . . . . . . . . . . . . . g.e.n.A.G.. V. o.lk. s.w.a.ge. n. A.G. d. . . . . . . . . . . . . . . . 100
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11.3 Adapters for setting up flushing circuits r.ise. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . 102
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refrigerant circuit, Caddy 2004 ► . . . . . . . . . . . . . . 110
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11.6 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 . . . . . . . . . . . . . . . . 117
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2020 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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12 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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12.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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12.2 Odours from heater and air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
13 Connecting the air conditioning service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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13.1 For vehicles that have connections on both low-pressure and high-pressure sides of
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refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

14 Checking pressures on vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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14.1 Checking pressures in the refrigerant circuit (using a air conditioning service station ) . . . . 161
14.2 Checking systems with a restrictor and collector (with internally regulated air conditioner
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14.3 Checking systems with an expansion valve and reservoir (with internally regulated air
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14.5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating
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14.7 With expansion valve, receiver and electrical air conditioner compressor . . . . . . . . . . . . . . 190
15 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
15.1 In the event of leaking or damaged components (apart from the air conditioner compressor,
receiver or reservoir) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
15.2 Renew the air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
15.3 Replace receiver or reservoir and restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
16 Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
16.1 List of test equipment, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
ii Contents
00 – Technical data
1 Safety information
(VRL013671; Edition 11.2019)
⇒ “1.1 Safety precautions when working on air conditioning sys‐
tems”, page 1
⇒ “1.2 Safety precautions when working on a high-voltage sys‐
tem”, page 1
⇒ “1.3 Safety precautions when working in the vicinity of high-
voltage components”, page 2
⇒ “1.4 Safety precautions when tow-starting or towing”,
page 2
1.1 Safety precautions when working on air conditioning systems

Risk of freezing injury from refrigerant
When working on the air conditioning system, there is a risk of
highly pressurised refrigerant escaping from the system. There is
a risk of injury to the skin and parts of the body due to freezing.
– Wear protective gloves. agen
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Risk of damage to refrigerant lines

There is a risk of damage to the refrigerant lines due to rupture of
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– Never bend refrigerant lines to a radius less than 100 mm.

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1.2 Safety precautions when working on a high-voltage system

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– Persons with life-preserving or other electronic medical devi‐ yri
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voltage system. Such medical devices include internal anal‐
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pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified technician.
1. Safety information 1
Risk of injury from engine starting unexpectedly

On electric and hybrid vehicles, the operational readiness of the
vehicle is difficult to detect. There is a risk of parts of the body
becoming trapped or drawn in.
– Switch off ignition.
– Always store the ignition key outside the vehicle.
Risk of damage to high-voltage cables

Improper handling of high-voltage cables or high-voltage connec‐
tors may result in damage to their insulation.
– Never support body weight on high-voltage cables or high-
voltage connectors.
– Never support any tools on high-voltage cables or high-volt‐
age connectors.
– Never kink or severely bend high-voltage cables.
– Always observe the coding when connecting high-voltage con‐
nectors.
AG. Volkswagen AG d
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Risk of injury from activated stationary air conditioning nte
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On electric and shybrid vehicles with active stationary air condi‐ c
tioning, the stationary air conditioning could switch on uninten‐
ce
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tionally. Risk of limbs becoming trapped or drawn in by the

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radiator fan starting automatically.

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– Deactivate the stationary air conditioning.

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1.3 Safety precautions when working in the vicinity of high-voltage components

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The high-voltage system is under high voltage. Damage to high-

voltage components can result in severe or fatal injury from
electric shock.
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– Perform visual check of high-voltage components and high-

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voltage cables.
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– Never use cutting or forming tools, or any other sharp-edged

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1.4 Safety precautions when tow-starting or towing

This vehicle is electrified by ABT e-Line.
All relevant repair and maintenance information regarding modi‐
fications by ABT e-Line are available in the Electronic Service
Information System (ElsaPro), section “Superstructures and
modifications”. These can also be obtained from ABT e-Line.
2 Rep. gr.00 - Technical data


This manual may have lost its validity due to modifications by ABT
e-Line, or may have to be supplemented by additional repair in‐
structions from ABT e-Line.
Please refer to the Electronic Service Information System (El‐
saPro), section “Superstructures and modifications” for relevant
repair manuals regarding modifications by ABT e-Line.
These can also be obtained from ABT e-Line.
AG. Volkswagen AG d
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1. Safety information 3
2 Repair notes
⇒ “2.1 Rules for cleanliness when working on high-voltage sys‐
tem”, page 4
2.1 Rules for cleanliness when working on high-voltage system

AG. Volkswagen AG d
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This vehicle is electrified by ABT ae-Line.
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urposes, in part or in wh
t to the co
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Air conditioning systems with refrigerant
gen AG
. VolksR134a
wagen A-GGeneral information - Edition 11.2019
d wa oes
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3 Hazard classification of high-voltage ris nte
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DANGER
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The vehicle’s high-voltage system and high-voltage battery are ot p
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dangerous and can cause burns or other injuries and even lead
, is n
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to a fatal electric shock.
hole
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– Any work on the high-voltage system, or on systems which
es, in part or in w
could be indirectly affected by it, may only be carried out by
t to the co
properly trained and qualified expert personnel.
– If there are any questions or there is any doubt regarding the
rrectness of i
terms “high-voltage technician” or “high-voltage expert”, like‐
wise if there are any questions about the high-voltage sys‐
l purpos
tem, the responsible importer must be contacted before

starting any work.
nf
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– Any repair work must be performed in accordance with ap‐
or
plicable laws and regulations, approved engineering practi‐
m
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ces, any relevant accident prevention regulations (in Ger‐
om
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many, including but not limited to the BGI/GUV-I 8686 –
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Training for work on vehicles with high-voltage systems), as
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well as this workshop manual.

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3. Hazard classification of high-voltage system 5

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Amarok 2011 ➤ , Amarok orise 2017 ➤ , Ameo 2017 ➤ , Arteon 2018 nte ➤ , Atlas 2 ...
eo
h
Air conditioning systems
s aut
with refrigerant R134a - General information r a - Edition 11.2019
c
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4 General information on air condition‐
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4.1 Other reference material
es, in part or in w
t to the co
♦ Technical Service Handbook with measures for rectifying lat‐
est malfunctions.
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♦ Workshop manual for service work specific to model ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 .
l purpos
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

cations
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♦ Catalogue of special tools / workshop testing.
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♦ Workshop manual for air conditioning system with R12 refrig‐
or c
erant (for vehicles that were manufactured up to model year
thi
te
sd
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1993). This workshop manual is only available as a hard copy.

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4.2 Basics of air conditioning technology
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4.2.1 Physical principles:

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The four familiar states of water apply to air conditioning refriger‐
ants as well.
1- Gas (invisible)
2- Vapour
3- Liquid
4- Solid
When water is heated in a vessel (heat absorption), water vapour

can be seen to rise. If the vapour is heated by further heat ab‐
sorption, the visible vapour becomes invisible gas. The process
is reversible. If heat is extracted from gaseous water, it changes
first to vapour, then to water and finally to ice.
A - Heat absorption
B - Heat dissipation

4.2.2 Heat always flows from a warmer to a

colder substance
Every substance consists of a mass of moving molecules. The
fast moving molecules of a warmer substance give off some of
their energy to the cooler and thus slower molecules. This causes
the molecular movement in the warmer material to slow down,
and that in the colder material to speed up. This continues until
the molecules in both materials are moving at the same speed.
They are then at the same temperature and no further heat ex‐
change takes place.
4.2.3 Pressure and boiling point

The boiling point given in tables for a liquid is always referenced
to an atmospheric pressure of 1 bar. If the pressure over a fluid
changes, its boiling point changes as well.
It is well known that, for example, the lower the pressure, the lower
the temperature at which water boils.
The vapour pressure curves for water and for refrigerant R134a
show that at constant pressure and falling temperature the vapour
becomes liquid (in the condenser), and that when pressure drops,
the refrigerant changes from liquid into the vapour state (evapo‐
rator).
Vapour curve, water
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A - Liquid agen oes
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B - Gaseous orise nte
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C - Vapour
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1 - Pressure on the liquid in bar (absolute)

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2 - Temperature in °C
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Vapour pressure curve for refrigerant R134a

A - Liquid
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B - Gaseous
D - Vapour pressure curve for refrigerant R134a
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1 - Pressure on the liquid in bar (absolute)

inform
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2 - Temperature in °C
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4.3 Vapour pressure table for refrigerant
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The vapour pressure table for every refrigerant is published in
agen
Prote AG.
literature for refrigeration system engineers. This table makes it
possible to determine the vapour pressure acting on the column
of liquid in a vessel if the temperature of the vessel is known.
Since a characteristic vapour pressure table is known for every
refrigerant, one can determine what refrigerant is present by
measuring pressure and temperature.
4. General information on air conditioning 7

Note
Absolute pressure means that 0 bar corresponds to an absolute

vacuum. The normal ambient pressure corresponds to 1 bar ab‐
solute pressure. On the scales of most pressure gauges, 0 bar
corresponds to an absolute pressure of 1 bar (indicated by -1 bar
mark below 0).
Temperature in °C Pressure in bar (positive pres‐

sure) R134a
-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00
-5 1.43
0 1.92
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6.70
35 7.83
40 9.10
45 10.54 n AG. Volkswagen AG do
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spec
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90 31.34
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4.4 Refrigerant R134a

rrectness of i
Air conditioners in vehicles use the evaporation and condensation

l purpos
process. Use is made of a substance with a low boiling point, re‐

ferred to as refrigerant.
nf
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The refrigerant employed is tetrafluoroethane or R134a, which

or
boils at -26.5 °C at a pressure of 1 bar.

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4.4.1 Physical data of refrigerant R134a

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Chemical formula CH2F–CF3 or CF3–CH2F

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Chemical designation Tetrafluoroethane

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Boiling point at 1 bar -26.5°C t. Cop py
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Rep. gr.00 - Technical data cted agen
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Solidification point -101.6°C

Critical temperature 100.6°C
Critical pressure 40.56 bar (technical) pressure
equates to 39.5 bar (standard)
pressure
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4.4.2 Critical point byV
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The critical point (critical temperature uand
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critical pressure) eo
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means the point above which there sis s no longer a surface of sep‐
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A substance above its critical point is always in the gaseous state.
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At temperatures below the critical point, all types of refrigerant
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contained within a pressure tank exhibit a liquid phase and a gas
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phase, so that there is a gas cushion above the liquid.
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As long as there is gas in the pressure vessel alongside the liquid,
the pressure depends directly on the ambient temperature
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⇒ page 7 .
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Note
ss
Different types of refrigerant are never to be mixed. Only the re‐
o
cial p
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frigerant prescribed for the respective air conditioning system
inform
may be used.
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4.4.3 Environmental aspects of refrigerant
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♦ R134a is a fluorocarbon and contains no chlorine.
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♦ R134a has a shorter atmospheric persistence than refrigerant Cop py
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♦ R134a does not damage the ozone layer, the potential to re‐ Prote
cted AG.
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duce the amount of ozone is zero.
♦ The Global Warming Potential (GWP) of R134a amounts to
approx. 1430 (the GWP for carbon dioxide amounts to 1).
♦ R134a contributes only one tenth as much to the greenhouse
effect as refrigerant R12.
4.5 Properties of refrigerant R134a
4.5.1 Trade names and designations

Refrigerant R134a is currently available under the following trade
names:
♦ H-FKW 134a
♦ SUVA 134a
♦ KLEA 134a

Note
♦ Different trade names may be used in other countries.

♦ Of the wide range of refrigerants available, this is the only one
which may be used for vehicles. The names Frigen and Freon
are trade names. They also apply to refrigerants which are not
to be used in vehicles.
4.5.2 Colour
Like water, refrigerants are colourless in both vapour and liquid
form. Gas is invisible. Only the boundary layer between gas and
liquid is visible (liquid level in indicator tube of charging cylinder agen
AG. Volkswagen AG d
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or bubbles in sight glass). Liquid refrigerant R134a may have a y Volksw not
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coloured (milky) appearance in a sight glass. This cloudinessisis ed
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caused by partially dissolved refrigerant oil and does not indicate hor eo
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a fault. ss a ra
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4.5.3 Vapour pressure

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In an enclosed container that is not completely full, refrigerant
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evaporates as vapour at the surface in a quantity sufficient to form
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vapour pressure. The vapour pressure is temperature-dependant
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⇒ page 7 .
t to the co
4.5.4 Physical properties of R134a
rrectness of i
As the vapour pressure curves of R134a and other refrigerants
are often very similar, unequivocal identification cannot be made
l purpos
simply on the basis of pressure.

The air conditioner compressor used for R134a is lubricated with
nform
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special synthetic refrigerant oils, such as PAG oils (polyalkylene

glycol oils).
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4.5.5 Effects on metal
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In its pure state, refrigerant R134a is chemically stable and does
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not react with iron or aluminium.
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However, impurities such as chlorine compounds in the refriger‐
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ant do attack certain metals and plastics. This can lead to block‐ ht. rig
rig ht
ages, leaks and deposits on the air conditioner compressor py by
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4.5.6 Critical temperature and critical pres‐

sure
The refrigerant R134a remains stable up to a pressure of 39.5 bar
(corresponding to a temperature of 101 °C). Above this temper‐
ature, the refrigerant decomposes (see "Combustibility").
4.5.7 Water content

Only very small amounts of water are soluble in liquid refrigerant.
On the other hand, refrigerant vapour and water vapour mix in
any ratio.
Any water present in the refrigerant circuit will be carried along as
droplets. The desiccant, desiccant bag or desiccant cartridge in
the receiver or reservoir are capable of holding approx. 7 grams
of water before they are full and cannot absorb any more water.
If there is further water in the circuit, it will flow to the expansion
valve jet or to the restrictor and becomes ice.
The air conditioning system stops cooling.

Water destroys the air conditioner because at high pressures and

temperatures it combines with other impurities to form acids.
4.5.8 Charge factor

There must be space both for liquid and vapour in a container. As
the temperature rises, the liquid expands. The vapour-filled space
becomes smaller. At a certain point, there will only be liquid in the
vessel. Beyond this, even a slight increase in temperature causes
great pressure to build up in the vessel as the liquid attempts to
continue expanding despite the absence of the necessary space.
The resultant force is sufficient to rupture the vessel. To prevent
containers from being overcharged, regulations governing the
storage of compressed gases specify how many kilograms may
be charged into a container for every litre of container volume.
This charge factor multiplied by the internal volume gives the per‐
missible charge quantity. The charge factor for refrigerant used
in vehicles is 1.15 kg/litre.
4.5.9 Detecting leaks

External damage, for example, can cause a leak in the refrigerant
circuit. Because a small leak will involve only small quantities of
refrigerant, leaks should be checked for using an electronic leak
detector or by introducing a leak detection additive to the refrig‐
erant circuit. Electronic leak detectors can detect leakage rates
of less than 5 grams loss of refrigerant per year. The leak detector
should be specific to the composition of the particular refrigerant
in use. For example, a leak detector for R12 refrigerant is not ap‐
propriate for R134a refrigerant because R134a refrigerant has no
chlorine atoms to which the lead detector responds.
4.6 Refrigerantagoil
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Refrigerant oil mixes ed b with the refrigerant (about 20 to 40%,
yV t gu
ara de‐
pending on air conditioner
horis compressor type and amount ofnrefrig‐
tee
erant) and circulates
aut constantly in the system, lubricating the or ac
moving parts.
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Special synthetic refrigerant machine oils such as polyalkylene

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glycol oil (PAG oil) are used in conjunction with R134a air condi‐
erm
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tioning systems. This is necessary because ordinary mineral oils

ility
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are immiscible in R134a. In addition the materials of the R134a

wit
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air conditioning system could be attacked if the mixture circulated

h re
ole,
within the refrigerant circuit under pressure and at high tempera‐

spec
tures, or the lubricant film in the air conditioner compressor broke

down. The use of unapproved oils can lead to the failure of the air
t to the co
conditioning system, so only approved oils must be used.

⇒ Electronic parts catalogue (ETKA)
rrectne
Type of oil for R134a in cars: PAG

ss o
cial p
f inform
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Cop py
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Prote AG.

Note
♦ Do not store refrigerant machine oils open to the atmosphere

since they are very hygroscopic (they readily absorb water).
♦ Always keep oil container sealed.
♦ Do not re-use old refrigerant oil.
♦ Disposal of used oils: Volkswagen InfoNet; Operation; Hand‐
books & dealer literature; Handbook Service; 15. Environmen‐
tal protection; under general instructions follow the link
“Environmental protection in the dealership and in the work‐
shop”; 4. Waste disposal; 6. Disposal channels; Disposal of agen
AG. Volkswagen AG d
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used oils; Refrigerant oils Volksw not
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♦ Used refrigerant oils from systems with halogenated hydro‐tho ris nte
eo
carbons (at least one hydrogen atom has been replaced sby au ra
c
e.g. the halogens fluorine, chlorine, bromine or iodine) must
s
ce
e
be disposed of as waste requiring particular care. They are not
nl
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to be mixed with other oils or substances. Proper storage and
itte
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disposal must be ensured in line with local regulations. Ob‐
erm
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serve, for example in the Federal Republic of Germany, the
ility
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Climate Protection Regulation Concerning Chemicals (Chem‐
wit
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ikalien-Klimaschutzverordnung) and the Closed Substance
h re
hole
Cycle Waste Management Law (Kreislaufwirtschaftsgesetz,
spec
KrWG) (in other countries other statutes and regulations may
es, in part or in w
t to the co
apply).
♦ Reference sources for technical rules and safety at work/ac‐
cident prevention for the Federal Republic of Germany.
rrectness of i
♦ Sources in other countries may be obtained from the respon‐
l purpos
sible authorities.
♦ Ester-based oils are suitable only for larger systems (not for
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air conditioning systems in cars).
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4.6.1 Properties of refrigerant oil

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The most important properties are high solubility with refrigerant,
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good lubricating quality, absence of acid and low water content.
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For this reason, only certain oils may be used. A list of approved
t.
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refrigerant oils and quantities can be found in the vehicle-specific C py
t. rig
workshop manuals in ⇒ Rep. gr. 00 or ⇒ Rep. gr. 87 .
gh ht
pyri by
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The PAG oils suitable for refrigerant R134a are strongly hygro‐ Prote
cted AG.
agen
scopic and are immiscible with other oils. Opened containers
should therefore be closed again immediately to prevent ingress
of moisture. Moisture and acids promote ageing of refrigerant oil,
causing it to become dark, viscous and aggressive towards met‐
als.
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.
♦ Disposal of used oils: Volkswagen InfoNet; Operation; Hand‐
books & dealer literature; Handbook Service; 15. Environmen‐
tal protection; under general instructions follow the link
“Environmental protection in the dealership and in the work‐
shop”; 4. Waste disposal; 6. Disposal channels; Disposal of
used oils; Refrigerant oils

4.7 Comfort
A basic requirement for concentration and safe driving is a feeling
of comfort in the passenger compartment. This comfort is only
reached by using an air conditioning system, particularly when it
is hot and humid. 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 temperature 30°C in the shade and
the vehicle in direct sunlight).
With air conditioning Without air condi‐ swagen AG. Volkswagen AG does
tioning by Volk not
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Head height 23°C 42°C
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Chest 24°C ss 40°C
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Footwell 30°C 35°C

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4.7.1 Environmental aspects
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ility
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As of around 1992, the air conditioning systems of newly manu‐
, is n
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factured cars have been successively changed to refrigerant
hole
spec
R134a. This refrigerant contains no chlorine and therefore does
es, in part or in w
no damage to the ozone layer.
t to the co
Until about 1992, the air conditioning systems were equipped with
refrigerant R12. Due to its chlorine atoms, this CFC has a high
rrectness of i
potential for destroying ozone and, in addition, a higher potential
for increasing the greenhouse effect.
l purpos
There are programs for exchanging old air conditioning systems

containing the ozone-damaging refrigerant R12.
nform
ercia
To protect the environment, no refrigerant should be released into

m
at
the atmosphere ⇒ page 43 (statutory texts and instructions).

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ion
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4.8 How air conditioning works

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ate
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The temperature in the passenger compartment depends on the

p
cum
or
amount of heat radiated through the windows and conducted by

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t.
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the metal parts of the body. In order to maintain comfortable tem‐
Co
op py
peratures for the occupants on very warm days, part of the t. C rig
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prevailing heat must be pumped away. pyri by
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Since heat spreads towards cooler bodies, a unit that can create Prote AG.
low temperatures is fitted in the vehicle interior Within this, refrig‐
erant is continually evaporated. The heat required to do this is
extracted from the air flowing 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‐
ditioner compressor on the refrigerant increases its heat content

and its temperature. Its temperature is now substantially higher

than that of the surrounding air.
The hot refrigerant flows with its heat content to the condenser.
where the refrigerant dissipates n Aits
G. Vheat
olkswto
agethe
n AGsurrounding air via
wage does
the condenser due to Vthe olks temperature gradient between not
g the re‐
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The refrigerantau thus acts as a heat transfer medium. As it is to rbe
t o
ac
re-used, thess refrigerant is returned to the evaporator.
ce
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pt
For this reason all air conditioning systems are based on the re‐
an
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itte
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frigerant circulation principle. There are however differences in
rm
ab
the composition of the units.
pe
ility
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wit
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4.9 General work safety
h re
hole
spec
♦ In accordance with VBG 20, the Federation of Employers Li‐
es, in part or in w
ability Insurance Associations.
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.
4.9.1 Product characteristics
nform
mercia
Refrigerants used in car air conditioning systems belong to the a

com
tio
new generation of refrigerants, the chlorine-free, partially-fluori‐
n in
r
dated hydrocarbons (H-CFC, R134a).

te o
thi
s
iva
do
With regard to their physical properties, these are refrigerants

r
rp
cum
which have been liquefied under pressure. They are subject to

fo
en
g
the regulations governing pressure vessels and use is only to be

n
t.
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made of approved and appropriately marked containers. C py
t. rig
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Compliance with specific conditions is required to ensure safe and
op Vo
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proper use. cted agen
Prote AG.
4.9.2 Handling refrigerants
Note
♦ Risk of freezing injuries.

♦ The refrigerant can emerge as liquid or as vapour.
♦ Do not open vessels containing refrigerant.
If refrigerant containers are opened, the contents may escape in

liquid or vapour form. The higher the pressure in the container,
the more violent the process.
How high the pressure is depends on two factors:
• What type of refrigerant is in the container. “This is because
the lower the boiling point, the higher the pressure.”
• The temperature “This is because the higher the temperature,
the higher the pressure.”
4.9.3 Wear safety goggles.

Put on safety goggles This will prevent the refrigerant entering the
eyes, which in certain circumstances can cause severe injury due
to frostbite.
4.9.4 Wear protective gloves and apron

Greases and oils dissolve readily in refrigerants. They would
therefore destroy the protective layer of grease if allowed to come

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
Amarok
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nte ➤ , Arteon 2018 ➤ , Atlas 2 ...
eo
h
Air conditioning
s aut
systems with refrigerant R134a - General r a information - Edition 11.2019
c
s
ce
e
nl
into contact with the skin. Degreased skin is however sensitive to
pt
du
an
the cold and germs.
itte
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erm
ab
4.9.5 Do not allow liquid refrigerant to come in
ility
ot p
wit
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contact with the skin
h re
hole
spec
The refrigerant draws heat for evaporation from the surrounding
es, in part or in w
area - even if this is the skin. This may give rise to extremely low
t to the co
temperatures. The result is local freezing (boiling point of R134a:
-26.5 °C at atmospheric pressure).
rrectness of i
4.9.6 Do not breath in refrigerant vapour
l purpos
Note
nf
ercia
orm
m
atio
In high concentrations, emerging refrigerant vapours can mix with
om
the air and displace the oxygen necessary for breathing.
n in
or c
thi
te
sd
iva
4.9.7 Absolutely NO SMOKING
o
r
rp
cu
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m
f
en
ng
A burning cigarette can cause refrigerant to decompose. The re‐

t.
yi Co
op
sultant substances are toxic and must not be inhaled. C py
t. rig
gh ht
yri by
4.9.8 Welding and soldering on refrigeration
cop Vo
by lksw
cted agen
systems
Prote AG.
Before welding and brazing on vehicles (in the vicinity of the air
conditioning system components), extract the refrigerant and
then purge the system by blowing through with compressed air
and using nitrogen.
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.
4.9.9 Pungent smell

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

• Following contact with eyes or mucous membranes, immedi‐
ately rinse with copious amounts of running water and consult
an eye specialist.
• Following contact with the skin, immediately remove clothing
affected and rinse skin with copious amounts of water.
• Following inhalation of highly concentrated refrigerant va‐
pours, person concerned is to be taken immediately into the
open air. Call a doctor. Administer oxygen in the event of
breathing difficulties. If the person affected is having great dif‐
ficulty breathing or is not breathing at all, tilt back head and
administer artificial respiration.
4.9.11 Handling pressure vessels

• Secure containers to prevent them falling over.
Secure upright cylinders to stop them falling over and cylinders
lying flat to stop them rolling away.
• Containers must never be thrown.

If they should fall, the containers may become severely deformed

and break open. The refrigerant evaporates immediately, liberat‐
ing considerable force. Flying fragments of cylinders can cause
severe injuries.
Valves may break off if cylinders are not properly transported. To
protect cylinder valves, cylinders are only to be transported with
a protective cap screwed on.
• Do not place near radiators!
High temperatures can occur near radiators. High temperatures
are also associated with high pressures and the maximum per‐
missible tank pressure may be exceeded.
4.9.12 Do not heat up above 50°C

To prevent danger, the pressure vessel regulations provide that
vessels shall not be heated to more than 50°C.
4.9.13 Do not expose to uncontrolled heat

Do not heat with a naked flame under any circumstances. The
local overheating that will result can change the structure of the
container's materials, thereby reducing the safe maximum pres‐
sure limit of the container. There is also a danger of the refrigerant
decomposing due to localised overheating. en AG. V
olkswagen AG
ag does
ksw not
Vol
4.9.14 Seal empty tanks/containers ed
by gu
ara
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oris eo
Empty refrigerant tanks/containers must
au always be closed to pre‐
th
ra
vent the ingress of moisture. Moisture
ss causes steel tanks/con‐ c
ce
le
tainers to rust. Rust weakens the tank/container walls. In addition,

un
pt
rust particles which ingress into refrigeration systems from con‐
an
d
itte
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tainers cause malfunctions.
erm
ab
ility
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4.9.15 Safety instructions for using extraction

wit
is n
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and charging equipment
ole,
spec
• Before connecting the charging system to the air conditioner, t to the co

make sure that all existing shut-off valves are closed.
• Before the charging equipment is decoupled from the air con‐
rrectne
ditioning system, ensure that the process has finished. The

reason for this is to ensure that no refrigerant oil escapes into
the atmosphere.
ss o
cial p
• Once the purified refrigerant from the charging system has

f in
been filled into an external compressed-gas cylinder, close the

form
mer
hand shut-off valves at the cylinder and charging system.

atio
om
• Do not expose charging system to moisture or use it in a wet

n
c
i
or
environment.
thi
te
sd
iva
• Before performing service work on the charging system, dis‐

pr
cum
r
fo
connect the power supply.

en
ng
t.
yi Co
op
• To reduce the risk of fire, avoid using an extension cable. If C py
t. rig
the use of an extension cable is unavoidable, use an extension
gh ht
pyri by
cable with a cross-section of at least 2.5 mm2.
co Vo
by lksw
cted agen
Prote AG.
• In case of fire, remove external cylinder.
• If entrained oil from the air conditioning system suction accu‐
mulator is trapped in the measuring beaker supplied, be sure
subsequently to pour the oil into a container that can be
sealed, since the oil contains a small amount of refrigerant.
Refrigerant must not be released into the environment.
• When the air conditioner service station is switched off, it must
be secured against rolling away.

4.10 Safety measures when working on ve‐

hicles with air conditioning and when
working
swa
gwith
en AG. Vrefrigerant
olkswagen AG R134a
does
k not
Vol gu
Air conditioner
ed service station
by ara
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is
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⇒ Workshop
au
th equipment ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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Risk of freezing injury from refrigerant
spec
es, in part or in w
When working on the air conditioning system, there is a risk of
t to the co
highly pressurised refrigerant escaping from the system. There is
a risk of injury to the skin and parts of the body due to freezing.
rrectness of i
– Wear protective gloves.
l purpos
– Wear safety goggles.

– Extract refrigerant and open the refrigerant circuit immediately
nf
ercia
afterwards.
orm
m
atio
– If more than 10 minutes have passed since the refrigerant was
om
extracted, repeat the extraction process before opening the n in

or c
refrigerant circuit. Pressure could build up in the refrigerant

thi
te
sd
a
circuit from continued evaporation.

iv
o
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ng
t.
yi Co
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pyri by
Risk of damage to refrigerant lines
o Vo
by c lksw
cted agen
Prote AG.
There is a risk of damage to the refrigerant lines due to rupture of
the inner foil.
– Never bend refrigerant lines to a radius less than 100 mm.
• Do not weld, braze or soft-solder any parts of the charged air

conditioning system. This also applies to welding and solder‐
ing work on the vehicle when the danger exists that parts of
the air conditioning system may heat up. When spray painting
is carried out, temperatures of objects in the drying booth or
the preheating zone must not exceed 80°C.
Reason
Heating causes great excess pressure to develop in the system,
which can cause the pressure release valve of the system to
open.
Remedy
– Drain the refrigerant circuit using the air conditioner service
station .
Note
Damaged or leaking components of the air conditioning system

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

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

service station ) must never be subjected to excessive heat or
exposed to direct sunlight.
Remedy:
– Containers must never be completely filled with liquid refrig‐
erant. Without sufficient expansion space (gas cushion), the
container will burst should the temperature rise with devastat‐
ing consequences ⇒ page 9 .
Under no circumstances may refrigerant be charged into systems
or vessels containing air.
Remedy:
– Evacuate systems and containers before charging with refrig‐
erant.
4.11 Basics for working on refrigerant circuit

• Observe instructions specific to the workplace; ⇒ Volkswagen
ServiceNet; Handbooks; Service handbook; Environmental
protection . Refrigerant from air conditioning systems / refrig‐
erant oils - to be displayed at refrigerant designated working
area.
• Observe the utmost cleanliness when working.
• When handling refrigerants and nitrogen, wear protective
clothing, protective glasses and protective gloves.
• Switch on exhaust gas fume extractor (if there is one).
• Drain the refrigerant circuit using only the air conditioner serv‐
ice station , and only then undo the screwed joints and renew
the defective components.
• Protect units and hoses against moisture and dirtwusing
agen sealing
AG. Volkswagen AG d
oes
caps. yV
olks not
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• Make exclusive use of tools and materials
ris intended for refrig‐ nte
tho e
erant R134a. s au or
ac
s
• Protect refrigerant oil by sealing container to prevent ingress
ce
e
nl
pt
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of moisture.
an
itte
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erm
ab
– Blow through refrigerant circuit with compressed air and nitro‐

ility
ot p
gen ⇒ page 68 .
wit
, is n
h re
– Flush refrigerant circuit with refrigerant R134a ⇒ page 70 .

hole
spec
In vehicles that have an air conditioner compressor without a

es, in part or in w
t to the co
magnetic clutch:
rrectness of i
l purpos
nf
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atio
om
n in
or c
thi
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

properly assembled. If, for example, the refrigerant lines are
not connected to the air conditioner compressor and the en‐
gine is running, the compressor may heat up so much through
internal warming that it will be destroyed.
♦ The air conditioner compressor regulating valve - N280- is not
activated when the refrigerant circuit is empty and the air con‐
ditioner compressor idles with the engine.
♦ If it is necessary to start engine with an empty refrigerant cir‐
cuit:
♦ The refrigerant circuit must be fully assembled.
♦ At least ¼ of the quantity of refrigerant oil specified for this
refrigerant circuit must be in the air conditioner compressor.
♦ The engine speed must not exceed 2000 rpm.
♦ The engine should run for less than 10 minutes.
4.11.1 O-ring
♦ Use only O-rings that are resistant to refrigerant R134a and
related refrigerant oils. O-rings are no longer colour-coded.
Coloured and black O-rings are used.
. Volkswagen AG
gen AG does
♦ Check that the O-rings used have the correct
olks internal diame‐
wa not
ters. byV gu
ara
ed nte
ris
⇒ Rep. gr. 87 ho eo
aut ra
ss c
ce
e
nl
pt
du
♦ Never reuse O-rings. an

itte
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erm
♦ Before installing, moisten O-rings lightly with refrigerant oil ab

ility
ot p
(PAG oil). wit

, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ When purging components with compressed air and nitrogen,

always collect the gas mixture exiting the component with suit‐
rrectness of i
able exhaust gas extraction equipment (workshop fume ex‐

tractor).
l purpos
♦ After completion of repair work screw sealing caps (with seals)

onto valve and service connections.
nform
mercia
at
Before operating the air conditioning system. Check the vehicle-

om
ion
specific charge quantities ⇒ Rep. gr. 87 .

c
in t
or
his
e
Do not top up refrigerant in circuit; discharge existing refrigerant

at
do
riv
and re-charge system.

p
cum
for
en
g
4.11.2 Before operating the air conditioning

n
t.
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op py
system after recharging with refrigerant
. C rig
ht ht
rig by
copy Vo
by lksw
– After installing a new air conditioner compressor or filling with Prote
cted AG.
agen
fresh refrigerant oil (e.g. after blowing out refrigerant circuit),
turn compressor pulley 10 revolutions by hand before starting
engine. This will prevent damage to the air conditioner com‐
pressor.
– On 5 or 10-cylinder diesel engine, turn air conditioner com‐
pressor at overload protection 10 times by hand. Then install

compressor. This will prevent damage to the air conditioner

compressor.
– Start the engine with the air conditioning system switched off
(the air conditioning system magnetic clutch - N25- and the air
conditioner compressor regulating valve - N280- are not acti‐
vated).
– After the engine has stabilised at its idling speed, switch on
the air conditioner compressor and allow the engine to idle for
at least 10 minutes at maximum cooling power.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
5 General information on refrigerant d by
Volksw not
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ara
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5.1 Components of refrigerant circuit
an
itte
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erm
ab
• All components of the refrigerant circuit that were submitted
ility
ot p
for quality monitoring must always be sealed (use the original
wit
, is n
sealing caps from the genuine part).
h re
hole
spec
• Renew damaged or leaky components of the refrigerant circuit
es, in part or in w
⇒ page 191 .
t to the co
• The genuine parts (air conditioner compressor, reservoir, re‐
ceiver, evaporator and condenser) are charged with nitrogen
rrectness of i
before shipment. This charge is being gradually discontinued.
Therefore, when the sealing plugs are unscrewed from the
l purpos
genuine part little or no pressure equalisation is noticeable.
5.1.1 Distribution of the refrigerant circuit
nf
ercia
orm
components and their influence on the
m
atio
m
high-pressure and low-pressure sides

o
n in
or c
thi
te
sd
On the high-pressure side, there are the condenser, the receiver
iva
o
r
and the restrictor or expansion valve that acts as the separation

rp
cu
o
m
between the high-pressure fluid and low-pressure fluid sides.
f
en
ng
t.
yi Co
op
High pressure is created because the restrictor or expansion
C py
t. rig
gh
valve forms a restriction and holds back the refrigerant, leading
ht
pyri by
Vo
to increased pressure and temperature.
o
by c lksw
cted agen
Prote AG.
Excessive pressure results if the circuit is filled with too much re‐
frigerant or refrigerant oil, or the condenser is dirty, the radiator
fan is defective, there is a blockage in the system or there is
moisture in the refrigerant circuit (causing the restrictor or expan‐
sion valve to ice up).
On the low-pressure side, there are the evaporator, the reservoir,
the temperature sensor for the evaporator and the air conditioner
compressor that acts as the separation between the high-pres‐
sure and low-pressure gas sides.
A loss of pressure in the system can be due to loss of refrigerant,
restrictor or expansion valve failure (not creating a restriction),
defective air conditioner compressor or an iced-up evaporator.
5. General information on refrigerant circuit 21

5.1.2 Air conditioning system compressor with

magnetic clutch:
The air conditioner compressor is driven by a V-belt from the en‐
gine.
An electromagnetic clutch is fitted to the air conditioner
wage
n AG. Vocompres‐
lkswagen AG
does
sor. When the air conditioning system is yswitched
Volks on, it transmits not
gu
the mechanical drive between the V-belt ed b pulley and the air con‐ ara
nte
ris
ditioner compressor drive shaft. uth o eo
ra
sa c
A fusible link is incorporated insthe air conditioner compressor V-
ce
e
belt pulley. In the event of stiffness in the air conditioner com‐

nl
pt
du
an
pressor, it trips the electromagnetic clutch and protects the V-belt
itte
y li
drive from overload.
erm
ab
ility
ot p
The air conditioner compressor draws refrigerant gas from the
wit
, is n
evaporator, compresses it and sends it to the condenser.
h re
hole
spec
es, in part or in w
t to the co
Note
♦ The air conditioner compressor contains refrigerant oil, which
rrectness of i
can be mixed with R134a refrigerant at any temperature.
l purpos
♦ The identification plate states the refrigerant for which the air
conditioner compressor is suitable. A valve regulates the pres‐
sure on the low-pressure side within the specified range (con‐
nform
ercia
trol characteristic).
m
at
♦ So that the air conditioner compressor suffers no damage
om
ion
when the refrigerant circuit is empty, the magnetic clutch is
c
in t
or
disconnected and the regulating valve for the air conditioner
his
ate
compressor - N280- is no longer activated (the air conditioner

do
priv
c
compressor idles with the engine).
um
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 no
d by
V
Amarok 2011 ➤ , Amarokt g2017 ua
ran ➤ , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2 ...
e
oris Air conditioning systems with refrigerant teeR134a - General information - Edition 11.2019
h
aut or
ac
ss
5.1.3 Air conditioner compressor without
ce
le
un
pt
magnetic clutch
an
d
itte
y li
erm
ab
The air conditioner compressor is driven by a V-belt from the en‐
ility
ot p
gine.
wit
is n
h re
ole,
A shear link is incorporated in the air conditioner compressor V-
spec
belt pulley. In the event of stiffness in the air conditioner com‐

pressor, it shears off and protects the V-belt drive from overload.
t to the co
rrectnes
Note
s o
cial p
f inform
mer
is miscible with R134a refrigerant at all temperatures.
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
c
um
r
fo
en
ng
t.
yi
♦ The regulating valve for this air conditioner compressor is ex‐
Co
op py
ternally activated. t. C rig
gh ht
pyri by
♦ The engine should be started only when the refrigerant circuit
o Vo
by c lksw
cted agen
has been fully assembled ⇒ page 18 .
Prote AG.
♦ The air conditioner compressor has an internal oil circuit to

ensure that the air conditioner compressor is not damaged
when the refrigerant circuit is empty. This means that approx.
40 to 50 cm3 of refrigerant oil remain in the air conditioner
compressor.

5.1.4 Air conditioner compressor without lksw

agen
AG. Volkswagen AG d
oes
not
magnetic clutch, with elastic bydrive cou‐
Vo gu
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ise nte
pling au
thor eo
ra
ss c
The air conditioner compressor is driven directly by the power
ce
le
un
steering vane pump.
pt
an
d
itte
y li
There is an overload protection on the drive shaft of the air con‐
rm
ab
pe
ditioner compressor, which shears in the event of the air condi‐
ility
tioner compressor seizing, thus permitting the power steering ot
wit
, is n
h re
vane pump to remain operational.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos

is miscible with R134a refrigerant at all temperatures.
nform
ercia
m
a
com
ti
on in
r
te o
thi
s
iva
♦ The regulating valve for this air conditioner compressor is ex‐
do
r
rp
c
ternally activated.
um
fo
en
ng
t.
yi
Co
op py
has been fully assembled ⇒ page 18 . t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
ensure that the air conditioner compressor is not damaged Prote AG.
compressor.
5.1.5 Electrical air conditioner compressor for

high-voltage system
DANGER
Danger to life from high voltage.
Severe or fatal injury from electric shock.
– The high-voltage system must be de-energised by a suitably
qualified technician.

Note
♦ The electrical air conditioner compressor requires a different

refrigerant oil!
♦ For capacities, see workshop manual for specific vehicle.
♦ Do not touch air conditioner compressor when drive units are
starting. Danger of short circuit!
Electrical air conditioner compressor

Note
Volkswagen AG
♦ The air conditioner compressor contains refrigerant oil,swwhich
agen
AG. does
is miscible with R134a refrigerant at all temperatures. yV
olk not
gu
edb ara
ris which the air nte
♦ The identification plate states the refrigerantthofor eo
conditioner compressor is suitable. The flow
ss
au
rate is controlled ra
c
via the engine speed.
ce
le
un
pt
an
d
itte
y li
has been fully assembled ⇒ page 18 .
erm
ab
ility
ot p
wit
is n
ensure that the air conditioner compressor is not damaged
h re
ole,
spec
compressor.
t to the co
♦ The air conditioner has a pressure relief valve.
rrectne
5.1.6 Condenser
ss o
cial p
f
The condenser transfers heat from the compressed refrigerant
inform
gas to the surrounding air.
mer
atio
When this happens, the refrigerant gas condenses to liquid.
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.

5.1.7 Evaporator
The liquid refrigerant evaporates in the tubes of the evaporator.
The required heat is extracted from the air flowing past the evap‐
orator ribs. The air cools down. 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 supplies a defined quantity of
refrigerant to the evaporator. In systems with an expansion valve
the flow rate is regulated such that only gaseous refrigerant
emerges at the evaporator outlet.
5.1.8 Reservoir
The reservoir collects the vaporised and gaseous mixture coming
from the evaporator to ensure the air conditioner compressor re‐ agen
AG. Volkswagen AG d
oes
ceives only gaseous refrigerant. The vapour becomes gaseous Volksw not
gu
refrigerant. sed by ara
ni tee
or
Refrigerant oil flowing in the circuit does not remain in the reser‐
au
th or
ac
voir because an oil extraction hole has been provided. ss
ce
le
un
pt
Any moisture which has entered the refrigerant circuit during as‐
an
d
itte
sembly will be trapped by a filter (drying bag) in the reservoir.
y li
rm
ab
pe
ility
Gaseous refrigerant with oil is drawn in by the air conditioner
ot
wit
compressor.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Renew the reservoir if the refrigerant circuit has stood open
for any length of time (more than the normal repair time) and
rrectness of i
moisture has entered the system, or if it is required because
l purpos
of a specific complaint ⇒ page 191 .

♦ Do not remove sealing plugs -A- and -B- until just before in‐
nform
ercia
stallation.
m
♦ The desiccant bag in an unsealed reservoir will become satu‐
a
com
tio
rated with moisture within a short time and is then unusable.
n in
r
te o
thi
♦ When installing, observe arrow indicating direction of flow if s
iva
do
applicable.
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.

5.1.9 Restrictor
The restrictor creates a constriction. This restriction limits the flow,
separating the high pressure and low pressure sides in the re‐
frigerant circuit. Upstream of the restrictor, the refrigerantgeisn warm
AG. Volkswagen AG d
due to the high pressure. Downstream of the restrictor, Volkswthe refrig‐
a oes
not
erant is cold due to the low pressure. Upstreamedof b the constriction
y gu
ara
is a strainer to catch dirt and downstream of horithe
s constriction is a nte
eo
strainer to atomise the refrigerant befores ait enters the evaporator.
ut ra
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s
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pt
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an
Note
itte
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erm
ab
ility
ot p
♦ Arrow -A- on the restrictor points to the evaporator.
wit
, is n
h re
♦ Renew it every time the refrigerant circuit is opened.
hole
spec
♦ Observe different versions.
es, in part or in w
t to the co
⇒ Rep. gr. 87
rrectness of i
l purpos
5.1.10 Receiver
nf
ercia
The receiver collects the liquid droplets and directs them in a
or
continuous stream to the expansion valve. Moisture which has
m
m
atio
m
entered the refrigerant circuit during assembly is collected by the

o
n in
c
desiccant bag in the receiver.

or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
♦ Renew the reservoir if the refrigerant circuit has stood open
C py
t. rig
gh
for any length of time (more than the normal repair time) and
ht
pyri by
moisture has entered the system, or if it is required because
co Vo
by lksw
cted agen
of a specific complaint ⇒ page 191 . Prote AG.
♦ Do not remove sealing plugs until just before installation.

♦ The desiccant bag in an unsealed receiver will become satu‐
rated with moisture within a short time and is then unusable.
♦ When installing, observe arrow indicating direction of flow if
applicable.
The new generation of receivers is mounted directly on the con‐

denser and contains a desiccant cartridge.
Note
♦ Renew the desiccant cartridge if the refrigerant circuit was

open for a longer period of time (more than the normal repair
time) and moisture has entered the system, or if it is required
because of a specific complaint ⇒ page 191 .
♦ Remove the dryer cartridge from its packaging only immedi‐
ately before installing it.
♦ A dryer cartridge in unsealed packaging will become saturated
with moisture within a short time and is then unusable.

5.1.11 Expansion valve

The expansion valve atomises incoming refrigerant and regulates
the flow so that, depending on the heat transport, the vapour does
not become a gas until it reaches the outlet of the evaporator.
5.1.12 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.
O-ring
• Strictly use only once:
• Check that diameters -a- and -b- are correct.
• Moisten with refrigerant oil before fitting AG. Volkswagen AG d
agen oes
olksw not
y V gu
5.1.13 Pipes and hoses of refrigerant circuit d b ara
rise nte
tho eo
u ra
The mixture of refrigerant oil and refrigerant R134a
ss a
attacks certain c
metals (e.g. copper) and alloys and dissolves certain hose mate‐
ce
e
nl
rials. Therefore, always use genuine spare parts. pt

du
an
itte
y li
erm
The pipes and hoses are joined with bolted connections or special ab
ility
connectors.
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Observe specified torques for bolted connections and use the

envisaged release tools for connectors.
rrectness of i
5.1.14 High-pressure safety valve

l purpos
The high pressure safety valve is fitted to the air conditioner com‐
pressor or the receiver.
nform
ercia
The valve opens at a pressure above approx. 38 bar and closes

m
at
om
again when the pressure has dropped (approx. 30 bar).

on
c
in t
or
Not all the refrigerant is lost from the system.

his
ate
do
priv
Depending on the version, a transparent plastic disc may be fitted,

cum
for
which breaks when the valve opens.

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

Note
♦ Depending on the version, a transparent plastic washer -B-

may be attached to the high pressure safety valve -A- which
breaks off as soon as the valve is actuated.
♦ Depending on the version of high pressure safety valve -A-, a
cover -C- may also be pushed onto the high pressure safety
valve -A-. Should the pressure in the refrigerant circuit actually
rise above the opening pressure of the high pressure safety
valve -A- and cause the valve to open, refrigerant will not es‐
cape in one direction but scatter through the openings -D-
beneath the cover -C- instead.
♦ If a high-pressure safety valve -A- needs to be renewed, the
specified torque for the new valve (depending on the manu‐
facturer and the version of the air conditioner compressor)
must be observed when installing. Air conditioner compres‐
sors manufactured by “Denso”, “Sanden” and “Valeo” are
equipped with an O-ring seal (currently valid torque settings
are: 10 Nm for “Denso” and “Zexel/Valeo” air conditioner com‐
pressors, and 15 Nm for “Sanden” air conditioner compres‐
sors). Air conditioner compressors manufactured by “Delphi”
are fitted with an oil seal (currently valid torque setting: 15 Nm).
♦ Renewing seals (oil seals or O-rings) ⇒ Electronic parts cata‐
logue .
♦ If a seal (oil seal or O-ring) fitted to the high-pressure safety
valve is not available as a replacement part, the removed old
part can be reused (as ks an
wageexception to the general
es n rule of using
new seals only). Vol
byThe old seal, however, must always ua be
ot g
checked forordamage prior to installation. If any damage teor de‐
ed ran
is
formationauis
t detected on the old seal, it must be renewede owith
h
ra
a commercially
ss available new part ⇒ Electronic parts cata‐c
logue .
ce
e
nl
pt
du
an
itte
♦ After filling the refrigerant circuit, check the installed high-

y li
erm
ab
pressure safety valve for leaks using e.g. an electronic leak

ility
ot p
detector.
wit
, is n
h re
hole
spec
5.2 Design of refrigerant circuit

es, in part or in w
t to the co
5.2.1 Refrigerant circuit with expansion valve

and evaporator
rrectness of i
1- Evaporator
l purpos
2- Expansion valve
nform
ercia
3- Valve for extracting, charging and measuring

m
at
om
4- Receiver with desiccant bag or cartridge

ion
c
in t
or
5- Condenser
his
ate
do
riv
6- Air conditioner compressor

p
cum
for
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co
Arrows show direction of refrigerant flow
by lksw
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Prote AG.

olkswagen AG
ag en AG. V
Amarok 2011 ➤ , Amarok 2017 ➤ ,VoAmeo lksw 2017 ➤ , Arteon 2018
does
no➤ , Atlas 2 ...
t gu
sed by
R134a - General information ar-a Edition 11.2019
n ri tee
ho
ut or
5.2.2 Refrigerant circuit with restrictor and
a ac
ss
ce
e
reservoir
nl
pt
du
an
itte
y li
1- Air conditioner compressor
erm
ab
ility
ot p
2- Condenser
wit
, is n
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3- Restrictor
hole
spec
es, in part or in w
4- Evaporator
t to the co
5- Reservoir with desiccant cartridge
rrectness of i
Note
l purpos
nf
ercia
orm
m
atio
5.3 Evacuation and charging valves for
om
n in
c
quick-release couplings of air condition‐

or
thi
te
sd
a
er service station on refrigerant circuit

iv
o
r
rp
cu
o
m
f
en
ng
Special tools and workshop equipment required

t.
yi Co
Cop py
♦ Torque wrench - V.A.G 1783- (2…10 Nm) with 1/4" ratchet ht. rig
rig ht
adapter - VAS 6234- py by
co Vo
by lksw
cted agen
Prote AG.
CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.
• Only valves and connections resistant to R134a refrigerant

and the related refrigerant oils may be used.
• Different connections (external diameter) for high-pressure
and low-pressure sides.
• Always screw on sealing caps.
Arrangement within the vehicle.
See vehicle-specific repair manual ⇒ Rep. gr. 87

5.3.1 Evacuation and charging valve with

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

6234-
♦ Appropriate insert - T10364- to remove Schrader valve core
⇒ page 205
A - Service port (soldered in)

B - Valve core (2.4 ± 0.2 Nm)
C - O-ring (for the valve) AG. Volkswagen AG d
agen oes
ksw
D - Sealing cap with seal by
Vol not
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ara
ed
ris nte
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5.3.2 Extraction and charging valve, high- ss aut ra
c
pressure side
ce
le
un
pt
an
d
itte
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erm
ab
ility
Note
ot p
wit
is n
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ole,
spec
6234-
t to the co
♦ Appropriate insert - T10364- to remove valve core
⇒ page 205
rrectne
1- Base with external or internal thread
2- Seal designation: black or colour-coded
ss o
cial p
f
3- Valve with external thread and groove for seal (7 Nm)
inform
mer
4- Seal designation: black or colour-coded atio

om
5- Cap
n
c
i
or
n thi
te
sd
va
5.3.3 Extraction and charging valve, low-pres‐

i
o
pr
cum
r
fo
sure side
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
o Vo
by c lksw
cted agen
Prote AG.

6234-
♦ Appropriate insert - T10364- to remove valve core
⇒ page 205
1- Connection with external thread and groove for O-ring

3- Valve with external thread and groove for seal (7 Nm)
5- Cap

5.4 Switches and senders in refrigerant cir‐

cuit and related connections
Note
See vehicle-specific refrigerant circuit for switching pressures,

removing and fitting switches, together with switch arrangement
and versions.
⇒ Rep. gr. 87
5.4.1 High-pressure switch for air conditioning

system - F23-
Function:
AG. Volkswagen AG d
agen
Switches radiator fan toVnext
olks higher speed when pressure
w oes
not increa‐
gu
ses in refrigerant circuit
ed b (approx. 16 bar).
y ara
n ris tee
utho 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
5.4.2 High-pressure switch for magnetic

clutch - F118-
rrectness of i
Function:
l purpos
In the event of excess pressure in the refrigerant circuit, switches

the air conditioner compressor off (at approx. 32 bar).
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
5.4.3 Low-pressure switch for air conditioning
AG.
system - F73-
Function:
In the event of pressure loss in the refrigerant circuit, switches the
air conditioner compressor off (at approx. 2 bar).

5.4.4 Connections with valve for switches in

refrigerant circuit
CAUTION
erant.
freezing.
ately afterwards.
. Volkswagen AG
a oes gen AG d
• The switches on the high pressure ksw
Vol and low pressure sides ot gu
n
by
have different threads. rised ara
nt ee
tho or
• Only valves and O-rings au resistant to R134a refrigerant and the ac
ss
related refrigerant oils may be used.
ce
e
nl
pt
du
A - Connection (brazed)
an
itte
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ab
B - O-ring
ility
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C - Valve (with O-ring)
, is n
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hole
spec
es, in part or in w
t to the co
5.4.5 Air conditioning system pressure switch
rrectness of i
- F129-
l purpos
This pressure switch has 3 functions:

nform
ercia
1. Switches radiator fan to next higher speed when pressure in‐

creases in refrigerant circuit (approx. 16 bar).
m
at
om
ion
c
2. Switches the air conditioning system off in the event of excess

in t
or
pressure (approx. 32 bar) (e.g. because of lack of engine cooling).

his
ate
do
priv
3. Switches the air conditioning system off in the event of insuffi‐

cum
for
cient pressure (approx. 2 bar) (e.g. because of loss of refrigerant).

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
The air conditioning system pressure switch - F129- replaces the
high-pressure switch for air conditioning system - F23- , the low-
pressure switch for air conditioning system - F73- and the high-
pressure switch for magnetic clutch - F118- .

5.4.6 High-pressure sender - G65-

This high-pressure sender - G65- is fitted in place of the air con‐
ditioning system pressure switch - F129- .
When voltage is applied to the high-pressure sender, it generates
a square wave signal, or data telegram. This signal changes with
the pressure in the system.
Using this signal, the control units that are connected in-line (ra‐
diator fan control unit, engine control unit, operating and display
unit for Climatronic air conditioning system - E87- or Climatronic
control unit - J255- etc.) calculate the pressure in the refrigerant
circuit and actuate the radiator fan, the engine, the air conditioning
system magnetic coupling - N25- accordingly and/or alter actua‐
tion from the air conditioning system compressor regulating valve
- N280- .
AG. Volkswagen AG d
agen oes
olksw not
5.4.7 Refrigerant pressure and temperature
y V gu
d b ara
ise nte
sender - G395- or eo
th
au ra
ss c
ce
le
CAUTION
un
pt
an
d
itte
y li
rm
ab
erant.
pe
ility
ot
wit
, is n
h re
freezing.
hole
spec
es, in part or in w
t to the co
ately afterwards.
rrectness of i

l purpos

nform
mercia
This refrigerant pressure and temperature sender - G395- is fitted

com
tion in
in place of the high-pressure sender - G65- or air conditioning

r
te o
system pressure switch - F129- .

thi
s
iva
do
r
The pressure signal is monitored continuously, whereas the tem‐

rp
cum
fo
perature signal is monitored only at temperatures greater than 0 °

en
ng
t.
yi
C.
Co
Cop py
t. rig
The Climatronic control unit - J255- works with this information
gh ht
pyri by
and controls the coolant radiator fans accordingly and actuates
co Vo
by lksw
cted
the air conditioning system compressor regulating valve - N280- .
agen
Prote AG.

5.4.8 Air conditioner compressor regulating

valve - N280-
The regulating valve is fitted to the air conditioner compressor. It
is activated by the operating and display unit for Climatronic air
conditioning system - E87- or the Climatronic control unit - J255-
The regulating valve influences the pressure on the low pressure
side and thus the temperature at the evaporator.
Note
The air conditioner compressor regulating valve - N280- is an in‐

tegral part of the air conditioner compressor and cannot be re‐
newed individually on all air conditioner compressors ⇒
. Volkswagen AG
Electronic parts catalogue . swagen AG does
olk not
yV gu
edb ara
ris nte
tho
5.5 Electrical components not installed in
eo
au ra
c
ss
refrigerant circuit
ce
le
un
pt
an
d
itte
5.5.1 Control and regulating unit for air condi‐
y li
erm
ab
tioning system - J127-
ility
ot p
wit
is n
h re
The control and regulating unit switches off the flow of refrigerant
ole,
via the 2nd evaporator if the temperature at the cooling ribs of the
spec
2nd evaporator drops to the freezing point for water (anti-freeze
t to the co
protection).
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
op
5.5.2 Radiator fan control unit - J293-
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Available in various designs, sometimes separately.
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.

5.5.3 Radiator fan control unit - J293-
Note
Available in various designs, sometimes fitted to the radiator fan

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

AG. Volkswagen AG d
E33- Volkswagen oes
not
g
y ua
db ran
Function: rise tee
tho or
au a
The temperature
ss switch for evaporator - E33- senses the tem‐ c
perature between the cooling fins of the evaporator. It prevents
ce
le
un
pt
the possibility of ice forming between the evaporator cooling fins

an
d
itte
y li
by interrupting the current to the air conditioner compressor mag‐

rm
ab
netic clutch if the temperature at the fins falls to the freezing point
pe
ility
of moisture in the air.

ot
wit
, is n
h re
The insertion depth of the sensor tube is marked on the device or

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

es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
5.5.5 Evaporator output temperature sender -

m
G263- or evaporator temperature sen‐

a
com
tion in
sor - G308-
r
te o
thi
s
iva
do
Function:
r
rp
cum
fo
en
The evaporator output temperature sender - G263- or evaporator

ng
t.
yi Co
temperature sensor - G308- reads the temperature downstream t. Cop py
from the evaporator. This value is transmitted to the air condi‐
rig
gh ht
yri by
tioning system control unit and serves as a reference signal for
op Vo
by c lksw
regulating the air conditioner compressor. This prevents icing of
cted agen
Prote AG.
the evaporator.
5.6 Pressures and temperatures in refriger‐

ant circuit
The pressures and temperatures in the refrigerant circuit depend
on the momentary operating conditions (e.g. engine speed, speed
1, 2, or 3 of radiator fan, engine temperature, whether air condi‐

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

(e.g. ambient temperature, humidity, required cooling output).
In vehicles with air conditioner compressor regulating valve -
N280- , the pressure on the low-pressure side is varied by acti‐
vating the valve.
Therefore, the values given in the following tables may only be
considered as guidelines. They occur at an engine speed of 1,500
to 2,000 rpm and an ambient temperature of 20°C after about
20 minutes.
The locations of connections provided for pressure measure‐
ments are vehicle-specific.
⇒ Rep. gr. 87
At 20°C and with the engine stopped, the refrigerant circuit will
adjust itself to a pressure of 4.7 bar positive pressure ⇒ page 7 .
Volkswa AG. gen AG
agen does
5.7 Refrigerant circuit with expansion valve db
yV
o lksw not
gu
ara
rise nte
A- low-pressure side of the refrigerant
tho circuit. eo
s au ra
c
B- high-pressure side of the refrigerant circuit. s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Component Refrigerant Pressure (bar) Temperature in degrees

state Centigrade
AG. Volkswagen AG d
wagen oes
-1- evaporator, from inlet to Vapour approx. 1.2 bar1) Vol
ks
approx. -7°C2) not
gu
by
outlet rised ara
nte
o eo
(approx. 1.8 bar)
aut 3)
h (approx. -1°C)3) ra
ss c
-2- Air conditioning system Gas approx. 1.2 bar1) approx. -1 °C
ce
le
un
compressor A-side
pt
an
d
itte
y li
(approx. 1.8 bar)3) (approx. +1 °C)3)
rm
ab
pe
ility
-3- Air conditioning system Gas approx. 14 bar approx. +65 °C
ot
wit
compressor B-side
, is n
h re
-4- Condenser Gas, vapour, approx. 14 bar at outlet approx. + 55 °C
hole
spec
liquid
es, in part or in w
t to the co
-5- Receiver Liquid approx. 14 bar approx. +55 °C
-6- Extraction and charging Liquid approx. 14 bar approx. +55 °C
valve, B side
rrectness of i
-7- Expansion valve Liquid expan‐ approx. 14 bar approx. +55 °C, reduced to
l purpos
ded to vapour -7 °C
-8- Extraction and charging Gas approx. 1.2 bar1) approx. -7°C2)
nform
ercia
valve, A side
(approx. 1.8 bar)3)
m
(approx. -1°C)3)
a
com
tion in
1) The pressure in refrigerant circuits with regulating air conditioner compressor is held to approx. 2 bar despite changing heat transport
r
te o
thi
and differing engine speeds. This applies however only within the rated range of the air conditioner compressor; if the rated range of the
s
iva
air conditioner compressor is exceeded, the pressure will increase ⇒ page 161 .
do
r
rp
cum
fo
2) The temperature in refrigerant circuits with regulating air conditioner compressor is held within the regulation range of the air conditioner
en
ng
t.
compressor despite changing heat transport and differing engine speeds. This applies however only within the rated range of the air op
yi Co
conditioner compressor; if the rated range of the air conditioner compressor is exceeded, the temperature will increase ⇒ page 161 . C py
t. rig
gh ht
yri by
3) Measured values for air conditioning systems with two evaporators op Vo
by c lksw
cted agen
Prote AG.
Note
♦ Air conditioning system compressors that do not self-regulate

their load are switched off by the respective control unit via the
air conditioner compressor regulating valve - N280- when an
evaporator temperature less than 0°C is sensed.
♦ In vehicles with air conditioner compressor regulating valve -
N280- , the pressure on the low-pressure side is varied by
activating the valve.
5.8 Refrigerant circuit with restrictor and reservoir

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

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
m
Component Refrigerant Pressure (bar) Temperature in degrees

o
n in
c
state Centigrade
or
thi
te
sd
a
-1- Air conditioning system com‐ Gas up to 20 bar to +70 °C

iv
o
r
rp
cu
pressor B-side
o
m
f
en
ng
-2- Condenser From gas to va‐ up to 20 bar to +70 °C

t.
yi Co
op
pour to liquid
C py
ht. rig
rig ht
-3- Restrictor From liquid to B-side up to 20 bar, A-side B-side up to +60 °C, A-
py by
co Vo
by lksw
vapour Prote
cted greater than 1.5 bar
AG.
agen
side warmer than -4 °C
-4- Evaporator From vapour to Greater than 1.5 bar Warmer than -4 °C
gas
-5- Reservoir Gas
-6- Air conditioning system com‐ Gas
pressor A-side
The pressures on the A-side are held at approx. 2 bar by the
“regulating” air conditioner compressor even at differing engine
speeds. This applies however only within the rated range of the
air conditioner compressor; if the rated range of the air conditioner
compressor is exceeded, the pressure will increase
⇒ page 161 .

Note
In vehicles with air conditioner compressor regulating valve -

N280- , the pressure on the low-pressure side is varied by acti‐
vating the valve.
5.9 Test and measurement work that can be

performed using a pressure gauge
Indicated on pressure gauge
1- Temperature scale for refrigerant R134a CF3–CH2F or
CH2F–CF3.
2- Pressure scale
In addition to the pressure scale, the pressure gauges can have
one or more temperature scales. The scale values for R134a are . Volkswage
assigned according to the vapour pressure table. Because adiffer‐
gen AG n AG d
oes
lksw not
ent refrigerants have different vapour pressures at bthey same
Vo gu
ara
temperature, each temperature scale is labelled rfor
ise the respective
d
nte
refrigerant. autho eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
5.9.1 Pressure gauges enable the following
erm
ab
ility
test and measurement work
ot p
wit
, is n
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a – Pressure and temperature measurement in the refrigerant cir‐
hole
spec
cuit
es, in part or in w
t to the co
♦ The high-pressure gauge allows the pressure and tempera‐
ture to be measured with the air conditioning system switched
on irrespective of whether this is at the outlet of the air condi‐
rrectness of i
tioner compressor through the condenser up to the restriction
(restrictor or expansion valve).
l purpos
♦ The low-pressure gauge allows the pressure and temperature

to be measured with the air conditioning system switched on
nform
ercia
irrespective of whether this is at the restriction (restrictor or

expansion valve) through the evaporator up to the inlet to the
m
at
om
air conditioner compressor.

ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
The relationship between pressure and temperature shown on
yi Co
op
the pressure gauge is valid only where the refrigerant in the circuit
C py
t. rig
gh
is liquid or vapour, but not when it is gas. In the gaseous state,
ht
pyri by
Vo
o
the temperature is approx. 10°C to 30°C higher than indicated on
c by lksw
cted agen
the pressure gauge.
Prote AG.
b – Evidence of refrigerant in a closed container

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

Note
The dependency between pressure and temperature described

on the pressure gauge no longer applies when there is no liquid
and the pressure is created by gas alone.
5.10 Air conditioner service and recycling

equipment
At present, various manufacturers offer air conditioner service
stations on the market for evacuating, cleaning and charging re‐
frigerant in vehicle air conditioning systems.
5.10.1 Classification of extraction and charging

devices in groups
Group 3:
Portable extraction and charging devices linking the air condi‐
tioning system to a fixed compressed gas container.
The fixed gas pressure vessel is charged with refrigerant or re‐
frigerant/oil mixture. The portable extraction and charging device
is then permanently attached to the pressure vessel. In accord‐
ance with § 3 section 5 no. 3 of the Regulations for Pressure
Tanks, in this case the terms "compressed gas container" and
"pressure tank" are equivalent.
Charging devices require:
♦ no approval and testing by officially recognised experts, be‐
cause the gas is filled into compressed gas vessels which are
equivalent to pressure vessels. (Devices for filling refrigerant
from these pressure tanks into compressed
agen
AG. Volksgas
wagecontainers
n AG d
oes
that are intended for third-partyolkswuse, in turn, require licensing
not
V gu
by
and they are subject toisechecking by an authorised official.) aran
d
r tee
ho
aut or
ac
ss
Note
ce
le
un
pt
an
d
itte
y li
The air conditioner service and recycling devices used in vehicle

rm
ab
workshops are Group 3 extraction and charging devices which do

pe
ility
not require a permit, but which can be operated only by skilled

ot
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, is n
staff. Instructions for the operation and service of the devices may
h re
hole
be found in the respective manufacturer's documentation.

spec
es, in part or in w
t to the co
5.10.2 Charging devices that do not require a

permit
rrectness of i
Charging devices that do not require a permit are mobile charging

l purpos
devices into which pressurised gases are charged into com‐

pressed gas containers for exclusive use of one company.
nform
ercia
Note:
m
Some air conditioner service devices are charging devices that

com
tio
do not require a permit. When working with such equipment, the

n in
r
te o
refrigerant is not transferred to mobile compressed-gas vessels,

thi
s
but rather into a permanently installed charging cylinder with visi‐

iva
do
r
ble level gauge and float switch.

rp
cum
fo
en
ng
t.
Recommendation: Cop
yi Co
py
t. rig
When surplus refrigerant is transferred for one's own require‐ gh ht
yri by
ments, it is recommended that a portable charging cylinder with
op Vo
by c lksw
visible level gauge and pressure relief valve be used.
cted agen
Prote AG.

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.
5.11 Notes to repairs on refrigerant circuit

Special tools and accessories
The performance of proper workmanlike repairs on an air condi‐
tioning system
• Special tools and materials are required; these are listed on
⇒ page 199 .
• The essential information on the leak detector should be re‐
ferred to ⇒ page 60 .
• Expert knowledge is necessary.
Note
Releasing refrigerant into the environment is not permitted

⇒ page 43 .
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
42
cted agen
Prote AG.
Rep. gr.00 - Technical data
6 Legal texts and regulations
6.1 Laws and regulations
Note
♦ The laws and regulations listed below are valid in Germany.

Other or additional laws and regulations may apply in other
countries.
sible authorities.
The effects concerning the changing climate can be seen world-

wide. Protection of the climate is therefore one of the most im‐
AG. Volkswagen AG d
portant roles of the human race. This role is a huge challenge
lksw
agen for oes
not
all concerned. by Vo gu
a d ran
ise
The so called Kyoto Protocol defines, among ut
ho other things, world-
r tee
or
wide targets to protect the climate. Thisssprotocol defines apart
a ac
from the reduction targets for carbon dioxide, the reduction tar‐
ce
le
un
pt
gets for fluoride containing greenhouse gases e.g. for refrigerant
an
d
itte
R134a due to the high greenhouse potential.
y li
rm
ab
pe
ility
Within Europe a large number of respective statutes exist for the
ot
motor industry. In Germany, for example, the Climate Protection
wit
, is n
h re
Regulation Concerning Chemicals (Chemikalien-Klimaschutz‐
hole
verordnung) came into force from the 1st of August 2008 in
spec
addition to European legislation.
es, in part or in w
t to the co
♦ Regulation (EC) No. 1005/2009
rrectness of i
♦ Regulation (EU) No. 517/2014
l purpos
nform
ercia

m
♦ Directive 2006/40/EC a
com
tion in
♦ Climate Protection Regulation Concerning Chemicals (Chem‐

r
te o
thi
ikalien-Klimaschutzverordnung), Closed Substance Cycle

s
iva
do
Waste Management Law (Kreislaufwirtschaftsgesetz, KrWG)

r
rp
cum
fo
en
g
Maintenance and repairs to refrigerant circuits for air conditioning

n
t.
yi Co
systems Cop py
t. rig
gh ht
yri
All personnel performing maintenance and repairs on air condi‐ p by
co Vo
lksw
tioning systems for motorized vehicles must have attended the
by
cted agen
Prote
respective training programme and have the appropriate knowl‐
AG.
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‐
6. Legal texts and regulations 43

frigerant for vehicle air conditioning systems ) so that a proof

of use document is available for presentation to the responsi‐
ble authorities upon request. A record sheet need no longer
be kept within the EU due to respective European parliament
legislation from 2005. Other legislation may apply in countries
not belonging to the EU.
♦ Companies that sell materials and preparations listed in the
above mentioned legislation have a duty to accept returned
materials and preparations after they have been used, or to n AG. Volkswagen AG do
wage
ensure that a specified third party will accept them. olks es n
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yV b ua
ed ran
♦ Maintenance work and decommissioning of products that riscon‐ tee
utho
tain refrigerant referred to in the above mentioned legislation. or
sa ac
as well as the acceptance of returned substances sand prepa‐
ce
le
rations referred to in this legislation may only be carried out by
un
pt
an
persons who have the necessary specialist knowledge and
d
itte
y li
technical equipment. erm
ab
ility
ot p
Offences and breaches of the regulations
wit
is n
h re
♦ A person is in breach of the regulations and laws referred to if
ole,
spec
that person performs acts of wilful misconduct or negligence
when operating, performing maintenance work on or decom‐
t to the co
missioning products that contain the refrigerants referred to,
contrary to the norms of technical practice, allows the sub‐
stances contained in them to escape into the atmosphere or
rrectne
wilfully or negligently breaches the applicable regulations and
laws mentioned above.
ss
Make sure to observe the corresponding technical rules (e.g.
o
cial p
f
TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS
inform
3145) when handling compressed gases and, in particular, when
mer
filling compressed gases from one compressed gas container into
atio
m
another one.
o
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi
The following paragraphs are only extracts from the Technical
Co
Cop py
Rules for Hazardous Substances (TRGS) (relevant for automo‐
t. rig
gh ht
yri
tive manufacturers and workshops).
p by
co Vo
by lksw
cted agen
Prote AG.
♦ TRGS 400 (Risk assessment for activities involving hazardous
substances).
♦ TRGS 402 (Identification and assessment of the risks from
activities involving hazardous substances: inhalation expo‐
sure).
♦ TRGS 407 (Risk assessment for activities involving gaseous
substances).
♦ TRGS 510 (Storage of hazardous substances in non-station‐
ary containers).
♦ TRBS 3145/TRGS 725 (Non-stationary compressed gas con‐
tainers – charging, storage, in-house transportation, empty‐
ing).

Note
♦ The Technical Rules for Compressed Gases (TRG), the Tech‐

nical Rules for Hazardous Substances (TRGS) and the Tech‐
nical Rules for Operational Safety (TRBS) reflect the state of
technology, occupational safety and health, occupational hy‐
giene as well as other definite knowledge relating to provision
and use of work equipment, operation of facilities requiring
supervision and activities involving hazardous substances.
♦ The technical rules stated here are valid in the Federal Re‐
public of Germany and do not necessarily reflect the rules and
regulations valid in other countries.
swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
Make sure to observe the corresponding
orise technical rules (e.g. nte
eo
TRGS 400, TRGS 402, TRGS auth
407, TRGS 510, TRGS 725, TRBS ra
3145) when handling compressed
ss gases and, in particular, when c
ce
e
filling compressed gases from one compressed gas container into

nl
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du
another one.
an
itte
y li
erm
ab
♦ Filling stations – general provisions.
ility
ot p
wit
♦ Terms and definitions.
, is n
h re
hole
♦ Filling stations – set-up and operation.
spec
es, in part or in w
Filling stations
t to the co
♦ This does not apply to vehicle manufacturers and workshops.
rrectness of i
♦ Filling stations are systems for charging non-stationary com‐
pressed gas containers. A filling station comprises its corre‐
l purpos
sponding premises and equipment.

♦ Charging systems that require authorisation are charging sys‐
nform
ercia
tems which are filled with compressed gases in mobile com‐

pressed gas containers for transfer to other containers.
m
at
om
ion
♦ Charging devices that do not require a permit are mobile

c
in t
or
charging devices into which pressurised gases are charged

his
ate
into compressed gas containers for exclusive use of one com‐

do
priv
pany.
um
for
en
ng
t.
yi
Employees and instructing employees
Co
Cop py
t. rig
Employees are to be instructed in the following points before be‐
gh ht
pyri by
ginning work as well as at regular, appropriate intervals, but at
co Vo
by lksw
cted
least annually:
agen
Prote AG.
• The particular hazards arising when handling compressed

gases;
• The safety regulations, particularly the existing Technical
Rules for Hazardous Substances (TRGS) and the Technical
Rules for Operational Safety (TRBS);
• The actions to be taken in the event of defects, damage or
accidents;
• The handing of fire extinguishers and protective equipment;
• The operation and maintenance of filling stations, with partic‐
ular reference to the user's manual.
Filling stations may be operated and maintained only by persons
who
• are at least 18 years of age;
• Possessing the necessary technical knowledge
• can be expected to fulfil their duties reliably.

Charging pressure tanks (for tanks from other countries, other

technical rules that are not mentioned here may apply).
♦ A compressed gas container may be charged only with the
compressed gas that is listed on its label, and only up to the
quantity indicated on the container in terms of pressure, weight
and volume (see Regulations for Pressure Tanks).
♦ A container that can be used for different types of compressed
gas must have a label on it listing the compressed gases with
which it may be charged. If the compressed gas concerned
has a tc ≥ -10°C (tc = critical temperature), the max. permis‐
sible charging weight in accordance with TRGS must also be
indicated on the container before it is connected for charging.
♦ Gas pressure vessels for which the highest permissible
charge positive pressure at 15°C is given in bar must be
charged by pressure gauge. If during charging the tempera‐
ture is different from 15°C, the pressure corresponding to the
different temperature should be determined by the charging
equipment; it must be ensured that the permissible overpres‐
sure for charging at 15°C in the gas pressure vessel is not
exceeded. To determine possible overfilling, the charged ves‐
sels must be checked by way of random pressure measure‐
ments.
♦ Compressed gas containers on which the maximum permis‐
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 vessels
are to be weighed during filling and subsequently subjected
AG. Volto
kswagen AG
agen over‐
a weight check on special scales to establishVopossible does
lksw not
filling. Scales used for this purpose mustedbe
by calibrated. gu
ara
is nte
or
♦ Under particular conditions, gases with
ut tc ≥ +70 °C from gas
h eo
ra
s a l volumetric contents
pressure vessels of no more than s150 c
may be charged into a gas pressure vessel of no more than ce
le
un
pt
1000 cc volumetric contents. The conditions of the TRGS ap‐ an
d
itte
y li
ply to charging mechanic's bottles with liquid gas.
erm
ab
ility
ot p
♦ For vehicle containers, different TRGS apply:

wit
is n
h re
– For gases with tc ≥ +70 °C.

ole,
spec
– For technical gas mixtures with tc ≥ +70 °C.

t to the co
– Liquid, deep-cooled compressed gases in variance to those

stated under item 4 may be charged by volume (volumetrical‐
ly), if the charging device and/or the container with equipment
rrectne
is equipped with devices for measuring or limiting the volume

of the charge and (except vehicle containers as specified un‐
s
der item 3) for measuring the temperature of the charge. When

s o
charging by volume it must be ensured that the permitted

cial p
f in
charge weight shown on the container is not exceeded. To

form
mer
determine possible overcharging, the charged containers are

atio
to be checked gravimetrically on a calibrated scale or – provi‐

om
ded that the pressurised gases are not highly toxic – volumet‐
c
i
or
n thi
rically. Volumetric checking presupposes that the appropriate

te
sd
a
equipment is in place; charging and checking equipment must

iv
o
pr
be independent of each other.

um
r
fo
en
ng
t.
yi
♦ The fill and check measurements must not be performed by
Co
op py
the same person. Check measurements must be performed
. C rig
ht ht
rig
immediately upon conclusion of the filling process. py by
co Vo
by lksw
cted agen
♦ Overfilled vessels must be discharged immediately and in a Prote AG.
safe manner down to the permissible fill quantity. Following
this, the quantity of compressed gas charged must be deter‐
mined once again.
♦ Some regulations of the TRGS 407 do not (fully) apply to con‐
tainers for liquid, deep-cooled compressed gases which are

Air conditioning systems with refrigerant R134a
AG. Volk-swGeneral
agen A information - Edition 11.2019 n G do
wage es n
Volks ot g
neither flammable nor toxic; regulations ed for traffic law remain
by ua
ran
unaffected. oris tee
th or
au ac
♦ When gas pressure vessels aressto be charged with gases in
the liquid state at charging temperatures ≤ -20°C, the gas
ce
le
un
pt
pressure vessel (if the vessel material is not tested for tem‐
an
d
itte
y li
peratures ≤ -20°C) must be released from the charging system
rm
ab
for transportation only when the vessel wall has achieved a
pe
ility
temperature ≥ +20°C.
ot
wit
, is n
h re
Converting R12 refrigerant circuits to R134a refrigerant circuits
hole
spec
and repairing them (retrofitting)
es, in part or in w
t to the co
Note
rrectness of i
♦ Due to the environmental situation and the consequent legis‐
l purpos
lation, refrigerant R12 is currently neither in production nor

available. Refrigerant R134a has been developed as a re‐
placement for R12.
nform
ercia
♦ However, air conditioning systems developed and designed

m
a
for refrigerant R12 cannot simply be charged with refrigerant
com
tion in
R134a. To ensure trouble-free operation of the air conditioning
r
te o
thi
system even after a retrofit, various components of the refrig‐
s
iva
erant circuit must be replaced.
do
r
rp
cum
fo
♦ An exact description of the procedure for conversion and in‐
en
ng
t.
yi
structions for repair of converted refrigerant circuits can be
Co
op py
found in the ⇒ Repair manual for air conditioning systems with
. C rig
ht ht
rig
refrigerant R12 parts 2 and 3 . This workshop manual is only py by
co Vo
available as a hard copy.
by lksw
cted agen
Prote AG.
Maintaining records on refrigerant

According to the environmental statistics law, a record concerning
the use of refrigerants must be kept.
Car manufacture and repair businesses must be prepared to fur‐
nish information concerning use of refrigerants to the statistical
office for the country in which the work is being performed. It is
therefore recommended to keep records of the amounts of refrig‐
erant handled during operation and maintenance (Refrigerant
Logbook) ⇒ Volkswagen ServiceNet, Environmental Protection;
Service handbook; Emission protection; Air contaminating sub‐
stances, refrigerant for vehicle air conditioning systems ) which
must be available for presentation to the responsible authorities
upon request.
Note
A record sheet need no longer be kept within the EU due to re‐

spective European parliament legislation from 2005. Other legis‐
lation may apply in countries not belonging to the EU.
6.2 Recycling and refuse law
Note

countries.
sible authorities.

Statutes and regulations concerning the use and disposal of re‐

frigerants and refrigerant machine oils are contained within the
climate protective regulation concerning chemicals and closed
substance cycle waste management and ensuring environmen‐
tally compatible waste disposal
agen
AG(only
. Volksfor
wagthe Federal
en AG
does Republic of
Germany, in other countries
olksw other statutes and regulations
not may
yV gu
apply). se
db ara
n ri tee
ho
6.2.1 ut
Disposal of refrigerant and refrigerant
ra o
a c
ss
machine oil
ce
e
nl
pt
du
an
itte
y li
Refrigerant
erm
ab
ility
ot p
Refrigerants intended for disposal are to be transferred to marked
wit
recycling containers, observing the permissible filling quantity.
, is n
h re
Observe, for example in the Federal Republic of Germany, the
hole
spec
Climate Protection Regulation Concerning Chemicals (Chemika‐
es, in part or in w
lien-Klimaschutzverordnung) and the Closed Substance Cycle
t to the co
Waste Management Law (Kreislaufwirtschaftsgesetz, KrWG) (in
other countries other statutes and regulations may apply).
rrectness of i
Refrigerant oil
l purpos
Disposal of used oils: Volkswagen InfoNet; Operation; Hand‐

books & dealer literature; Handbook Service; 15. Environmental
protection; under general instructions follow the link “Environ‐
nf
ercia
mental protection in the dealership and in the workshop”; 4.

Waste disposal; 6. Disposal channels; Disposal of used oils; Re‐ orm
m
atio
m
frigerant oils
o
n in
or c
Used refrigerant oils from systems with halogenated hydrocar‐

thi
te
sd
a
bons (at least one hydrogen atom has been replaced by e.g the
iv
o
r
rp
cu
halogens fluorine, chlorine, bromine or iodine) must be disposed

o
m
f
of as waste requiring particular care. They are not to be mixed

en
ng
t.
yi Co
with other oils or substances. Proper storage and disposal must Cop py
be ensured in line with local regulations. Observe, for example in
t. rig
gh ht
yri
the Federal Republic of Germany, the Climate Protection Regu‐
p by
co Vo
by lksw
lation Concerning Chemicals (Chemikalien-Klimaschutzverord‐ Prote
cted AG.
agen
nung) and the Closed Substance Cycle Waste Management Law
(Kreislaufwirtschaftsgesetz, KrWG) (in other countries other stat‐
utes and regulations may apply).

Reference sources for technical rules and safety at work/accident

prevention for the Federal Republic of Germany.
Sources in other countries may be obtained from the responsible
authorities.
6.3 Converting R12 refrigerant circuits to

R134a refrigerant circuits and repairing
them (retrofitting)
Note

countries. swa
gen AG
. Volkswagen AG
does
k not
Vol
by ua g
ed ran
sible authorities.thoris tee
or
au ac
♦ Due to the environmental
situation and the consequent legis‐
ss
ce
le
lation, refrigerant R12 is currently neither in production nor

un
pt
available. Refrigerant R134a has been developed as a re‐
an
d
itte
y li
placement for R12.
rm
ab
pe
ility
♦ However, air conditioning systems developed and designed
ot
wit
, is n
for refrigerant R12 cannot simply be charged with refrigerant
h re
R134a. To ensure trouble-free operation of the air conditioning
hole
spec
system even after a retrofit, various components of the refrig‐
es, in part or in w
erant circuit must be replaced.
t to the co
♦ An exact description of the procedure for conversion and in‐
structions for repair of converted refrigerant circuits can be
found in the ⇒ Repair manual for air conditioning systems with rrectness of i
refrigerant R12 parts 2 and 3 . This workshop manual is only
l purpos
available as a hard copy.

nform
ercia
6.4 Maintaining records on refrigerant

m
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp

um
fo
en

ng
t.
yi Co
countries. t. Cop py
rig
gh ht
♦ Sources in other countries may be obtained from the respon‐ pyri by
Vo
o
by c
sible authorities.
lksw
cted agen
Prote AG.
The quantities used during operation and maintenance work

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

7 Refrigerant circuit
7.1 Important repair notes on air condition‐

ing
• Air conditioning systems designed for refrigerant R12 must not
be charged with refrigerant R134a until specific conversion
measures have been performed ⇒ page 49 .
• The refrigerant oils specifically developed for R134a refriger‐
ant circuits must never be mixed with the refrigerant oils spe‐
cifically developed for R12 refrigerant circuits.
• Air conditioner service stations which come in contact with the
refrigerant must be used only for the intended refrigerant.
n AG. Volkswagen A
• Components for R134a olks
warefrigerant
ge circuits Gare
doeidentified
s no by
lettering or a green by label, or are so designed (e.g. with
V t gu different
a
ed ran
threads), thatoristhey cannot be confused with components teefor
R12 refrigerant
au
th
circuits. or
a
ss c
• Within the engine compartment, on the bonnet catch striker ce
e
nl
plate or in the plenum chamber there is an information plate pt

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an
itte
which states what refrigerant is used. y li

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ility
• Different refrigerants must never be mixed.
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7.2 Converting refrigerant circuits from R12

h re
hole
spec
refrigerant to R134a
es, in part or in w
t to the co
Chlorofluorocarbon (CFC) is no longer used as a refrigerant in the

automotive sector.
rrectness of i
R12Converting refrigerant circuits from refrigerant R12 to refrig‐

erant R134a and repairing the converted circuits.
l purpos
⇒ Repair manual for air conditioning systems with refrigerant R12

parts 2 and 3 . This workshop manual is only available as a hard
nform
ercia
copy.
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at
om
ion
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or
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ate
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8 Working with the wair

agen conditioner dserv‐
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Note
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♦ Volkswagen AG does not authorise the use of chemical sub‐
rm
ab
stances (leak inhibitor additives) for purposes of sealing leaks
pe
ility
ot
in refrigerant circuits. There are currently no permanent, ef‐
wit
, is n
fective or material compatible tests that guarantee never caus‐
h re
hole
ing damage or malfunctions in an air conditioning system or
spec
air conditioner service station.
es, in part or in w
t to the co
♦ The leak inhibitor additives currently available on the market
have differing physical and chemical characteristics that may
subsequently affect the function of the air conditioning system
rrectness of i
and air conditioner service station or even cause a total failure.
l purpos
♦ Volkswagen rejects the use of chemical substances for pur‐

poses of sealing leaks in refrigerant circuits.
nform
ercia
♦ Chemical substances used for sealing leaks in refrigerant cir‐

cuits often react with the surrounding air and the humidity
m
a
com
ti
contained within. They cause deposits to build up in the re‐
on in
frigerant circuit (and your air conditioner service station),
r
te o
thi
valves to malfunction and defects in other components with
s
iva
do
which they come into contact. These deposits cannot be com‐
r
rp
cum
pletely removed from the components.
fo
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ng
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♦ It is often not possible to detect from the outside whether Cop py
. rig
chemical substances have been used to seal leaks in the re‐
t
gh ht
yri by
frigerant circuit. The adhesive label that serves to identify its
cop Vo
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use can usually not be found. Therefore, exercise caution on cted agen
Prote AG.
vehicles for which you have no service or repair record.
♦ Containers or tanks are offered as accessories on the open
market that are designed to separate these chemical substan‐
ces (to seal leaks). Since Volkswagen rejects the use of these
substances, no statement can be made at this point regarding
the effectiveness and separation rate of these filters.
8.1 Important instructions for working with

the air conditioner service station
• The fitted filter and dryer must be renewed at the latest when
the operational time specified in the related operating instruc‐
tions has been reached.
• Fill only with refrigerant oils which have been approved for the
vehicle-specific refrigerant circuit.
Refrigerant that has been extracted may not be reused, even after
cleaning within the station, in any of the following circumstances:
• If there is damage to the air conditioner compressor, such that
decomposition of the refrigerant due to overheating might
have occurred.
• If there are dark sticky deposits in the refrigerant circuit (these
can be detected only by opening up the system).
• If there is any doubt about the composition of the refrigerant
extracted from the refrigerant circuit.
In all of these circumstances the air conditioner service station
must be drained ⇒ page 53 , the system must be cleaned and
the filter, dryer and any filled refrigerant oil must be renewed.
8. Working with the air conditioner service station 51

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

Germany, be returned to the supplier in so-called recycling bottles
for recycling or for environmentally sound disposal (in other coun‐
tries other or additional regulations may apply).
The commercially available air conditioner service stations can
be divided into 2 groups:
♦ A. Air conditioner service stations that clean the extracted re‐
frigerant for reuse (so-called evacuating and recycling sta‐
tions) e.g. air conditioner service station .
♦ B. Air conditioner service station, called extraction stations,
that charge the extracted refrigerant into recycling bottles (for
reprocessing in bulk).
8.2 Connecting a air conditioner service sta‐

tion for measuring and testing
• Depending on the type of equipment chosen, there may be
variations in the required procedure; therefore always follow
the user's manual for the equipment being used.
AG. Volkswagen AG d
agen oes
lksw not
Note byV
o gu
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ed
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Always follow the procedure described in the user's smanual
au
th
for ra
your air conditioning service station . s c
ce
le
un
pt
an
d
itte
The charging hoses must only be connected according to the fol‐
y li
rm
ab
lowing work procedure to prevent air or moisture from entering
pe
ility
the refrigerant circuit:
ot
wit
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h re
hole
spec
– Connect the air conditioner service station to the power sup‐
es, in part or in w
ply.
t to the co
– Unscrew sealing caps from service station connections or
from connections with valve (see vehicle-specific refrigerant
rrectness of i
circuit).
l purpos
⇒ Rep. gr. 87
– Evacuate charging hose.
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
Connect the charging hose to the service connections of the re‐

iva
do
r
frigerant circuit using quick-release couplings.

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cum
fo
en
ng
t.
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op py
NOTICE
. C rig
ht ht
rig by
py
Risk of damage to the air conditioner compressor or air condi‐
co Vo
by lksw
cted
tioner service station.
agen
Prote AG.
Opening the valves with the air conditioning system switched

on can cause a short circuit between the high pressure and low
pressure side.
– Never open valves on the high pressure or low pressure side
with the air conditioning system switched on.
– Turn hand wheel into quick-release coupling adapter until the

valve in the service connection is definitely open (observe
pressure gauge; do not over-tighten valve).
– Start the engine and perform the planned tests and measure‐
ments.

– Compare determined values with specifications ⇒ page 161 .

– Before disconnecting the quick-release coupling, close it by
turning out the handwheel.
8.3 Drain the refrigerant circuit using the air

conditioner service station .
• Depending on the type of equipment chosen, there may be
variations in the required procedure (always follow user's man‐
ual for the equipment being used).
• The refrigerant circuit must be discharged if parts of the re‐
frigerant circuit are to be removed, if there is any doubt about
the quantity of refrigerant in the circuit or if required by the
safety precautions.
• All operational instructions important for working with the air
conditioning service station for refrigerants can be found in the
air conditioning service station user's manual.
Draining n AG. Volkswagen AG do
lkswage es n
o ot g
– Switch off ignition. d byV ua
ran
ir se tee
– Connect the air conditioning serviceuth station to the service con‐
o
or
nections as described in the user's
ss
a
manual for the vehicle ⇒ ac
Rep. gr. 87 and start the service station.
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
♦ Sometimes, refrigerant oil is extracted from the refrigerant cir‐
h re
ole,
cuit along with the refrigerant and there is no way of stopping
spec
this. To ensure lubrication of the air conditioner compressor,
t to the co
the refrigerant oil quantity should be topped up with fresh oil
⇒ Rep. gr. 87 .
♦ On vehicles with air conditioner compressor and no magnetic
rrectne
coupling (with air conditioner compressor regulating valve -
N280- ) the engine should only run for less than 10 minutes
s
with empty refrigerant circuit and closed refrigerant circuit (the
s o
cial p
air conditioner compressor runs with it continually). The en‐ f in

gine speed must not exceed 2000 rpm.
form
mer
atio
♦ On vehicles with air conditioner compressor and magnetic

om
coupling, the engine may be started as the air conditioning

n
c
i
or
system pressure switch - F129- or high-pressure sender -

thi
te
sd
a
G65- (checks whether refrigerant is in the circuit) switches off

iv
o
r
the magnetic coupling as soon as there is no refrigerant in the

p
cum
r
fo
refrigerant circuit.
en
ng
t.
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Cop py
t. rig
8.4 Evacuating refrigerant circuit using air
gh ht
pyri by
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co
conditioner service station
by lksw
cted agen
Prote AG.
• Always follow the procedure described in the user's manual

for your air conditioning service station .
• The procedure described here is that for the air conditioning
service station .
Before the refrigerant circuit is charged with refrigerant, it should
be evacuated (air empty) for 45 minutes for single evaporator
system and 60 minutes for 2 evaporator systems. In addition,
moisture is removed from the circuit.
Leakage can be determined when evacuating the refrigerant cir‐
cuit.

Evacuating
NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.

– If necessary, check the refrigerant oil quantity in the refrigerant
circuit; see vehicle-specific repair manual ⇒ Rep. gr. 87 .
ply.
– Check the refrigerant quantity in the air conditioning service
station .
– Connect the charging hose of the air conditioning service sta‐
tion to the vehicle refrigerant circuit using quick-release con‐
nector adapters (see vehicle-specific refrigerant circuit).
agen
AG. Volkswagen AG d
o
w es n
olks ot g
⇒ Rep. gr. 87 d byV ua
ran
ise tee
or
– Turn the handwheel of the quick-releaseau
th coupling adapter far or
ac
enough inwards to ensure that the valves
ss on the service con‐
nections are open (do not overstress the valve).
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Where a vehicle has a service connection on only one side of the
h re
hole
refrigerant circuit, if the system pressure has to be measured after
spec
charging, use the valve adapter and charging hose with valve
es, in part or in w
t to the co
opener.
– Check the vacuum phase in the air conditioning service sta‐
rrectness of i
tion . The refrigerant circuit will be evacuated automatically
(observe preset evacuation period).
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When the vacuum phase has been completed, the leakage test
of the refrigerant circuit will start. The displays show the vacuum
nf
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in bar and the time in seconds.

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atio
m
If the vacuum is not maintained, proceed as follows:

o
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or c
thi
– Check the vacuum phase in the air conditioning service station

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sd
a
again. The refrigerant circuit will be evacuated automatically

iv
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(observe preset evacuation period). Observe vacuum gauge

o
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f
en
ng
for a longer period. Only when a vacuum is maintained can

t.
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charging commence. Cop py
t. rig
gh ht
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♦ If there is a leak so major that it causes air to escape to such p by
co Vo
a degree during evacuation that the air conditioner service
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station is incapable of generating a sufficient vacuum or the
AG.
vacuum gauge indicates immediately after switching off the air

conditioner service station that air has entered the system and
negative pressure is lost.
– Search for the leak in the refrigerant circuit as follows:
⇒ page 57
8.5 Filling refrigerant circuit with air condi‐

tioner service station .
• Always follow the procedure described in the user's manual
for the air conditioning service station .
• Before charging the refrigerant, check the refrigerant oil quan‐
tity ⇒ Rep. gr. 87 .

• The entire refrigerant charging quantity can be introduced ei‐

ther into the high-pressure or the low-pressure side.
Charging refrigerant circuit
– Evacuate the refrigerant circuit with the air conditioner service
station ⇒ page 53 .
– Unscrew handwheel on quick-release coupling adapter (to
close).
– Allow refrigerant to flow into charging hose.
– Screw handwheel of quick-release coupling adapter inwards
(do not overstress the valve) and charge system with prescri‐
bed quantity of refrigerant.
– Switch off air conditioning service station .
AG. Volkswagen AG d
agen oes
Note yV
olksw not
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ise nte
r
If the air conditioner compressor
ut
ho was removed, the V-belt pulley / e or
freewheel must be sturned
s a
by hand approx. 10 times prior to initial ac
operation. This does not apply for the electrical air conditioner
ce
le
un
pt
compressor. This prevents any damage occurring from a fluid
an
d
itte
hammer in the air conditioner compressor when the air condition‐
y li
erm
ab
ing system is switched on for the first time. If there is oil in the
ility
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cylinder of the air conditioner compressor, it will be forced out by
wit
is n
the rotation.
h re
ole,
spec
– Start engine with air conditioner compressor switched off (ver‐
t to the co
sion with magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect “ECON” mode or “A/C Off” (if version without magnetic
rrectne
clutch but with regulating valve).

s
– Wait until idling speed has stabilised:

s o
cial p
– Switch air conditioner compressor on and let system run for at

inform
least 2 minutes with engine idling.

mer
atio
m
– If necessary, check the pressures in the refrigerant circuit, us‐

o
n
c
ing the air conditioning service station .

i
or
n thi
te
sd
a
– Switch off engine.

iv
o
pr
cum
r
fo
– Turn out handwheel on quick-release coupling adapter.

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ng
t.
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op
– Detach the charging hose from the refrigerant circuit. C py
ht. rig
rig ht
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– Screw protective caps back on. copy Vo
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8.6 Bringing air conditioning system into
AG.
service after charging
Note
If the air conditioner compressor was removed, the V-belt pulley /

freewheel must be turned by hand approx. 10 times prior to initial
operation. This prevents any damage occurring from a fluid ham‐
mer in the air conditioner compressor when the air conditioning
system is switched on for the first time. If there is oil in the cylinder
of the air conditioner compressor, it will be forced out by the ro‐
tation.

– Start engine with air conditioner compressor switched off (ver‐

sion with magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect “ECON” mode or “A/C Off” (if version without magnetic
clutch but with regulating valve).
– Wait until idling speed has stabilised:
– Switch air conditioner compressor on and let system run for at
least 2 minutes with engine idling.
– If necessary, check the pressures in the refrigerant circuit, us‐
ing the air conditioning service station .
– Switch off engine.
– Turn out handwheel on quick-release coupling adapter.
– Detach the charging hose from the refrigerant circuit.
– Screw protective caps back on.
8.7 Charging the container in the air condi‐

tioning service station with refrigerant
. Volkswagen AG
a gen AG d
• Always follow the procedure
Vol
ksw described in the user's
oes
not manual
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for your air conditioning
ed
by service station . ara
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or
• A certain quantity
au
th of refrigerant is specified as charge for each
or
a
air conditioning
ss system. To ensure that the system is neither c
ce
e
overcharged nor undercharged with refrigerant (both circum‐

nl
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du
stances will impair the function of the air conditioning system),

an
itte
y li
the refrigerant container is on a weighing machine.

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ab
ility
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8.8 Emptying air conditioner service station

wit
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h re
hole
spec
es, in part or in w
Note
t to the co
♦ If it becomes necessary to drain the air conditioning service

station (e.g. because contaminated refrigerant was extracted),
rrectness of i
all filters and dryers are to be renewed as a rule. Do not take

the filters and dryers out of their airtight packaging until im‐
l purpos
mediately prior to installation in order to keep moisture ab‐

sorption (hygroscopic property) as low as possible.
nf
ercia
♦ Refrigerant bottles filled with contaminated, used refrigerant

rm
m
are known as “recycling bottles”.

atio
om
n in
c
♦ Recycling bottles must be evacuated as a rule before being

or
thi
e
filled for the first time with refrigerant. Refrigerant bottles that
t
sd
iva
have air in them must not be filled with refrigerant.

o
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rp
cu
o
m
f
en
♦ Different types of refrigerants must not be mixed with each

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t.
yi Co
other. Mixed refrigerants cannot be processed for reuse. They Cop py
have to be disposed of. If there is any doubt about the com‐
ht. rig
rig ht
by
position of the contents of the container, the refrigerant recy‐ copy Vo
by lksw
cler is to be informed accordingly. cted agen
Prote AG.

9 Detecting leaks in refrigerant circuit
Note
♦ Different processes are described in this workshop manual for

leak detection in the refrigerant circuit. These processes have
been tested and lead to a positive result under the different
conditions of use if the application is carried out correctly and
in accordance with the complaint.
♦ When leak detection using compressed air/nitrogen or vac‐
uum does not produce results, useG.electronic
Volkswagen leak detector or
UV leak detector additive.lkswagen A AG do
es n
o ot g
yV
♦ Small leaks can beisedetected with, for example, an electronic
db ara u
n
leak detector oruthaorUV leak detector lamp. tee
or
sa ac
♦ A wide ranges of
processes are offered on the open market for
ce
e
finding leaks in refrigerant circuits. These processes do not

nl
pt
du
an
always produce conclusive results. If they are not used pre‐
itte
y li
cisely according to the specifications, they may even cause
erm
ab
components of the refrigerant circuit to develop leaks where
ility
ot p
there were none before. Furthermore, certain processes can
wit
, is n
cause preliminary or permanent damage to the components
h re
hole
of the refrigerant circuit
spec
es, in part or in w
♦ Components that are found to be leaking must not be repaired.
t to the co
They have to be replaced with genuine parts.
♦ A leaking refrigerant circuit must not be charged with refriger‐
rrectness of i
ant, therefore evacuate an empty refrigerant circuit and check
for leaks before charging the system with refrigerant
l purpos
⇒ page 53 .
nform
mercia
at
Note
om
ion
c
in t
or

his
ate

do
priv
cum
or

f
en
ng
t.
yi
Co
op py
contained within. They cause deposits to build up in the re‐ t. C rig
gh ht
frigerant circuit (and your air conditioner service station), pyri by
Vo
co
by lksw
cted agen
Prote
AG.
pletely removed from the components (not even by flushing).

♦ It is often not possible to detect from the outside whether
use can usually not be found. Therefore, exercise caution on
♦ Containers or tanks are offered as accessories on the open
market that are designed to separate these chemical substan‐
ces (to seal leaks). Since Volkswagen rejects the use of these
substances, no statement can be made at this point regarding
the effectiveness and separation rate of these filters.
9. Detecting leaks in refrigerant circuit 57

9.1 Leak detection in refrigerant circuit us‐

ing compressed air or nitrogen
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
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cted agen
Prote AG.

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

by pressurising the circuit to a maximum of 15 bar using
cleaned and dried compressed air or nitrogen ⇒ page 68 . If
the leak is large, the leakage point can be detected by sound
as the air or gas escapes.
♦ Introduce the compressed air or the nitrogen through the serv‐
ice connection.
♦ The quick-release coupling adapter for serviceGconnection
. Volkswage
can
be fitted with a modified charging hose -A-
lksw
agen(e.g.
A
with a 5/8"-18
n AG d
oes
UNF thread, depending on the thread of the quick-release
o not
y V gu
b ara
coupling adapter) and a suitable ris adapter -B- to connect to the
ed
nte
workshop compressed airausystem ⇒ page 207 . To ensure that
tho eo
ra
no moisture, oil or dirt from
ss the workshop compressed air sys‐ c
tem enters the refrigerant circuit of the air conditioning system,
ce
le
un
pt
use e.g. a combination fine filter unit for compressed air sys‐
an
d
itte
tems with an oil, dirt and water separator, which is commonly
y li
erm
ab
used in paint spraying facilities. Install this between the com‐
ility
ot p
pressed air system and the charge hose -A- ⇒ Workshop
wit
is n
equipment catalogue .
h re
ole,
spec
♦ Using the manifold gauge with pressure reducer for nitrogen
(maximum reduced pressure: 15 bar) -1- you can connect a
t to the co
gas cylinder -3- filled with nitrogen via a charging hose -2- (e.g.
with 5/8"-18 UNF threaded connection) to the service connec‐
tion (to which a quick-release coupling adapter is connected)
rrectne
of the closed refrigerant circuit. ⇒ page 207
ss
– Slowly increase pressure in refrigerant circuit to a maximum
o
cial p
f
of 15 bar.
inform
mer
CAUTION
atio
om
n
c
Risk of injury from nitrogen escaping under high pressure.

i
or
n thi
te
– Use pressure limiter for nitrogen tank.

sd
iva
o
pr
cum
r
fo
en
ng
– Search for leak by sound, which is created by the escaping

t.
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op
gas. Use Ultrasonic tester - V.A.G 1842- to ease localisation C py
t. rig
of sounds.
gh ht
pyri by
Vo
co lksw
by
– Press nitrogen out of refrigerant circuit using cleaned and Prote
cted AG.
agen
dried compressed air. Nitrogen must not enter the service cyl‐
inder. This prevents the service cylinder from being filled with
condensible gases.
– Rectify leak.
– Evacuate again and observe the vacuum display over a period
of hours. Only when a vacuum is maintained can charging
commence.
♦ If a leak is present of a size where no or very little air is drawn
in and the air conditioning service station can create sufficient
vacuum. The vacuum gauge does not increase or increases
very slowly after switching the air conditioner service station
off. This indicates that there may be a very small ingress of air
and the vacuum is lost.
– Charge circuit with 100 g of refrigerant and search for the pos‐
sible leak using an electronic leak tester and rectify fault as
necessary ⇒ page 60 or add an approved UV contrast sub‐
stance to the refrigerant and search for the possible leak in the
circuit using leak detector system VAS 6201 or later model and
rectify fault as necessary ⇒ page 60 .
– Evacuating refrigerant circuit if necessary ⇒ page 53

– Evacuate refrigerant circuit and observe the vacuum gauge

over a period of hours. Only when a vacuum is maintained can
charging commence.
9.2 Searching for leaks in refrigerant circuits

using leak detector - V.A.G 1796-
Note
Small leaks can be detected with, for example, an electronic leak

detector.
Volkswa
– Evacuate refrigerant e.g. with air sconditioning
agen
AG. service station
gen AG
does
k w
⇒ page 53 . by Vol not
gu
a
ed ran
oris tee
th or
au ac
Note ss
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e
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pt
du
♦ If a larger leak is detected during the evacuation process, de‐
an
itte
y li
termine cause and rectify as described ⇒ page 53 .
erm
ab
ility
ot p
♦ If during the evacuation process no leak is detected or a very
wit
, is n
small leak is detected that but cannot be located, proceed as
h re
follows ⇒ page 58 .
hole
spec
es, in part or in w
♦ Refrigerant gas is quickly dispersed by movement of air.
t to the co
Draughts must therefore be avoided during leak detection.
♦ If the refrigerant circuit is completely empty, charge with about
rrectness of i
10 % of refrigerant capacity (sticker R134a or vehicle-specific
workshop manual).
l purpos
Leak search:
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ercia
– Start the leak detector according to the operating instructions.

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m
atio
m
– Always hold probe tip under location of suspected leak.

o
n in
or c
thi
If clicking rate increases or a warning tone sounds (depends on

te
sd
a
model), this indicates that the leak has been located (refer to op‐
iv
o
r
rp
cu
erating instructions for leak detector).

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.
9.3 Detecting leaks in refrigerant circuit us‐

ing leak detecting system - VAS 6196-
or leak detecting system - VAS 6201- or
a later model
Note
Small leaks can be detected with, for example, an UV leak de‐

tector additive.

– Evacuate refrigerant e.g. with air conditioning service station

⇒ page 53 .
Note
♦ If a larger leak is detected during the evacuation process, de‐

termine cause and rectify as described ⇒ page 53 .
♦ If during the evacuation process no leak is detected or a very
small leak is detected that but cannot be located, proceed as
follows ⇒ page 58 .
♦ Refrigerant gas is quickly dispersed by movement of air.
Draughts must therefore be avoided during leak detection.
♦ If the refrigerant circuit is completely empty, charge with about
10 % of refrigerant capacity (sticker R134a or vehicle-specific
workshop manual).
Leak detecting system - VAS 6196-

or
Leak detecting system - VAS 6201- or later model

1- Hand pump with low-pressure service hose, service cou‐
pling and non-return valve - VAS 6201/1-
2- Cartridge - VAS 6201/2-
3- Cleaning agent - VAS 6201/3-
4- UV leak detector lamp - VAS 6201/4-
5- UV absorbing eye protection - VAS 6201/6-
6- Stickers - VAS 6201/7-
7- Tube AG. Volkswagen AG d
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8- Safety gloves - VAS 6201/9- rised
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Pouring in leak detection additive with refrigerant circuit empty

wit
, is n
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The cartridge -A- contains 15.4 ml of leak detecting additive (one

hole
spec
unit -B- equates to 2.5 ml).

es, in part or in w
t to the co
rrectness of i
l purpos
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or c
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Cop py
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Prote AG.

– Assemble hand pump - VAS 6201- item -1- and cartridge item
-2- -VAS 6201/2- .
– Connect filler hose - VAS 6201/8- ( ⇒ page 61 item -7-) to hand
pump.
– Open service valve of hand pump.
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
r
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thi
s
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cum
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Cop py
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rig ht
py by
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Prote AG.

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Air conditioning systems with refrigerant R134a - General information - Edition 11.2019 ss
ce
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an
When the refrigerant circuit is empty, the leak detection additive
itte
y li
can best be poured in via an open connection.
erm
ab
ility
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– Open the refrigerant circuit at a readily accessible connection.
wit
, is n
h re
– Cover the surrounding area with sheeting or absorbent paper.
hole
spec
es, in part or in w
– Hold tube upwards.
t to the co
– Turn T-bar of hand pump until the leak detecting additive flows
out of the tube.
rrectness of i
– Inject 2.5 ± 0.5 ml (millilitre = cm3) of leak detecting additive
l purpos
into the refrigerant circuit.
nform
ercia
Note
m
at
om
io
Note the following, if a leak detecting additive has been injected
n
c
in t
r
during a previous repair of the refrigerant circuit, only inject new

o
his
te
leak detecting additive if the refrigerant machine oil has been re‐
a
do
riv
placed. If only some of the refrigerant machine oil was replaced

p
cum
or
then only the respective amount of leak detecting additive should

f
en
ng
t.
yi
be injected. If for example 100 ml of machine oil was replaced on
Co
op py
a vehicle with 250 ml of refrigerant machine oil, inject only 1 ml t. C rig
gh ht
(cm3) of leak detecting additive. pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Renew O-rings at opened connection.
– Assemble refrigerant circuit.
– Attach a label, close to the service connection, which has in‐
formation showing that the refrigerant circuit has been injected
with a leak detecting additive.
– Evacuate and fill the refrigerant circuit as per specifications
⇒ page 53 and ⇒ page 54 .
– Start air conditioning system.
Note
The air conditioning system must be operated for at least 60 mi‐

nutes to ensure that the injected leak detecting additive is distrib‐
uted throughout the entire refrigerant circuit (air conditioner
compressor must run). The leak may become visible after a short
period, but this depends on the size of the leak.
– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
erant circuit ⇒ page 65 .
Note
Using cleaning solution - VAS 6201/3- , clean the engine com‐

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

Pouring in leak detection additive with refrigerant circuit charged

Volkswa n AG. gen AG
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♦ Note the following, if a been injec‐ leak detecting additive has
s c
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ted during a previous repair of the refrigerant circuit, only inject
nl
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new leak detecting additive if the refrigerant machine oil has
an
itte
y li
been replaced. If only some of the refrigerant machine oil was
erm
ab
replaced then only the respective amount of leak detecting
ility
ot p
additive should be injected. If for example 100 ml of machine
wit
, is n
oil was replaced on a vehicle with 250 ml of refrigerant ma‐
h re
hole
chine oil, inject only 1 ml (cm3) of leak detecting additive.
spec
es, in part or in w
♦ A small amount of leak detecting additive remains in the serv‐
t to the co
ice connection. This is to be carefully removed so as to avoid
subsequent erroneous leak detection.
rrectness of i
l purpos
The cartridge -A- contains 15.4 ml of leak detecting additive (one

unit -B- equates to 2.5 ml).
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.
– Remove sealing cap from service connection on low-pressure
side of refrigerant circuit.
– Assemble hand pump - VAS 6201- item -1- and cartridge item
-2- -VAS 6201/2- .
Note
Ensure the hose of the hand pump is completely filled with leak
detecting additive.
– Fit the quick release coupling to the service connection of the

low-pressure side and open the service coupling by turning the
hand wheel. Hold hose upwards and turn T-bar of hand pump
until the leak detecting additive starts to flow out of the tube.
– Cover area of service connection on vehicle with foil or ab‐

sorbent paper.
– Turn T-bar of hand pump and inject 2.5 ± 0.5 ml (millilitre =
cm3) of leak detecting additive into the refrigerant circuit.

– Close the service coupling and remove it from the service

connection.
– Remove the remains of the leak detecting additive from the
service connection, with for example, absorbent paper.
– Seal service connection using sealing cap.
– If necessary, use cleaning agent to clean area around service
connection.
– Attach a label, close to the service connection, which has in‐
formation showing that the refrigerant circuit has been injected
with a leak detecting additive.
– Start air conditioning system.
Note
The air conditioning asystem gen AG must benoperated

. Volkswage AG
does for at least 60 mi‐
nutes to ensure Vothat
lksw the injected leak detecting not additive is distrib‐
g
uted throughout
ise d b the entire refrigerant circuit (air uconditioner
y ara
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compressor hor must run). The leak may become visible after
eo a short
ut
period,
ss a but this depends on the size of the leak. ra
c ce
e
nl
pt
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– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
an
itte
y li

erm
ab
ility
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wit
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Note
h re
hole
spec
Using cleaning solution - VAS 6201/3- , clean the engine com‐

es, in part or in w
t to the co
partment and, if necessary, the components of the refrigerant

circuit, to remove leak detection additive residue left from the re‐
pair work.
rrectness of i
Searching for leaks in the refrigerant circuit using UV lamp VAS

l purpos
6196/4
nf
ercia
CAUTION
orm
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atio
Risk of eyes being dazzled by UV light.

om
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c

or
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– Never glare into the UV lamp.

iva
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– Never point a UV lamp at another person.

o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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Prote AG.

Note
♦ The air conditioning system must be operated for at least

60 minutes to ensure that the injected leak detecting additive
is distributed throughout the entire refrigerant circuit (air con‐
ditioner compressor must run). The leak may become visible
after a short period, but this depends on the size of the leak.
♦ In the event of leaks at the evaporator, the additive may be
washed out with the condensate and emerge via the conden‐
sate drain. As the evaporator is not accessible on the majority
of models without a great amount of pre-preparation, a check
of the condensed water drain point can indicate a leaking
evaporator. The additive must have been in the refrigerant cir‐
cuit for a long time to make this possible.
♦ The protective goggles are not only designed to provide eye
protection. They also make the additive more readily visible
under UV light.
♦ Independent of the accessibility togethe
swa
n AGvarious
. Volkswacomponents
gen AG
does of
the refrigerant circuit, it may y V become necessary to removet gua
olk no
certain components from ris
ed bthe vehicle (e.g. bumper or air filter). ran
t ee
tho or
s au ac
s
– Move vehicle to a poorly lit area of the workshop (daylight or
ce
le
un
pt
bright artificial lighting diminishes the effect of the UV light).
an
d
itte
y li
erm
– Check the accessibility to the various components of the re‐ ab

frigerant circuit and remove components in the vicinity of the ility
ot p
wit
refrigerant circuit that obstruct the view of the respective circuit
is n
h re
components (e.g. sound insulation and bumper).
ole,
spec
– Protect eyes with protective glasses.

t to the co
– Connect UV lamp to a 12 V battery (vehicle battery). Take care

to ensure correct polarity.
rrectne
– Switch on UV lamp and illuminate components of refrigerant

circuit. Positions at which refrigerant - along with refrigerant oil
s
and leak detection additive - can leak out fluoresce (light-up)

s o
under UV light.
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
♦ The leak detection additive can be allowed to remain in the

te
sd
va
i
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pr
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r
fo
♦ Using cleaning solution - VAS 6201/3- , clean the engine com‐

en
ng
t.
yi Co
partment and, if necessary, the components of the refrigerant Cop py
circuit, to remove leak detection additive residue left from the ht. rig
rig ht
repair work.
py by
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auth R134a - General information - Edition 11.2019 or
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ss
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10 Clearing refrigerant circuit of contam‐
an
d
itte
y li
erm
inants
ab
ility
ot p
wit
is n
⇒ “10.1 Vehicles with high-voltage system (hybrid vehicles)”,
h re
ole,
page 67
spec
⇒ “10.2 Blowing through refrigerant circuit with compressed air
t to the co
and nitrogen”, page 68
⇒ “10.3 Flushing refrigerant circuit with refrigerant R134a”,
rrectne
page 70
10.1 Vehicles with high-voltage system (hybrid vehicles)
ss o
cial p
f
inform
mer
atio
om
n
electric shock.
c
i
or
n thi
te
sd
iva
o
r
voltage cables.
p
cum
r
fo
en
ng

t.
yi Co
op
tools.
C py
t. rig
gh ht
yri by
– Never use heat sources such as welding, brazing, soldering, cop Vo
by lksw
cted agen
Prote AG.
If repair work in the vicinity of high-voltage components and ca‐

bles is necessary, carry out a visual check for damage on high-
voltage components and cables ⇒ Electrical system; Rep. gr.
93 ; General warning instructions for work on the high-voltage
system .
If repair work on high-voltage components is necessary, de-en‐
ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;
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

contained within. They cause deposits to build up in the re‐
frigerant circuit (and your air conditioner service station),
The refrigerant circuit can only be repaired by replacing all
components that have come into contact with this substance.
• In order to remove dirt (e.g. abraded matter from a defective

air-conditioning compressor) as well as old refrigerant oil as
10. Clearing refrigerant circuit of contaminants 67

cleanly as possible and with as little work as possible, rinse

the refrigerant circuit with R134a refrigerant.
On vehicles with electrical air conditioner compressor, observe
the notes on renewing the electrical air conditioner compressor -
V470-. If the electronics of the air conditioner compressorAareG. Volkswagen AG d
damaged, the refrigerant circuit must not always be l
cleaned
ksw
agen oes
not
⇒ page 194 . db
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ris tee
10.2 Blowing through refrigerant circuit with autho or
ac
ss
compressed air and nitrogen
ce
le
un
pt
an
d
• Use compressed air to force moisture and other contaminants

itte
y li
out of the refrigerant circuit and use nitrogen to force moisture
rm
ab
pe
ility
out of the refrigerant circuit.
ot
wit
, is n
• The method of blowing through the refrigerant circuit with
h re
hole
compressed air and nitrogen often requires a lot more work
spec
than purging with refrigerant R134a. When purging with re‐
es, in part or in w
t to the co
frigerant R134a, cleaning of the components is considerably
better. It is therefore always best to purge the system in the
event of complaints (the method of blowing through should
only be selected for certain complaints and for individual com‐
rrectness of i
ponents).
l purpos
Only individual components are to be blown through if:

♦ There is no way of purging the refrigerant circuit with refriger‐
nform
ercia
ant R134a.
m
a
com
ti
♦ If there is dirt or contamination in individual components of the
on in
r
te o
thi
s
iva
do
♦ If during evacuation of a leak-tight refrigerant circuit the vac‐
r
rp
c
uum display is not constant on gauge (moisture in the refrig‐
um
fo
en
g
erant circuit, which generates vapour pressure).

n
t.
yi Co
Cop py
♦ If the refrigerant circuit has been left open for longer than nor‐
t. rig
gh ht
yri
mally required for repairs (e.g. following an accident). p by
co Vo
by lksw
cted agen
♦ Pressure and temperature measurements in the circuit indi‐ Prote AG.
cate that there is moisture in the refrigerant circuit.
♦ The vehicle-specific repair manual ⇒ Heating, air conditioning
deems it necessary after replacement of certain components.
Note
♦ Blowing through the refrigerant circuit with compressed air and

nitrogen will not achieve the same degree of cleanliness as
purging with refrigerant R134a. When purging with refrigerant
R134a, the refrigerant oil is shifted and cleaning of the com‐
ponents is better ⇒ page 70 .
♦ When blowing through, a maximum working pressure of 15 bar
must not be exceeded (if necessary, use pressure limiter for
compressed air as well).
CAUTION
Risk of injury from nitrogen escaping under high pressure.
– Use pressure limiter for nitrogen tank.
– Always flush components in direction opposite to refrigerant

flow.
Compressed air and nitrogen cannot be blown through the re‐
strictor, expansion valve, air conditioner compressor, receiver or
reservoir.

– In cases where condensers have a drying agent cartridge in

the integrated receiver, this drying agent
agen cartridge must
AG. Volkswagen AGbe
doere‐
moved. olksw s no
t gu
yV b ara
ed
– First blow out soiling usingho compressed air and then dry com‐
ris nte
e
ponents with nitrogen. s aut or
ac
s
– Fit adapter for connection of pressure hose to refrigerant cir‐
ce
e
nl
pt
du
cuit ⇒ page 87 and ⇒ Heating, air conditioning .
an
itte
y li
erm
ab
To prevent oil and moisture from the compressed air system
ility
ot p
making its way into the refrigerant circuit, the following points must
wit
, is n
be observed.
h re
hole
♦ The compressed air must be fed through a compressed air
spec
es, in part or in w
cleaning unit to clean and dry it. Therefore, use compressed
t to the co
air filter and dryer (included in items supplied with tools for
painting work) ⇒ Workshop equipment and Special tools cata‐
logue .
rrectness of i
♦ If refrigerant pipes have threads or union nuts at connections,
l purpos
use adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- to

connect to 5/8" - 18 UNF charging hose. These adapters can
be found in the adapter case for VW/Audi passenger vehicle
nf
ercia
set - VAS 6338/1- and adapter case for commercial vehicle
orm
set - VAS 6338/50- .
m
atio
om
n in
♦ On refrigerant pipes with no thread or union nut on the con‐
or c
thi
nection, use adapter from adapter case for VW/Audi passen‐
te
sd
a
ger vehicle set - VAS 6338/1- or adapter case for commercial

iv
o
r
rp
cu
vehicle set - VAS 6338/50- or commercially available air blow
o
m
f
en
ng
gun with rubber nozzle. yi

t.
Co
Cop py
t. rig
gh ht
yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
♦ Always extract any escaping air and/or nitrogen from the com‐
ponents using appropriate local exhaust ventilation LEV (e.g.
workshop extraction system).
♦ Certain contaminants and old refrigerant oil cannot be shifted
from the refrigerant circuit at all with compressed air or if the
compressed air is insufficient. These contaminants can only
be removed by purging with refrigerant R134a ⇒ page 70 .

wage e n
Amarok 2011 ➤ , Amarok yV
olks 2017 ➤ , Ameo 2017s➤ ot,gArteon 2018 ➤ , Atlas 2 ...
b ua
Air conditioning ir sesystems with refrigerant R134a - General
d ran information - Edition 11.2019
tee
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10.2.1 ss Flushing refrigerant circuit
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
, is n
♦ On vehicles where no adapters fit the refrigerant pipes, blow
h re
through individual components using, for example, an air blow
hole
spec
gun with rubber nozzle. When doing this, be particularly care‐
es, in part or in w
ful not to damage the connections (do not crush or scratch
t to the co
them).
♦ The evaporator should be blown through from the connection
rrectness of i
to the low pressure side (large diameter), with the expansion
valve or restrictor removed.
l purpos
♦ Always flush components in direction opposite to refrigerant

flow.
nf
ercia
orm
♦ Examine the expansion valve; renew if dirty or corroded.
m
atio
om
n in
♦ Replace any components on which dark, sticky deposits can‐
or c
not be removed with compressed air.
thi
te
sd
iva
o
♦ Thin, light grey deposits on the insides of refrigerant pipes do
r
rp
cu
o
m
not impair the function of the components.
f
en
ng
t.
yi Co
op
♦ After blowing out the system, always renew the receiver or C py
t. rig
reservoir and the restrictor. If the condenser has a dryer, re‐
gh ht
pyri by
new the dryer cartridge or dryer.
co Vo
by lksw
cted agen
Prote AG.
10.3 Flushing refrigerant circuit with refriger‐

ant R134a
⇒ “10.3.1 Principle circuit diagrams for various purging circuits”,
page 78
⇒ “10.3.2 Purging electrical air conditioner compressor”,
page 83
⇒ “10.3.3 Adapters for setting up flushing circuits”, page 87
The refrigerant circuit must be flushed with refrigerant R134a if
♦ Dirt or other contaminants are in the refrigerant circuit.
mally required for repairs (e.g. following an accident).
♦ Pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the refrigerant circuit.
♦ There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit. If the air conditioner compressor is to be reinstal‐
led, drain refrigerant oil out of air conditioner compressor via
the block connections. 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 circuit with total amount of refrigerant oil (50 g direct
into air conditioner compressor) according to ⇒ vehicle-spe‐
cific workshop manual . Take account of oil volume for
2nd evaporator system.
♦ The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
♦ If it is required by the workshop manual for the specific vehicle
following the renewal of certain components.

♦ a different air conditioner compressor with other refrigerant oil

is to be fitted.
Tools required
♦ Air conditioner service station with purging device or air con‐
ditioner service station with purging device - VAS 6337- .
These air conditioner service stations feature an additional
function for “purging the refrigerant circuit with R134a” and the
purging device for refrigerant circuits necessary for this pro‐
cedure ⇒ Workshop equipment and special tools catalogue .
♦ Adapter case VW/Audi passenger vehicle set - VAS 6338/1-
⇒ page 87 and ⇒ Workshop equipment and special tools
catalogue .
♦ Adapter case commercial vehicle set - VAS 6338/50-
⇒ page 87 and ⇒ Workshop equipment and special tools
catalogue .
Note
♦ If you do not have either of the two air conditioner service sta‐
tions indicated above, you can also rinse the refrigerant circuit
with the air conditioner service station you do have if the sta‐
tion is of the right type (at least 7 kg of R134a refrigerant in the
refrigerant bottle) by using the flushing device for refrigerant
circuits - VAS 6336/1- or flushing device for refrigerant circuits
- VAS 6337/1- . The purging process must AGthen
. Volksbe
wagcarried
en AG out
agen
manually ⇒ page 76 . Volksw
does
not
y gu
db ara
♦ On vehicles with threaded
or
isconnections
e on the refrigerant cir‐ nte
cuit, adapter - V.A.G 1785/1-
au
th to adapter - V.A.G 1785/8- from eo
ra
adapter case VW/Audi s passenger vehicle set - VAS 6338/1-
s c
or adapter case commercial vehicle set - VAS 6338/50- can
ce
e
nl
pt
du
be used. On vehicles with threaded connections on the air

an
itte
y li
conditioner compressor and on the reservoir, the adapter -

erm
ab
V.A.G 1785/8- is required two-fold.

ility
ot p
wit
, is n
♦ In the adapter case there is also a charging hose - VAS

h re
6338/31- with 5/8 - 18 UNF connections and large internal di‐

hole
spec
ameter to bridge components (commercially available type).

es, in part or in w
t to the co
Preparations
– Drain refrigerant circuit ⇒ page 53 .
rrectness of i
– Remove air conditioner compressor ⇒ Heating, air condition‐

l purpos
ing .
On vehicles with restrictor and reservoir.
nf
ercia
orm
– Remove restrictor (vehicle-specific) and join the refrigerant

m
atio
m
lines together again ⇒ Heating, air conditioning .

o
n in
or c
– Remove reservoir (vehicle-specific) ⇒ Heating, air condition‐

thi
te
sd
a
ing and join refrigerant pipes together again (to do this, use
iv
o
r
rp
cu
adapter and charging hose - VAS 6338/31- from adapter case

o
m
f
VW/Audi passenger vehicle set - VAS 6338/1- )

en
ng
t.
yi
⇒ page 87 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
The collector could be purged but due to its large inner volume it
would require too much refrigerant. During extraction, the refrig‐
erant ices up the reservoir heavily and the extraction procedure
takes much longer as a result.

On vehicles with expansion valve and receiver

– Remove the receiver ⇒ Heating, air conditioning (vehicle-
specific, not necessary on all vehicles) and join the refrigerant
lines together (use the adapter and the charging hose - VAS
6338/31- to do this) ⇒ page 87 .
– Remove the expansion valve ⇒ Heating, air conditioning (ve‐
hicle-specific) and insert an adapter in its place ⇒ page 87 .
Note
If there is not a suitable adapter for the expansion valve in the

adapter case VW/Audi passenger vehicle set - VAS 6338/1- or
adapter case commercial vehicle set - VAS 6338/50- , the re‐
moved expansion valve can also be drilled out (the old expansion
valve must be subsequently renewed).
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ Disregard item -3-. d byV
o gu
ara
ise nte
r
♦ When drilling out, ensure that the flow holes -2- and ut -4- in the
ho eo
ra
expansion valve -1- are located offset to each other.
ss a c
ce
e
♦ Failure to observe this measure can result in the sealing sur‐

nl
pt
du
an
face on the expansion valve -1- becoming damaged when
itte
y li
drilling, thereby rendering the expansion valve useless for set‐
erm
ab
ility
ting up the flushing circuit.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

expansion valve.
♦ There are two types of expansion valve. For type -A-, parts
-B-, -C- and -D- must be removed. Now separate part -E- from
control element -D-. Then drill out the expansion valve in area
-F- using a suitably sized drill bit (6 mm in diameter).
♦ On version -G-, parts -H-, -I- and -K- must be removed and
then area -L- drilled out with a suitably sized drill bit (6 mm in
diameter).
♦ Clean away any swarf from the drilled out expansion valve.
♦ Reinstall parts -B-, -C- and -D- on type -A- or part -H- on type
-G-.
AG. Volkswagen AG d
agen oes
olksw not
Note d by V gu
ara
rise nte
tho eo
On svehicles
sa
u
with two evaporators, the circuit to the second
evap‐
ra
c
orator must be isolated from the circuit to the first evaporator and
ce
le
purged in a separate procedure ⇒ Heating, air conditioning and

un
pt
an
d
⇒ page 87 .
itte
y li
erm
ab
ility
ot p
Drill open shut-off valve.

wit
is n
h re
ole,
spec
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.

Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
♦ Two shut-off valves are required for purging othe ris refrigerant
ed
nte
circuit. A shut-off valve must be drilled open,ut if no shut-off tap
h eo
ra
- VAS 6338/42- is available, for example.s s a c
ce
le
un
♦ Remove the solenoid -A- and the solenoid valve -B- before
pt
an
d
drilling open the shut-off valve.
itte
y li
erm
ab
♦ Drill open the shut-off valve -C- using a suitable drill bit (e.g.
ility
5 mm in diameter). ot p
wit
is n
h re
ole,
♦ Remove any metal shavings resulting from drilling hole -D-
spec
from shut-off valve -C-.
t to the co
♦ Reinstall the solenoid valve -B- with the respective seal -E- to
the shut-off valve -C- which has been drilled open.
rrectne
Flush
s
– Check the refrigerant volume in the air conditioning bottle.
s o
There must be at least 7 kg of R134a refrigerant.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
If necessary, switch on the heater fitted to your refrigerant bottle

t
sd
va
for 30 minutes before you start rinsing. In this way, pressure in

i
o
pr
cum
r
the refrigerant bottle is increased and charging of the purging cir‐

fo
en
ng
cuit is accelerated.
t.
yi Co
Cop py
t. rig
gh ht
yri
– Drain the waste oil container of the air conditioner service sta‐ p by
o Vo
by c lksw
tion . Prote
cted AG.
agen
– Connect the supply hose (high-pressure side) of the air con‐

ditioner service station with an adapter ⇒ page 87 to the low-
pressure line leading to the air conditioner compressor (line
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 87 to the high-pressure line leading
to the air conditioner compressor (line with smaller diameter).

Note
♦ The components must always be purged against the direction

of refrigerant flow when the air conditioning system is in oper‐
ation (not applicable for electrical air conditioner compressor)
⇒ page 78 .
♦ When flushing, contaminants from the refrigerant circuit enter
the flushing device for refrigerant circuits and the air condi‐
tioner service station and are retained in the filters and dryers G. Volkswagen
installed within. Depending on the impurity, these componentslksw
agen
A AG do
es n
are to be replaced at shorter intervals in accordance by Vowith the ot g
ua
operating instructions for the air conditioner service
ris
ed
station or ran
tee
the rinsing device for refrigerant circuits. autho
or
a
ss c
♦ The filter in the rinsing device for refrigerant circuits is to be
ce
e
replaced after 2 rinsing cycles at the latest (rinsed vehicle), nl
pt
du
an
depending on the type and degree of contamination of the
itte
y li
erm
rinsed refrigerant circuit. If a heavily contaminated refrigerant
ab
ility
circuit is purged (the refrigerant oil from the refrigerant circuit
ot p
wit
is black and viscous or there are large amounts of shavings in
, is n
h re
the refrigerant circuit) renew filter after purging refrigerant cir‐
hole
spec
cuit. After such heavy contamination of the refrigerant circuit,
es, in part or in w
we suggest purging the system again after changing the filter.
t to the co
♦ Depending on the type of contamination, deposits (old refrig‐
erant oil and friction dust from the air conditioner compressor)
rrectness of i
will gather in the sight glass of the rinsing device for refrigerant
circuits. Clean the sight glass(es) after purging and purge the
l purpos
refrigerant circuit once more as a precautionary measure after

purging.
nf
ercia
♦ Fluid refrigerant cannot flow at the necessary speed through
orm
the expansion valve, the restrictor and the desiccant cartridge
m
atio
m
of certain receivers. These components must therefore be re‐

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

or
thi
conditioning .
te
sd
iva
o
r
rp
cu
♦ Adapter for connecting the air conditioning service station and
o
m
f
for bridging certain components in the refrigerant circuit

en
ng
t.
yi
⇒ page 87 .
Co
Cop py
ht. rig
rig ht
py by
– Switch on the air conditioner service station and flush the re‐
co Vo
by lksw
cted
frigerant circuit (duration approx. 1 to 1.5 hours for one flushing
agen
Prote AG.
cycle with three flushes using approx. 4 kg of refrigerant
R134a for each flush).

Note
♦ Rinsing of a refrigerant circuit is to be carried out in accordance

with the operating instructions for the air conditioning service
station .
♦ The container for old oil holds only approx. 125 cm3 of refrig‐
erant oil, depending on the type of air conditioning service
station . If a system with a greater amount of refrigerant oil has
to be purged, it may be necessary to empty the waste oil con‐
tainer after the first purge of the purging cycle.
♦ Watch the refrigerant that flows out of the refrigerant circuit.
When the refrigerant flows through the sight glass of the purg‐
ing device into the air conditioner service station clear and
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
evaporator, though this is not important).
♦ Where contamination is particularly high, it may be necessary
to carry out the flushing cycle twice (two flushing cycles with
three flushes each). Purging device filter must be renewed
before starting second purging cycle.
Sequence of steps in a rinsing run (which is determined automat‐

ically by the program of the air conditioning service station )
♦ After switching on, the purging cycle (refrigerant circuit with
connection hoses and purging device for refrigerant circuits)
is first evacuated and the refrigerant circuit thereby checked
for leaks. It may be necessary to start the next steps manually,
depending on the type of air conditioning service station . AG. Volkswagen AG d
agen oes
ksw
♦ A predetermined amount of refrigerant (e.g. 4 kg) is pumped by V ol not
gu
ara
into the evacuated rinsing circuit via the high-pressure side riseof
d
nte
the air conditioning service station (opposite to the direction
ut
ho
of eo
ra
flow that is normal during operation of the air-conditioning
ss a
sys‐ c
tem and, therefore, at the low-pressure end of the vehicle's
ce
le
un
pt
refrigerant circuit). Depending on the type of air conditioning
an
d
itte
service station , refrigerant is pumped in until the rinsing circuit
y li
rm
ab
has been completely filled with liquid refrigerant. This is indi‐
pe
ility
cated by the fact that refrigerant stops flowing into the circuit
ot
wit
, is n
for a certain amount of time, for example.

h re
hole
spec
♦ After the specified amount of refrigerant has been pumped in,
es, in part or in w
the heater of the rinsing device for refrigerant circuits is switch‐ t to the co
ed on, for example, depending on the type of air conditioning
service station and rinsing device for refrigerant circuits (only
if the refrigerant is extracted from the rinsing device for refrig‐
rrectness of i
erant circuits in gaseous form).

l purpos
♦ Once the refrigerant has been extracted, the heater (if there is
one) of the rinsing device for refrigerant circuits is switched off
(it is possible that the refrigerant circuit will then be briefly
nform
ercia
evacuated again, depending on the type of equipment). After

m
evacuation, the refrigerant oil extracted from the refrigerant

a
com
tio
circuit is separated by the air conditioning service station .

n in
r
te o
thi
♦ The sequence for filling with refrigerant, extracting (and evac‐

s
iva
do
uating) is carried out twice (that means a total of three times).

r
rp
cum
fo
♦ After the third extraction, the rinsing circuit is evacuated, de‐

en
ng
t.
yi
pending on the type of air conditioning service station .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– After a rinsing cycle, check the sight glass(es) of the rinsing

device for refrigerant circuits and, if they are dirty, clean them
in accordance with the operating instructions for the rinsing
device for refrigerant circuits or the air conditioning service
station . Carry out a purging cycle once more as a precaution‐
ary measure. One flushing sequence 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 must be no
overpressure in the refrigerant circuit.
– Renew these components according to the type of vehicle.
♦ Restrictor and reservoir
♦ Expansion valve and liquid container or desiccant cartridge in
the liquid container
– ⇒ Heating, air conditioning and ⇒ Parts catalogue .
– Replace air conditioner compressor depending on complaint
⇒ Heating, air conditioningn Aand ⇒lksParts
o catalogue or drain
wagen A
e G. V
the remaining refrigerant olkswagoil from the removed
G do
esair
no conditioner
compressor ⇒ page d by 191 (renewing components oft grefrigerant
V ua
ran
circuit) and fill
orisit with the prescribed amount of fresh refrigerant
e
tee
oil ⇒ vehicle-specific
au
th
workshop manual . or
a
ss c
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ There is a predetermined amount of refrigerant oil in the gen‐

ot
wit
uine air conditioner compressor. On vehicles with two evapo‐

, is n
h re
rators, a certain amount of refrigerant oil may have to be added

hole
spec
to the circuit as appropriate ⇒ vehicle-specific workshop man‐

es, in part or in w
ual .
t to the co
♦ If the air conditioner compressor does not have to be renewed,

the volume of refrigerant oil in the air conditioner compressor
rrectness of i
must be replenished in accordance with the fill volume (pour

out refrigerant oil and refill the prescribed amount in the air
l purpos
conditioner compressor or the refrigerant circuit)

⇒ page 191 (renewing components of refrigerant circuit) and
⇒ vehicle-specific workshop manual .
nform
mercia
– Assemble the refrigerant circuit back together again complete‐

com
tio
ly ⇒ Heating, air conditioning .

n in
r
te o
thi
– Evacuate and fill the refrigerant circuit as per specifications

s
iva
do
⇒ page 53 and ⇒ page 54 .

r
rp
cum
fo
en
g
– Bring the air conditioning system into operation as per speci‐

n
t.
yi Co
op
fications ⇒ Heating, air conditioning and ⇒ page 55 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10.3.1 Principle circuit diagrams for various

purging circuits olks
wage es n
ot
yV gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
e
nl
♦ The arrows in the following illustrations show the direction of
pt
du
an
flow of the refrigerant during purging. The refrigerant flows
itte
y li
erm
against the direction of flow during normal conditioning of the
ab
ility
air, which is why the high-pressure system of the air condi‐
ot p
wit
tioning service station is connected to the low-pressure con‐
, is n
h re
nection of the refrigerant circuit to the air conditioner
hole
spec
compressor.
es, in part or in w
t to the co
♦ These principle circuit diagrams show a refrigerant circuit with
restrictor and reservoir and a refrigerant circuit with expansion
valve, receiver and a second evaporator (extra equipment on
rrectness of i
certain vehicles).
l purpos
♦ Depending on the design of the air conditioning service sta‐

tion , non-return valves may be installed between the refriger‐
ant circuit and the air conditioning service station . This
nf
ercia
ensures the correct direction of flow of refrigerant during purg‐
orm
ing.
m
atio
om
n in
or c
Refrigerant circuit with restrictor and reservoir
thi
te
sd
iva
o
r
rp
cu
o
m
Note
f
en
ng
t.
yi Co
Cop py
On vehicles with restrictor and reservoir, the restrictor and the
t. rig
gh ht
yri by
reservoir are removed. The refrigerant pipes of the restrictor are op Vo
by c lksw
assembled again. The refrigerant pipes to the removed reservoir cted agen
Prote AG.
are joined together with two adapters and the charging hose -
VAS 6338/31- (from adapter case VW/Audi passenger vehicle set
- VAS 6338/1- .

1 - Air conditioner service sta‐

tion
❑ with an electronic con‐
trol and a flushing pro‐
gramme, e.g. air condi‐
tioner service station
with flushing device -
VAS 6337-
❑ If an air conditioner
service station without
flushing program is
used, the sequencegehas n AG. Volkswagen AG do
to be carried Vout lks wa
man‐ es n
o ot g
ually (evacuate,
ed
by flush ua
ran
3 times thorwith at least 4 kg
is tee
or
of refrigerant
au each time ac
ss
and extract refrigerant
ce
e
nl
again, evacuate).
pt
du
an
itte
y li
2 - Refrigerant hose of air con‐
erm
ab
ditioner service station
ility
ot p
wit
❑ From high pressure side
, is n
h re
of air conditioning serv‐
hole
spec
ice station (normally col‐
es, in part or in w
oured red) to connection
t to the co
for low pressure side of
air conditioner compres‐
sor on refrigerant circuit
rrectness of i
(larger diameter)
l purpos
3 - Adapter for connection to

low pressure side in refrigerant
circuit
nf
ercia
or
❑ Different versions de‐

m
m
atio
pending on vehicle
om
⇒ page 87 .
n in
or c
thi
e
❑ From adapter case VW/

t
sd
iva
Audi passenger vehicle

o
r
rp
cu
set - VAS 6338/1- .

o
m
f
en
ng
t.
yi Co
4 - Connection of low pressure side in refrigerant circuit t. Cop py
rig
❑ Different versions depending on vehicle ⇒ page 87 .
gh ht
pyri by
Vo
co
❑ On refrigerant line from air conditioner compressor to reservoir.
by lksw
cted agen
Prote AG.
5 - Connection to reservoir
❑ On refrigerant line from air conditioner compressor to reservoir.
6 - Adapter for bridging removed reservoir
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
7 - Charging hose for refrigerant ⇒ page 87
❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS
6338/1- ).
8 - Adapter for bridging removed reservoir
9 - Connection to reservoir

10 - Evaporator
11 - Location of restrictor
❑ The restrictor is removed.
❑ Removing restrictor ⇒ Heating, air oconditioning
en AG. V
lkswagen AG .
ag does
ol ksw n
12 - Threaded connection bin
y Vrefrigerant line
ot g
ua
ed ra
❑ After removinghothe
ri restrictor, screw back together again ⇒nteHeating,
s
e air conditioning .
t or
au ac
13 - Condenser ss
ce
le
un
pt
14 - Connection for high pressure side on refrigerant circuit
an
d
itte
y li
rm
ab
pe
ility
15 - Adapter for connection of high pressure side in refrigerant circuit
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
16 - Charging hose of flushing device for refrigerant circuits
❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant
rrectness of i
circuits - VAS 6337/1- .
l purpos
17 - Flushing device for refrigerant circuits

❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging
nform
ercia
device for refrigerant circuits - VAS 6337/1- .

m
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
a
com
tion in
r
Note
te o
thi
s
iva
do
r
Depending on the layout of the air

rp
cum
fo
conditioner service station and the

en
ng
t.
yi
flushing device for refrigerant cir‐
Co
op py
cuits, there may be a service cou‐
t. C rig
gh ht
yri
pling for refrigerant circuits fitted at
p by
co Vo
the outlet and in some cases at the
by lksw
cted agen
Prote
inlet of the flushing device. If a serv‐
AG.
ice connection with a valve is instal‐

led to the outlet of the flushing
device, this valve must be opened
completely when the service cou‐
pling is connected. If the valve is not
opened completely, it restricts the
refrigerant flow.
– If there is a connection for a service coupling fitted at the inlet of the flushing device, the inlet must be
adapted to allow for the refrigerant hose coming from the vehicle to be connected directly.
Note
A service coupling and a valve in the

inlet of the flushing device restrict
the refrigerant flow from the vehicle
into the flushing device.
18 - Refrigerant hose of air conditioner service station

❑ From the low pressure side of the air conditioner service station (normally coloured blue) to the outlet of
the flushing device for refrigerant circuits.

Refrigerant circuit with expansion valve, receiver and second

evaporator
Note
♦ This principle circuit diagram shows a refrigerant circuit with

expansion valve, receiver and a second evaporator (extra
equipment on certain vehicles).
♦ On vehicles with expansion valve and receiver, the expansion
valve is removed and an adapter installed in its place. The
receiver must be purged, depending on the vehicle or the dryer
cartridge removed. Depending on the type of receiver, this
should be removed and the line connections to the receiver
joined together using two adapters and a charging hose.
AG. Volkswagen AG d
agen
♦ On vehicles with just oneVoevaporator,
lksw the components
oes
nofrom
tg
position “16” are notseinstalled
db
y
or not required. ua
ran
ri tee
utho or
a ac
ss
ce
e
nl
pt
du
tion
an
itte
y li
❑ with an electronic con‐
erm
ab
ility
trol and a flushing pro‐
ot p
wit
gramme, e.g. air condi‐
, is n
h re
tioner service station
hole
with flushing device -
spec
es, in part or in w
VAS 6337-
t to the co
❑ If an air conditioning
service station is used
which does not have a
purging programme, rrectness of i
then the sequence must
l purpos
be performed manually.
– Extract refrigerant, if
nf
ercia
there is any in the sys‐

rm
m
atio
tem.
om
n in
or c
– Connect flushing device

thi
te
sd
for refrigerant circuits -

iva
o
r
VAS 6337/1- between

rp
cu
o
air conditioner service

f
en
ng
t.
yi
station and return line
Co
op py
for refrigerant circuit.
t. C rig
gh ht
pyri by
Vo
co
– Evacuate refrigerant cir‐
by lksw
cted agen
Prote
cuit for 20 minutes, then
AG.
fill system with 4 kg of

refrigerant R134a. Then
extract again and repeat
process two further
times. If after the 3rd
purging process the re‐
frigerant in the sight
glass/glasses is not
clear, repeat process
again.
2 - Refrigerant hose of air con‐

ditioner service station
❑ From high pressure side of air conditioning service station (normally coloured red) to connection for low
pressure side of air conditioner compressor on refrigerant circuit (larger diameter)
3 - Adapter for connection to low pressure side in refrigerant circuit

4 - Connection of low pressure side in refrigerant circuit

5 - Adapter for removed expansion valve
6 - Evaporator
7 - Connection to receiver
❑ Not included on vehicles with a dryer cartridge in the receiver on the condenser or one in the receiver
integrated within the condenser ⇒ Heating, air conditioning .
8 - Adapter for bridging removed receiver
❑ Not required on all vehicles.
9 - Charging hose for refrigerant ⇒ page 87
❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS
6338/1- ).
10 - Condenser agen
AG. Volkswagen AG d
oes
olksw not
❑ If there is a receiver with dryer cartridge installed on the condenser,
d byV the dryer cartridge must gbe
ua removed
ran
(seal receiver again on or in condenser following removal)orise
⇒ Heating, air conditioning . tee
th o
❑ If the receiver is attached directly to the condenser,
ss
au
remove the receiver after purging and renew ⇒r ac
Heating, air conditioning .
ce
le
un
pt
an
11 - Connection for high pressure side on refrigerant circuit
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
rrectne
ameter) to inlet of flushing device for refrigerant circuits.
ss
❑ Different versions and different design, e.g. flushing device for refrigerant circuits - VAS 6337/1- .
o
cial p
f in
form
mer
atio
m
Note
o
n
c
i
or
n thi
e

t
sd
va

i
o
pr
cum
r

fo
en
ng
cuits, there may be a service cou‐

t.
yi Co
op
pling for refrigerant circuits fitted at C py
ht. rig
the outlet and in some cases at the rig ht
py by
inlet of the flushing device. If a serv‐
co Vo
by lksw
cted
ice connection with a valve is instal‐
agen
Prote AG.
refrigerant flow.

Amarok 2011 ➤ , Amarok gen A2017
G. Volk➤
sw,ag
Ameo
en AG 2017 ➤ , Arteon 2018 ➤ , Atlas 2 ...
does
swa
Air conditioning systemsy with
Volk refrigerant R134a - General not information - Edition 11.2019
gu b ara
ed nte
oris e
th or
Note au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
16 - Adapter to seal outlet to second evaporator
rrectne
❑ Only fitted on certain vehicles with “second evaporator” as optional equipment.
❑ From adapter case commercial vehicle set - VAS 6338/50- .
ss o
17 - Adapter to seal outlet to second evaporator
cial p
f in
form
mer
atio
om
n
c
18 - Connection of low pressure side in refrigerant circuit to second evaporator
i
or
n thi
te
sd
iva
o
pr
c
um
r
fo
en
ng
t.
yi
19 - Connection of high pressure side on refrigerant circuit to second evaporator
Co
Cop py
. rig
ht ht
rig by
opy Vo
❑ Only fitted on certain vehicles with “second evaporator” as optional equipment. by c lksw
cted agen
Prote AG.
20 - Adapter for removed expansion valve on second evaporator
21 - Second evaporator
10.3.2 Purging electrical air conditioner com‐

pressor
Vehicles with high-voltage system
electric shock.
voltage cables.
tools.

system .


Note
The electrical air conditioner compressor must be purged, if you

suspect that there is too much refrigerant oil in the refrigerant cir‐
cuit or if contaminated refrigerant oil (contaminated with moisture)
must be extracted from the air conditioner compressor. In these
cases the refrigerant circuit must be purged as well in order to
clean the refrigerant circuit and to re-establish the correct amount
of refrigerant oil.
If an electrical air conditioner compressor is renewed without hav‐

ing a mechanical fault (e.g. defective printed circuit board), the
amount of refrigerant oil from this electrical air conditioner com‐
pressor must be determined.
Note
♦ The air conditioner compressor must be purged in order to

extract the refrigerant oil which needs to be determined.
AG. Volkswagen
♦ Purge the air conditioner compressor
lksw in normal direction of es n
agen AG do
flow (from low-pressure inlet dtobyhigh-pressure
V o
outlet). ot g
ua
ran
e
ris tee
♦ In order to purge as muchuth refrigerant oil from the air condi‐
o
or
tioner compressor as spossible
s a make sure that the high-pres‐ ac
sure outlet of the air conditioner compressor is in the lowest
ce
le
un
pt
position possible.
an
d
itte
y li
♦ If an air conditioning service station without purging pro‐

rm
ab
pe
ility
gramme is used, the sequence has to be carried out manually

ot
(evacuate, purge 3 times with at least 2 kg of refrigerant each

wit
, is n
h re
time and extract refrigerant again, evacuate).

hole
spec
es, in part or in w
Determined amount e.g. 50 cm³

t to the co
Then, remove as much refrigerant oil from the new air conditioner
compressor as is necessary to ensure that only the same amount
rrectness of i
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
l purpos
example, the new original air conditioner compressor is filled with

e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
nform
ercia
– Pour old refrigerant oil out of air conditioner compressor. Han‐

m
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐

com
tio
book; Environmental protection; Waste disposal; Current

n in
r
te o
situation; Disposal channels; Disposal of used oils; Refrigerant

thi
s
oils .
iva
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t.
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Note
Co
Cop py
ht. rig
rig ht
py by
If the amount of refrigerant oil which can be removed from the co Vo
by lksw
new air conditioner compressor is not sufficient, the new air con‐
cted agen
Prote AG.
ditioner compressor must be purged. After the new air conditioner
compressor has been purged, fill the amount of refrigerant oil
which has been determined when purging the old air conditioner
compressor.


tion
Note
The air conditioner compressor is

purged manually.
– Extract refrigerant, if
there is any in the sys‐
tem.
– Discharge the waste oil

container of the nair
AG.con‐
Volkswagen AG
wage station .
ditioner service does
olks no t gu
yV
db ara
rise nte
tho Note eo
s au ra
c
s
Some air conditioner service sta‐
ce
e
nl
pt
du
tions first separate the oil in the vac‐
an
itte
uum phase and then fill it into the
y li
erm
ab
used-oil container.
ility
ot p
wit
, is n
– At the air conditioner

h re
hole
service station , set the

amount of refrigerant to spec
es, in part or in w
t to the co
2 kg and the amount of
oil to 0.
rrectness of i
– Connect purging device

for refrigerant circuits -
l purpos
VAS 6336/1- or purging

device for refrigerant cir‐
cuits - VAS 6337/1- be‐
nform
ercia
tween air conditioner

service station and re‐
m
at
om
turn line for refrigerant

on
c
in t
circuit.
or
his
ate
do
riv
– Evacuate the refrigerant

p
cum
or
circuit for 10 minutes. Then observe the vacuum gauge. If the vacuum persists, fill 2 kg of R134a refrig‐
f
en
ng
erant into the circuit. Then, extract and evacuate again and repeat the process.
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging
device for refrigerant circuits - VAS 6337/1- .

Note

cuits, there may be a service cou‐ swagen AG. Volkswagen AG does
pling for refrigerant circuits fitted by
at
Vol
k not
gu
the outlet and in some cases ris
eat the
d ara
nte
inlet of the flushing device.uth If a serv‐
o eo
ra
ice connection with a valve
ss
a is instal‐ c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
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refrigerant flow.
h re
ole,
spec
t to the co
Note
rrectne
s
s o
cial p
f in
form
mer
atio
m

o
n
c
i
or
n
❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
thi
te
ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant
sd
iva
o
r
circuits - VAS 6337/1- .

p
cum
r
fo
en
ng

t.
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op py
❑ Adapter - VAS 6338/1- from adapter set for refrigerant circuits - VAS 6338/3- t. C rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
If the adapter - VAS 6338/40- is

available, the charging hose can be
connected directly to the air condi‐
tioner compressor.
6 - High-pressure side refrigerant line from air conditioner compressor
Note
Will not be used if the adapter - VAS

6338/40- is available.
– Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/3- fits properly.
7 - Electrical air conditioner compressor

❑ Purge the air conditioner compressor in normal direction of flow (from low-pressure inlet to high-pressure
outlet).
❑ In order to purge as much refrigerant oil from the air conditioner compressor as possible make sure that
the high-pressure outlet of the air conditioner compressor is in the lowest position possible.
8 - Low-pressure side refrigerant line to air conditioner compressor
Note
Will not be used if the adapter - VAS

6338/41- is available.
– Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/6- fits properly.

wage e
9 - Adapter for connection to low pressure side Vin
olksrefrigerant circuit s no
t gu
d by ara
❑ Adapter - VAS 6338/1- from adapter oriseset for refrigerant circuits - VAS 6338/6- nte
th eo
s au ra
c
Note s
ce
e
nl
pt
du
an
If the adapter - VAS 6338/41- is
itte
y li
available, the charging hose can be
erm
ab
ility
connected directly to the air condi‐
ot p
tioner compressor.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ From high-pressure side of the air conditioning service station (usually coloured in red) for connection
to low-pressure line or directly to air conditioner compressor using adapter - VAS 6338/41- .
rrectness of i
10.3.3 Adapters for setting up flushing circuits
l purpos
– The desiccant bag and the desiccant cartridge must always
nf
ercia
be removed before any flushing routine. Then close the re‐
orm
ceiver again.
m
atio
om
– On condensers with a permanent dryer, this can be flushed
n in
or c
along with the other components. A new condenser must then
thi
te
sd
a
be installed.
iv
o
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rp
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en
ng
t.
yi Co
Note t. Cop py
rig
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yri by
If a flushed refrigerant circuit is not reassembled immediately after
op Vo
by c lksw
flushing, the adapters must be left on the connections. These as
cted agen
Prote AG.
well as components that are still open must be sealed with clean
bungs from engine bung set - VAS 6122- .
On successful completion of flushing procedure, remove all

adapters and renew following components during assembly
♦ Air conditioner compressor (only after renewal of air condi‐
tioner compressor due to internal damage)
♦ Restrictor and expansion valve
♦ Desiccant bag and desiccant cartridge
♦ Evacuating and charging valve, high-pressure side and low-
pressure side
♦ Oil seals
Ameo 2017 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/34-
♦ Adapter - VAS 6338/12-
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 72

Arteon 2018 ▶
compressor
or
Atlas 2017 ▶
Flushing adapter refrigerant lines to Flushing adapter expansion valve Sealing adapter and flushing adapt‐
air conditioner compressor er for vehicles with second evapo‐
rator
Low-pressure side ♦ Adapter - VAS 6338/38- agen Low-pressure
AG. Volkswagen AGside
does of front refriger‐
♦ Adapter - VAS 6338/12- olksw ant circuit
not
or d by
V
♦ Sealing adapter
gu
- VASara 6338/63-
High-pressure side ♦ Drilled ise
out expansion
r valve nte
ho eo
♦ Adapter - VAS 6338/3- ⇒ spage
aut
72 High-pressure side of front refriger‐
ra
c
s ant circuit
Rear refrigerant circuit
ce
e
♦ Sealing adapter - VAS 6338/5-

nl
pt
du
♦ Drilled out expansion valve
an
itte
y li
⇒ page 72 Low-pressure side to second evap‐
erm
ab
orator
ility
ot p
wit
, is n
h re
High-pressure side to second evap‐
hole
spec
orator
es, in part or in w
t to the co
rrectness of i
Beetle 1999 ▶; Beetle Cabriolet 2003 ▶
l purpos
Flushing adapter refrigerant lines to Flushing adapter expansion valve Other adapters
air conditioner compressor
nf
ercia
orm
Low-pressure side ♦ Adapter - VAS 6338/19- Bridge removed refrigerant lines on
m
atio
m
♦ Adapter - VAS 6338/7- condenser

o
or
n in
c
♦ Adapter - VAS 6338/2- , qty. 2

or
High-pressure side ♦ Drilled out expansion valve thi

te
sd
a
♦ Adapter - VAS 6338/2- ⇒ page 72 ♦ Hose - VAS 6338/31-

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Beetle 2012 ▶; Beetle Cabriolet 2013 ▶
gh ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
compressor
or

Bora 1999 ▶
or ♦ Adapter - VAS 6338/2- , qty. 2
High-pressure side ♦ Drilled out expansion valve
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
CC 2009 ▶ utho eo
ra
s a c
s
ce
e
nl
pt
compressor
du
an
itte
y li
erm
ab
ility
ot p
or
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
e-Golf 2014 ▶
rrectness of i
l purpos
compressor
nform
ercia

or
m
at
om
ion
c
in t
or
his
ate
do
priv
c
♦ Adapter - VAS 6338/40- and adapter - VAS
um
for
6338/41- en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
e-Golf 2014 ▶ with heat pump Prote AG.
Flushing adapter refriger‐ Flushing adapter expan‐ Other adapters Miscellaneous

ant lines to air conditioner sion valve
compressor
Low-pressure side Install adapter
– - VAS Bridge removed
– refrig‐ Start “Basic
– setting” in
♦ Adapter - VAS 6338/38- in place of ex‐ erant lines on condens‐ ⇒ Vehicle diagnostic
6338/12- connected to pansion valve (or a dril‐ er tester, and start the
air conditioner service led out expansion valve ♦ Adapter - VAS function “Charge refrig‐
station and adapter - ⇒ page 72 ) 6338/6- , qty. 2 erant circuit”.
VAS 6338/48- . ♦ This will open the elec‐
After flushing,
– install a ♦ Hose - VAS 6338/31- trical valves in the re‐
High-pressure side new expansion valve. frigerant circuit.
♦ Adapter - VAS 6338/3- After purging,
– install a
new reservoir (dryer). ♦ The function is active
Purging electrical air con‐ and must not be termi‐
ditioner compressor nated until purging of
♦ Adapter - VAS the refrigerant circuit
6338/40- and adapter - has been completed.
VAS 6338/41-
♦ Leave ⇒ Vehicle diag‐
Adapter - VAS 6338/48- to nostic tester connected
air conditioner service sta‐ to keep the valves
tion Observe notes: open.
⇒ page 83

Eos 2006 ▶
compressor
or
Fox 2005 ▶
compressor
or
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
Golf 1992; Vento 1992; Passat 1994s au ra
c
s
ce
le
un
pt
an
d

itte
y li
erm
ab
♦ Adapter - VAS 6338/14- ♦ Adapter - VAS 6338/19- Bridge removed refrigerant lines on
ility
ot p
condenser
wit
is n
or ♦ Adapter - VAS 6338/28- and
h re
ole,
adapter - VAS 6338/29-
spec
⇒ page 72
t to the co
Golf 1998 … 2003; Golf Variant 1998 … 2003; Golf Cabriolet 1998 rrectne
… 2002; Vento 1993 … 1999
ss
o
cial p

inform
mer

atio
m

o
or
c
♦ Adapter - VAS 6338/2- , qty. 2

i
or

thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
Golf 2013 ▶, Golf Estate 2014 ▶, Golf 2017 ▶; Golf Estate 2017 ▶
rig ht
py by
co Vo
by lksw
cted agen
Flushing adapter refrigerant lines to air conditioner Prote Flushing adapter expansion valve
AG.
compressor
Low-pressure side ♦ Adapter - VAS 6338/18- or adapter - VAS 6338/38-
or

Golf 2004 ▶; Golf Estate 2004 ▶; Golf Cabriolet 2012 ▶; Golf Plus
2005 … 2014; Golf SV 2014 ▶; Golf 2014 (NAR)
compressor
or
High-pressure side. Volkswag ♦ Drilled out expansion valve ⇒ page 72
♦ Adapter - VAS 6338/3- kswagen AG en AG
does
ol not
yV gu
edb ara
ris nte
tho eo
s au ra
c
Golf MEX 2018s ▶
ce
e
nl
pt
du
an
itte
y li
erm
compressor
ab
ility
ot p
wit
, is n
h re
or
hole
spec
es, in part or in w
t to the co
rrectness of i
Golf GTE 2014
l purpos
nf
ercia
Low-pressure side ♦ Adapter - VAS 6338/38- Renew shut-off valves -N541- and - orm
m
atio
m
♦ Adapter - VAS 6338/12- N542-

o
n in
or
c
♦ Shut-off tap - VAS 6338/42- ,

or

thi
qty. 2
te
sd
a
♦ Adapter - VAS 6338/3- ⇒ page 72

iv
o
r
rp
cu
Remove restrictor in refrigerant line

o
Electrical air conditioner compres‐

f
to heat exchanger for high-voltage

en
ng
t.
sor
yi
battery and drill it out
Co
op py
♦ Adapter - VAS 6338/40- and t. C rig
gh ht
adapter - VAS 6338/41- yri
p by
o Vo
by c lksw
cted agen
Prote AG.
Jetta 2005 … 2012

compressor
or
Jetta 2013 … 2014

compressor
or

Jetta 2015 ▶
compressor
or
Lupo 1999 ▶, up to VIN 70000

High-pressure side ♦ Drilled out expansion valve adapter - VAS 6338/29-
♦ Adapter - VAS 6338/2- ⇒ page 72
Lupo 1999 ▶, from VIN 70001

G. Volkswagen AG d
Flushing adapter refrigerant lines to Flushing adapter expansion valve
ksw
agen
A
Other adapters
oes
not
air conditioner compressor y Vol gu
b d ara
ise nte
tho
r Bridge removed refrigerant lines e o on
♦ Adapter - VAS 6338/12- sa
u
condenser ra
c
ors ♦ Adapter - VAS 6338/28- and
ce
le

un
pt
an
d
♦ Adapter - VAS 6338/2- and ⇒ page 72

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Passat 1997… 09/2000
es, in part or in w
t to the co
Flushing adapter refrigerant lines to air conditioner Other adapters and work steps
compressor
rrectness of i
Low-pressure side Bridge removed refrigerant lines on condenser
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/9- and adapter - VAS 6338/10-
l purpos
High-pressure side ♦ Hose - VAS 6338/31-

nform
ercia
Remove restrictor and seal refrigerant lines again

m
a
com
tion in
r
te o
Passat 10/2000 … 12/2000

thi
s
iva
do
r
rp
um
fo
compressor
en
ng
t.
yi Co
op
C py
t. rig
gh
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/10- , qty. 2
ht
pyri by
Vo
o
by c lksw
cted
High-pressure side ♦ Hose - VAS 6338/31-
agen
Prote AG.
Remove restrictor and seal refrigerant lines again

Passat 2001 … 2005

compressor
♦ Adapter - VAS 6338/12- AG. Volkswagen AG d
lksw
agen or oes
not
High-pressure side d by
Vo
♦ Drilled out expansiongu
ara valve ⇒ page 72
♦ Adapter - VAS 6338/3- rise nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
Passat 2006 … 2014
y li
rm
ab
pe
ility
ot
wit
compressor
, is n
h re
hole
spec
es, in part or in w
or
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
a
com
tio
In the Passat 2015 and Passat Estate 2015 with bi-turbo engine,
n in
the refrigerant circuit is not flushed. In these vehicles, it would
r
te o
thi
require too much effort to remove the expansion valve. If the air
s
iva
do
conditioner compressor is defective, check whether swarf has
r
rp
cum
fo
entered the condenser or whether there is swarf in the condenser
en
ng
t.
outlet. If there is only swarf on the inlet side but not on the outlet
yi Co
op
side, renew only the condenser and the air conditioner compres‐
C py
t. rig
gh
sor.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Passat 2015 ▶; Passat Estate 2015 ▶; Passat GTE 2015 ▶; Pas‐
sat (NMS-US) 2016 ▶
compressor
Low-pressure side ♦ Adapter - VAS 6338/18- , adapter - VAS 6338/38-
♦ Adapter - VAS 6338/12- or adapter - VAS 6338/74-
High-pressure side or
♦ Adapter - VAS 6338/3- ♦ Drilled out expansion valve ⇒ page 72
Phaeton 2003 ▶
compressor
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/6- , qty. 2
High-pressure side on 6-cylinder petrol engine, 8- and ♦ Hose - VAS 6338/31-
12-cylinder diesel engine
♦ Adapter - VAS 6338/2- Remove restrictor and– seal refrigerant lines again.
High-pressure side on 6- and 10-cylinder diesel engine


Polo 1995 … 2001, up to VIN 50000

♦ Adapter - VAS 6338/14- ♦ Adapter - VAS 6338/19- Bridge removed refrigerant lines on
condenser
♦ Drilled out expansion valve en AG. Volkadapter - VAS
does 6338/29-
swagen AG
⇒ page 72 olkswag not
yV gu
db ara
ir se nte
ho eo
aut ra
ss c
Polo 1995 … 2001, from VIN 50001
ce
e
nl
pt
du
an
itte
y li
erm
ab
compressor
ility
ot p
wit
, is n
h re
hole
or
spec
es, in part or in w
t to the co
rrectness of i
Polo 2002 … 2009
l purpos
nform
ercia
compressor
m
at
om
io
n
c
or
in t
or
his
e

at
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Polo 2010 … 2013
p by
co Vo
by lksw
cted agen
Prote
AG.
compressor
or
Polo IND 2010 ▶; Polo RUS 2011 ▶; Polo MY 2014 ▶

compressor
or

Polo 2014 … 2017

compressor
or
Polo 2018 ▶
compressor
or
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Scirocco 2009 oris▶
e nte
eo
th
au ra
Flushing
s adapter refrigerant lines to air conditioner
s c Flushing adapter expansion valve
compressor
ce
e
nl
pt
du
an
itte

y li
erm
ab

ility
or
ot p

wit
, is n
h re

hole
spec
es, in part or in w
t to the co
Sharan 1996 … 2010

rrectness of i
Flushing adapter refriger‐ Flushing adapter expan‐ Sealing adapter and flush‐ Other adapters and work
l purpos
ant lines to air conditioner sion valve ing adapter for vehicles steps
compressor with second evaporator
nform
Low-pressure side ♦ Adapter - VAS ♦ Lower-pressure line for Remove – receiver and
ercia
♦ Adapter - VAS 6338/7- 6338/35- 2nd evaporator adapt‐ connect refrigerant

m
at
er - V.A.G 1785/7- pipes to adapter - VAS

om
io
High-pressure side or 6338/37- .

n
c
in t
♦ Adapter - VAS 6338/2- ♦ Drilled out expansion ♦ High-pressure line for

or
his
e
valve ⇒ page 72 2nd evaporator adapt‐

at
do
riv
er - V.A.G 1785/5-
p
cum
for
en
g
♦ Adapter - V.A.G
n
t.
yi Co
1785/3- with sealing
Cop py
t. rig
yri
gh by cap -VAS 6338/30- to
ht
seal front refrigerant
cop Vo
by lksw
circuit.
cted agen
Prote AG.
♦ Adapter - V.A.G
1785/1- with sealing
cap -VAS 6338/30- to
seal front refrigerant
circuit.

AG. Volkswagen AG d
Sharan 2011 ▶ agen oes
olksw not
byV gu
ara
d
Flushing adapter refrigerant lines to Flushing adapter expansionoris valve Sealing adapter and flushing adapt‐
e nte
eo
air conditioner compressor aut
h er for vehicles with second evapo‐ ra
ss rator c
ce
e
nl
pt
Low-pressure side Front refrigerant circuit Low-pressure side of front refriger‐
du
an
itte
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/18- ant circuit
y li
erm
ab
ility
ot p
♦ Adapter - VAS 6338/3- ♦ Drilled out expansion valve High-pressure side of front refriger‐
wit
, is n
h re
⇒ page 72 ant circuit
hole
spec
es, in part or in w
t to the co
♦ Adapter - VAS 6338/33- Low-pressure side to second evap‐
orator
or ♦ Adapter - VAS 6338/3-
rrectness of i
⇒ page 72 High-pressure side to second evap‐
orator
l purpos
nform
mercia
at
om
io
T-Cross 2019 ▶
n
c
in t
or
his
e
at
do
riv
compressor
p
cum
for
en
g

n
t.
yi Co
op
♦ Adapter - VAS 6338/12- C py
or
ht. rig
rig ht
py by
co Vo
by lksw
♦ Adapter - VAS 6338/3- Prote
cted AG.
agen
T-Roc 2018 ▶
compressor
or
Tiguan 2008 … 2015

compressor
or

en AG. V
olksR134a
wagen AG- General information - Edition 11.2019
ag does
ksw not
Vol gu
Tiguan 2016 ▶; Tiguan RUS 2017ed▶b y ara
nte
ris
ho eo
Flushing adapter refrigerantaut lines to air conditioner Flushing adapterra expansion valve
ss c
compressor
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
or
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Touareg 2003 … 2010, up to VIN 50000
rrectness of i
l purpos
rator
Low-pressure side ♦ Adapter - VAS 6338/17- Low-pressure side of front refriger‐
nform
ercia
♦ Adapter - VAS 6338/12- ant circuit

or ♦ Sealing adapter - VAS 6338/11-
m
a
com
tio
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 72 High-pressure side of front refriger‐
n in
r
te o
er - VAS 6338/3- ant circuit
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orator
cted agen
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Touareg 2003 … 2010, from VIN 50001

rator
Low-pressure side ♦ Adapter - VAS 6338/17- or Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- adapter - VAS 6338/33- ant circuit
♦ Adapter - VAS 6338/2- or adapt‐ ♦ Drilled out expansion valve High-pressure side of front refriger‐
er - VAS 6338/3- ⇒ page 72 ant circuit
orator
orator

Touareg 2010 … 2018; Touareg Hybrid 2010 ▶

rator
Low-pressure side ♦ Adapter - VAS 6338/17- or Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- adapter - VAS 6338/33- ant circuit
♦ Adapter - VAS 6338/2- or adapt‐ ♦ Drilled out expansion valve High-pressure side of front refriger‐
er - VAS 6338/3- ⇒ page 72 ant circuit
Electrical air conditioner compres‐
sor Low-pressure side to second evap‐
♦ Adapter - VAS 6338/40- and orator
adapter - VAS 6338/41- ♦ Adapter - VAS 6338/3-
orator
Touareg 2018 ▶
Flushing adapter refrigerant lines to air conditioner
olks
wage Flushing
es n adapter expansion
ot g
valve
compressor db
y V ua
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Low-pressure side tho ♦ Adapter - VAS 6338/44- or
♦ Adapter - VAS 6338/12- s au ac
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spec
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compressor
rrectness of i
Low-pressure side ♦ Adapter - VAS Receiver Start “Basic

– setting” in
♦ Adapter - VAS 6338/44- ♦ No adapter required. ⇒ Vehicle diagnostic
l purpos
6338/12- connected to Dryer is removed from tester, and start the

air conditioner service Or receiver on condenser, function “Charge refrig‐
♦ Drilled out expansion
nform
ercia
station and adapter - and opening is sealed erant circuit”.

VAS 6338/48- . valve ⇒ page 72 again afterwards. ♦ This will open the elec‐
m
at
trical valves in the re‐

om
io
High-pressure side ♦ After purging, install a

n
frigerant circuit.
c
in t
r
♦ Adapter - VAS 6338/3- new reservoir (dryer).

o
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♦ The function is active

at
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Shut-off valve and must not be termi‐

p
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or
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( refrigerant shut-off
n
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yi Co
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valve for heater and air
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cted
and shut-off valve - nostic tester connected
agen
Prote AG.
VAS 6338/42- is instal‐ to keep the valves
led instead open.
♦ Renew refrigerant
shut-off valve for heat‐
er and air conditioner
unit - N541- after flush‐
ing.

Touran 2003 … 2015

compressor
or
Touran 2016 ▶
compressor
or
up! 2012 ▶, e-up! 2014 ▶

compressor
or
♦ Adapter - VAS 6338/3- . Volkswagen AG
gen AG does
swa
Electrical air conditioner compressoryV
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♦ Adapter - VAS 6338/40- isedand adapter - VAS
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Prote AG.

11 Clearing refrigerant circuit of contaminants, commercial vehicles

⇒ “11.1 Vehicles with high-voltage system”, page 100

⇒ “11.2 Flushing refrigerant circuit with refrigerant R134a”,
page 101
⇒ “11.3 Adapters for setting up flushing circuits”, page 102
. Volkswagen AG
⇒ “11.4 Procedure for setting up and flushing refrigerant circuit, kswagen AG does
not
Amarok 2010 ►”, page 105 by
Vol gu
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⇒ “11.5 Procedure for setting up and flushing refrigerantthocircuit,
r eo
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Caddy 2004 ►”, page 110 ss
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⇒ “11.6 Procedure for setting up and flushing refrigerant circuit,

nl
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Crafter ►2017”, page 117
itte
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Crafter 2017 ► or MAN TGE ►, Crafter Grand California ►”, page
wit
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130
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Transporter 2016 ►, Transporter 2020 ►”, page 143
t to the co
11.1 Vehicles with high-voltage system
rrectness of i
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electric shock.
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voltage cables.
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ate
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system .
Note

♦ Chemical substances wused
agen for sealing leaks
AG. Volkswagen AG d in refrigerant cir‐
oe
cuits often react with Vol the surrounding air and theothumidity
ks sn
contained within. byThey cause deposits to build up gin rthe
an re‐
d ua
e
ris
frigerant circuit
tho (and your air conditioner service station),tee
or
valves to
ss
amalfunction
u
and defects in other components with ac
which they come into contact. These deposits cannot be com‐ ce
le
un

pt
an
d
The refrigerant circuit can only be repaired by replacing all

itte
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components that have come into contact with this substance.

ab
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• In order to remove dirt (e.g. abraded matter from a defective

rrectne
air conditioner compressor) as well as old refrigerant oil as

cleanly as possible and with as little work as possible, flush
s
the refrigerant circuit with R134a refrigerant.

s o
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11.2 Flushing refrigerant circuit with refrigerant R134a

nform
mer
atio

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n
c
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thi
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t
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pr
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t.
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saPro), section “Superstructures and modifications” for relevant C py
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Vo
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by
These can also be obtained from ABT e-Line. Prote
cted AG.
agen
The refrigerant circuit must be flushed with refrigerant R134a if

♦ Dirt or other contaminants are in the refrigerant circuit.
mally required for repairs (e.g. following an accident).
11. Clearing refrigerant circuit of contaminants, commercial vehicles 101

♦ Pressure and temperature measurements in the refrigerant

circuit indicate that there is moisture in the refrigerant circuit.
♦ There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit. If the air conditioner compressor is to be reinstal‐
led, drain refrigerant oil out of air conditioner compressor via gen AG
. Volkswagen AG
does
swa
the block connections. To facilitate this process, turn the air y Volk not
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conditioner compressor over by hand at the poly V-belt pulley risedb ara
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or coupling disc of the magnetic coupling. After purging, ufill tho eo
ra
refrigerant circuit with total amount of refrigerant oil (50 sgs direct
a c
into air conditioner compressor) according to ⇒ vehicle-spe‐
ce
le
un
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cific workshop manual . Take account of oil volume for
an
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of internal damage (e.g. noisy or lack of power).
is n
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♦ If it is required by the workshop manual for the specific vehicle ole,
spec
following the renewal of certain components.
t to the co
♦ a different air conditioner compressor with other refrigerant oil
is to be fitted.
rrectne
11.3 Adapters for setting up flushing circuits
s
– The desiccant bag and the desiccant cartridge must always
s o
be removed before any flushing routine. Then close the re‐
cial p
f in
ceiver again.
form
mer
– On condensers with a permanent dryer, this can be flushed
atio
m
along with the other components. A new condenser must then

o
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be installed.
thi
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Note
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flushing, the adapters must be left on the connections. These as op Vo
by c lksw
well as components that are still open must be sealed with clean cted agen
Prote AG.

♦ Air conditioner compressor
♦ Restrictor and expansion valve
♦ Desiccant bag and desiccant cartridge
pressure side
♦ Oil seals
Note
Only flushing adapters for the following commercial vehicles are

listed:
♦ Caddy 1996 … 2004 ⇒ page 103

♦ LT 2 from 1997 ⇒ page 103
♦ Transporter 1991 … 1995 ⇒ page 103
♦ Transporter model 7H 2004 … 2010 ⇒ page 104
♦ Transporter model 7J 2004 … 2010 ⇒ page 104


♦ e-Crafter 2019 ▶; e-TGE 2019 ▶ with heat pump
⇒ page 105
Note
All commercial vehicles listed here are described in separate

. Volkswagen AG
chapters: swa
gen AG does
k not
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d by ara
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♦ Amarok 2010 ► ⇒ page 105 ris nte
utho eo
ra
a
♦ Caddy 2004 ► ⇒ page 110 ss c
ce
le
un
pt
♦ Crafter ►2017 ⇒ page 117
an
d
itte
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♦ Crafter 2017 or MAN TGE ►, Crafter Grand California ►
erm
ab
ility
⇒ page 130
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♦ Transporter 2016 ▶, Transporter 2020 ▶ ⇒ page 143
h re
ole,
spec
Caddy 1996 … 2004
t to the co
rrectne
s
s
o
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f
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 72
inform
er - VAS 6338/14-
mer
atio
om
n
c
i
or
n thi
te
sd
a
LT 2 from 1997
iv
o
pr
cum
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fo
en
ng
t.
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Co
op py
rator
t. C rig
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pyri by
co Vo
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♦ Adapter - VAS 6338/7- Prote AG.
condenser
or ♦ Adapter - VAS 6338/29- , qty. 2
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 72 ♦ Hose - VAS 6338/31-
er - VAS 6338/20-
Transporter 1991 … 1995

Flushing adapter refriger‐ Flushing adapter expan‐ Sealing adapter and flush‐ Miscellaneous
ant lines to air conditioner sion valve ing adapter for vehicles
♦ Adapter - VAS ♦ Adapter - VAS ♦ Adapter - VAS Vehicles with auxiliary
6338/54- 6338/55- 6338/29- for receiver evaporator on roof
♦ Adapter - VAS
or ♦ Adapter - VAS 6338/51- and adapter -
♦ Drilled out expansion 6338/57- for refrigerant VAS 6338/52-
valve ⇒ page 72 line of 2nd Evaporator
♦ Adapter - VAS
6338/58- for refrigerant
line of 2nd Evaporator

Transporter 1996 … 2004

Flushing adapter refriger‐ Flushing adapter expan‐ Sealing adapter and flush‐ Miscellaneous
ant lines to air conditioner sion valve ing adapter for vehicles
Low-pressure side ♦ Adapter - VAS ♦ Adapter - VAS Vehicles with auxiliary
♦ Adapter - VAS 6338/7- 6338/55- 6338/29- for receiver evaporator on roof
♦ Adapter - VAS
High-pressure side or ♦ Adapter - VAS 6338/51- and adapter -
♦ Adapter - VAS 6338/2- ♦ Drilled out expansion 6338/57- for refrigerant VAS 6338/52-
valve ⇒ page 72 line of 2nd Evaporator
♦ Adapter - VAS
6338/58- for refrigerant
line of 2nd Evaporator
Transporter model 7H 2004 … 2010

rator
♦ Adapter - VAS 6338/7- or adapt‐ ♦ Adapter - VAS 6338/56- ant circuit
er - VAS 6338/12- ♦ Sealing adapter - VAS 6338/11-
or
High-pressure side ♦ Drilled out expansion valve High-pressure side of front refriger‐
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 72 ant circuit
er - VAS 6338/3- ♦ Sealing adapter - VAS 6338/5-
♦ Adapter - VAS 6338/33- Low-pressure side to second evap‐
orator
or ♦ Adapter - VAS 6338/3-
♦
n AGDrilled
. Volkswout
agenexpansion
AG do valve
lkswage ⇒ page 72 es n High-pressure side to second evap‐
Vo ot g
ed
by ua
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oris tee ♦ Adapter - VAS 6338/4-
th or
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Transporter model 7J 2004 … 2010

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♦ Adapter - VAS 6338/7- , adapter ♦ Adapter - VAS 6338/56- ant circuit

- VAS 6338/12- or adapter - VAS ♦ Sealing adapter - VAS 6338/11-
6338/52- or
rrectness of i
♦ Drilled out expansion valve High-pressure side of front refriger‐

High-pressure side ⇒ page 72 ant circuit
l purpos
♦ Adapter - VAS 6338/2- , adapter ♦ Sealing adapter - VAS 6338/5-

- VAS 6338/3- or adapter - VAS Rear refrigerant circuit
6338/51- ♦ Adapter - VAS 6338/56- Low-pressure side to second evap‐
nf
ercia
orator
or
or
m

m
atio

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n in
⇒ page 72 High-pressure side to second evap‐

or c
orator
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Prote AG.

Transporter 2010 … 2016, Transporter 2020 ▶

rator
Low-pressure side ♦ Adapter - VAS 6338/56- Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- ant circuit
or ♦ Sealing adapter - VAS 6338/11-
♦ Adapter - VAS 6338/3- ⇒ page 72 High-pressure side of front refriger‐
ant circuit
orator
orator
e-Crafter 2019 ▶; e-TGE 2019 ▶ with heat pump

compressor
Low-pressure side Use ⇒ Vehicle
– diagnos‐ Bridge removed refriger‐ Start function
– “Charge
♦ Adapter - VAS tic tester to perform ant lines on condenser refrigerant circuit” us‐
6338/12- function Charge re- ♦ Adapter - VAS ing ⇒ Vehicle diagnos‐
frigerant circuit . 6338/6- , qty. 2 tic tester.
High-pressure side
♦ Adapter - VAS 6338/3- ♦ Hose - VAS 6338/31- Leave ⇒– Vehicle diag‐
The function
– is active
Electrical air conditioner and must not be termi‐ nostic tester connected
compressor nated until purging of to keep the valves
♦ Adapter - VAS the refrigerant circuit open.
6338/40- and adapter - has been completed.
VAS 6338/41- AG. Volkswagen AG d
agen oes
olksw not
V gu
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11.4 Procedure for setting up and flushing re‐s a c
s
ce
le
frigerant circuit, Amarok 2010 ►

un
pt
an
d
itte
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⇒ “11.4.1 Connection diagram for flushing circuit”, page 105

erm
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ility
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⇒ “11.4.2 Procedure for setting up and flushing refrigerant circuit”,

wit
is n
page 106
h re
ole,
spec
11.4.1 Connection diagram for flushing circuit

t to the co
Note
rrectne
The following connection diagram was created for the 2.0 l common rail engine equipped for left-hand drive.
s
The connection diagram for other engines should be adapted accordingly.

s o
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f inform
mer
atio
om
n
c
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or
n thi
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105
op Vo
by c lksw
Prote
cted 11. Clearing refrigerant circuit of contaminants, commercial vehicles
AG.
agen
1 - Refrigerant lines
❑ Qty. 2
❑ High-pressure and low-
pressure side
2 - Expansion valve adapter -
VAS 6338/33-
❑ from adapter set for re‐
frigerant circuit - VAS
6338/50-
3 - Refrigerant line
❑ Low-pressure side
❑ High-pressure side
5 - Adapter - VAS 6338/3-
❑ from adapter set for re‐ AG. Volkswagen AG d
agen
frigerant circuit - VAS Volksw
oes
not
gu
6338/50- ed by ara
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6 - Refrigerant hose aut
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❑ from air conditioner
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7 - Adapter - VAS 6338/12-
wit
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6338/50-
es, in part or in w
t to the co
8 - Refrigerant hose
rrectness of i
service station
l purpos
nf
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orm
m
atio
m
11.4.2 Procedure for setting up and flushing re‐

o
n in
or c
frigerant circuit
thi
te
sd
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rp
cu

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f
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ng
t.
♦ Torque wrench - V.A.G 1410-
yi Co
Cop py
t. rig
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Vo
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by c lksw
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Prote AG.

♦ Engine bung set - VAS 6122-
♦ Adapter set for refrigerant circuit - VAS 6338/50-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ss c
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♦ Air conditioner service station , e.g. air conditioner service

nl
pt
du
an
station - VAS 6746A-

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♦ Drill bit, ∅ 6 mm
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
♦ The following procedure was created for the 2.0 l common rail
o
r
rp
cu
engine equipped for left-hand drive. The procedure for other

o
m
f
en
ng
engines should be adapted accordingly.

t.
yi Co
Cop py
♦ Flushing a contaminated refrigerant circuit is carried out
t. rig
gh ht
yri by
against the direction of normal flow.
cop Vo
by lksw
cted agen
Prote
♦ To install the individual flushing adapters, the original threaded
AG.
connections (nuts and bolts) are to be used and tightened to

the respective torque.

Setting up
Prepare air conditioner service station as follows
Air conditioner service station with integrated flushing device
– Unscrew quick-release fastener -1- on refrigerant hose on
high-pressure side (red) -2-.
– Unscrew quick-release fastener -1- on refrigerant hose on low-

pressure side (blue) -2-.
Air conditioner service station with external flushing device

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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nl
pt
du
an
itte
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ab
ility
ot p
wit
, is n
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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
108
Prote AG.
Rep. gr.00 - Technical data
– Connect coolant hose on low-pressure side (blue) -1- from air

conditioner service station to filter cartridge -3- of flushing de‐
vice using quick-release fastener -2-.
Note
The flushing procedure is carried out with the existing coolant

hose (blue) of the external flushing device.
Continuation for all

– Check quantity of refrigerant oil in refrigerant bottle via menu
of air conditioner service station .
• There must be at least 7 kg of R134a refrigerant.
– Remove expansion valve ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; Removing and installing expansion
valve .
– Install expansion valve adapter - VAS 6338/33- from adapter
set for refrigerant circuit - VAS 6338/50- .
– Connect refrigerant lines to expansion valve adapter - VAS
6338/33- .
– Remove desiccant bag ⇒ Heating, air conditioning system;
Rep. gr. 87 ; Refrigerant circuit; Removing and installing des‐
iccant bag/desiccant cartridge .
– Close receiver onwcondenser
agen
AG. Volksagain.
wagen AG
doe
ks s no
Vol t
– Remove air d b conditioner compressor ⇒ Heating,
y gu
arair
an condition‐
ing; Rep. risegr. 87 ; Air conditioner compressor; Removing
tee and
ho
aut
installing air conditioner compressor . or
a
s s c
ce
e
nl
pt
– Connect refrigerant line of air conditioner compressor on high-

du
an
itte
pressure side (smaller diameter) -1- to adapter - VAS 6338/3-

y li
erm
ab
-4-.
ility
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wit
– Connect refrigerant line of air conditioner compressor on low-

, is n
h re
pressure side (larger diameter) -2- to adapter - VAS 6338/12-

hole
-3-.
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.

– Connect refrigerant hose on low-pressure side (blue) -1- of air

conditioner service station to threaded connection of adapter
- VAS 6338/3- -2- of refrigerant line for air conditioner service
station on high-pressure side (smaller diameter) -3-.
– Connect refrigerant hose on high-pressure side (red) -6- of air
station on low-pressure side (larger diameter) -4-.
Flush
– Start flushing procedure via menu of air conditioner service
station .
Note

flushing, the adapters must be leftenon the
. Volconnections.
kswagen AG These as
g AG
well as components that areolkstillswaopen must be sealed with
does
not clean
bungs from engine bung ed bset
y V - VAS 6122- . gu
ara
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On successful of flushing procedure, remove all completion
ss
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c
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e
nl
pt
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itte
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erm
♦ Expansion valve ab
ility
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♦ Desiccant bag h re
hole

spec
es, in part or in w
pressure side
t to the co
♦ Oil seals
– Charge refrigerant circuit ⇒ page 54 .
rrectness of i
– Perform leakage test on reattached line connections of refrig‐

l purpos

– Bring air conditioning system into operation after charging re‐
nform
ercia
frigerant circuit ⇒ Heating, air conditioning; Rep. gr. 87 ;

m
Refrigerant circuit; Bringing air conditioning system into oper‐

at
om
ation after charging refrigerant circuit .

on
c
in t
or
his
ate
11.5 Procedure for setting up and flushing re‐

do
priv
cum
or
frigerant circuit, Caddy 2004 ►

f
en
ng
t.
yi Co
op
⇒ “11.5.1 Connection diagram for flushing circuit”, page 110
C py
t. rig
gh ht
yri by
⇒ “11.5.2 Procedure for setting up and flushing refrigerant circuit”,
cop Vo
by lksw
cted
page 111
agen
Prote AG.
11.5.1 Connection diagram for flushing circuit
Note
The following connection diagram was created for the 2.0 l com‐
mon rail engine equipped for left-hand drive. The connection
diagram for other engines should be adapted accordingly.

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Air conditioning systems with refrigerant R134a ris - General information - Edition 11.2019 tee
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5 - Adapter - VAS 6338/12- or com
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VAS 6338/18-
6338/1-
11.5.2 Procedure for setting up and flushing re‐

frigerant circuit

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♦ Engine bung set - VAS 6122- au
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♦ Adapter set for refrigerant circuit - VAS 6338/1- l purpos
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Air conditioning systems with refrigerants R134a - General information - Edition 11.2019
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Setting up
itte
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Note


valve .
set for refrigerant circuit - VAS 6338/1- . . Volkswagen AG
gen AG does
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Vehicles with Showa condenser
hole
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Note
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rrectness of i
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l purpos
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m
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t
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
ion in
installing air conditioner compressor .

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-1-.
-4-.


- VAS 6338/3- or adapter - VAS 6338/2- -2- of refrigerant line
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- VAS 6338/12- or adapter - VASu6338/7-
tho -5- of refrigerant line or
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11.6 Procedure agen

for
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olkswagen Aup
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es n
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⇒ “11.6.1uConnection
tho diagram for flushing circuit, vehicles
ee
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one evaporator”,
ss
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ce
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⇒ “11.6.2 Connection diagram for flushing circuit, vehicles with

un
pt
an
d
second evaporator”, page 118

itte
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ab
⇒ “11.6.3 Procedure for setting up and flushing refrigerant circuit,
ility
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vehicles with one evaporator”, page 119
wit
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ole,
spec
vehicles with second evaporator”, page 124
t to the co
11.6.1 Connection diagram for flushing circuit,
vehicles with one evaporator
rrectnes
Note
s o
cial p
f in
The following connection diagrams were created for the 2.0 l
form
mer
common rail engine equipped for left-hand drive. The connection
atio
m

o
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p
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t.
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⇒ Heating, air condi‐ Cop py
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tioning; Rep. gr. 87 ; yri
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ht
Refrigerant circuit; Re‐
op Vo
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cted agen
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expansion valve
service station
6338/50-
6338/50-
service station

8 - Adapter for connecting desiccant cartridge connection - VAS 6338/68-

9 - Condenser
❑ Assembly overview ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit; Assembly
overview - condenser
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11.6.2 Connection diagram for flushing circuit, ed
ris nte
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1 - Adapter for connecting ex‐
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rrectness of i
❑ For sealing front refrig‐
l purpos
erant circuit when rear

refrigerant circuit is be‐
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frigerant circuit
4 - Adapter for connecting ex‐
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❑ For sealing rear refriger‐
ant circuit when front re‐
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6338/50-
service station
❑ from adapter set for refrigerant circuit - VAS 6338/50-

❑ from air conditioner service station
11 - Adapter for connecting desiccant cartridge connection - VAS 6338/68-
12 - Condenser
❑ Assembly overview ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit; Assembly
overview - condenser
11.6.3 Procedure for setting up and flushing refrigerant circuit, vehicles with one
evaporator
Special tools and workshop

equipment required
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Note
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rrectness of i
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l purpos
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– Connect refrigerant lines to drilled out expansion valve -1-.
nform
ercia
– Remove desiccant cartridge ⇒ Heating, air conditioning sys‐

m
tem; Rep. gr. 87 ; Refrigerant circuit; Removing and installing

com
tion in
desiccant cartridge .
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– Close and secure desiccant cartridge connection on condens‐

er -1- using adapter for connecting desiccant cartridge con‐
nection - VAS 6338/68- -2-.
Vehicles with PR numbers 9AS or 9AP

-2-.
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Vehicles with PR number 2AB

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ercia

-2-.
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-2-.
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Continued for all vehicles
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for air conditioner service station on low-pressure side (larger
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♦ Expansion valve
♦ Desiccant cartridge
nform
mercia
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pressure side
on in
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agen
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Specified torques
♦ Refrigerant circuit; Assembly overview - expansion valve ⇒
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
cuit; Assembly overview - expansion valve
Component Torque setting

Bolt securing desiccant cartridge on condenser ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
frigerant circuit; Removing and installing desiccant
cartridge
11.6.4 Procedure for setting up and flushing refrigerant circuit, vehicles with sec‐
ond evaporator


equipment required
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or c
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pyri by
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♦ Adapter for connecting desiccant cartridge connection - VAS
6338/68-
♦ Adapter for connecting expansion valve - VAS 6338/69-

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Airs aconditioning
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s
ce
e
nl
pt
du
an
itte
y li
Note
erm
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ility
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♦ If the vehicle has a second evaporator, the rear refrigerant cir‐
wit
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cuit (roof air conditioning system) must be rinsed first.
h re
hole
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es, in part or in w
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nf
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Setting up
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or c
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t.
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Note


n AG. Volkswagen A
– Remove expansion valve with refrigerant olks
wcirculation
age solenoidG does no
valve - N43- ⇒ Heating, air conditioning by
V system; Rep. gr. 87 ; t gu
ara
ed
Refrigerant circuit of roof air conditioning
ris system; Evaporator; nte
ho eo
Removing and installing expansion
aut valve with refrigerant cir‐ ra
culation solenoid valve - N43- .
ss c
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nf
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m
atio
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circulation solenoid valve - N43- -1- as shown using ∅ 6 mm

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drill bit -3-.

or
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iv
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cted
– Connect refrigerant lines to drilled out expansion valve with
agen
Prote AG.
refrigerant circulation solenoid valve - N43- -1-.
valve .
– Attach and secure refrigerant lines of first refrigerant circuit to
adapter for connecting expansion valve - VAS 6338/69- .
– Remove desiccant cartridge ⇒ Heating, air conditioning sys‐
tem; Rep. gr. 87 ; Refrigerant circuit; Removing and installing
desiccant cartridge .

– Close and secure desiccant cartridge connection on condens‐

er -1- using adapter for connecting desiccant cartridge con‐
nection - VAS 6338/68- -2-.
Vehicles with PR numbers 9AS or 9AP

-2-.
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es, in part or in w
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nform
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Vehicles with PR number 2AB

ion in
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um
fo
en
ng
t.
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-2-.
Continued for all vehicles


for air conditioner service station on low-pressure side (larger
diameter) -1-.
Flush
– Start first flushing sequence via menu of air conditioner service
station .
AG. Volkswagen AG d
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au ra
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– Remove adapter for connecting expansion valve - VAS

wit
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h re
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– Connect refrigerant lines to drilled out expansion valve of first

es, in part or in w
t to the co
– Remove drilled out expansion valve with refrigerant circulation

solenoid valve - N43- ⇒ Heating, air conditioning system; Rep.
rrectness of i
gr. 87 ; Refrigerant circuit of roof air conditioning system;

Evaporator; Removing and installing expansion valve with re‐
l purpos
frigerant circulation solenoid valve - N43- .

nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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ht. rig
rig ht
by
129
copy Vo
by lksw
agen
Prote AG.
– Attach and secure refrigerant lines -1- to adapter for connect‐

ing expansion valve - VAS 6338/69- -2-.
– Start second flushing sequence via menu of air conditioner
service station .
Note


♦ Expansion valve
♦ Expansion valve with refrigerant circulation solenoid valve -
N43-
♦ Desiccant cartridge
pressure side gen AG
. Volkswagen AG
d wa oes
olks not
♦ Oil seals byV gu
ara
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ris
– Charge refrigerant
tho circuit ⇒ page 54 . eo
au ra
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un
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ility
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wit
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Specified torques
t to the co
♦ Refrigerant circuit; Assembly overview - expansion valve ⇒

Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
cuit; Assembly overview - expansion valve
rrectne
Component Torque setting

ss o
Bolt securing desiccant cartridge on condenser ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
cial p
f in
frigerant circuit; Removing and installing desiccant

form
mer
cartridge
atio
m
Bolts securing expansion valve on refrigerant circula‐ ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
o
n
c
tion solenoid valve - N43- frigerant circuit of roof air conditioning system; Evap‐
or
n thi
e
orator; Removing and installing expansion valve with

t
sd
iva
refrigerant circulation solenoid valve - N43-

pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
11.7 Procedure for setting up and flushing re‐

rig ht
py by
co Vo
by lksw
frigerant circuit, Crafter 2017 ► or MAN
cted agen
Prote AG.
TGE ►, Crafter Grand California ►
Note
If the vehicle has a second evaporator, the rear refrigerant circuit

(roof air conditioning system) must be rinsed first ⇒ page 136 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Amarok oris 2011 ➤ , Amarok 2017 ➤ , Ameo 2017
e nt➤
ee , Arteon 2018 ➤ , Atlas 2 ...
h
Air conditioning
aut systems with refrigerant R134a - General information or
ac - Edition 11.2019
ss
ce
le
un
pt
an
d
one evaporator”, page 131
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
vehicles with one evaporator
ss o
cial p
f inform
Note
mer
atio
om
n
c
i
or
n
thi
te
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a

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o
pr
cum
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en
ng
t.
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op
C py
t. rig
gh ht
yri
❑ Low-pressure side p by
o Vo
by c lksw
cted agen
2 - Refrigerant line Prote AG.
VAS 6338/38-
4 - Adapter for refrigerant cir‐
cuit on low-pressure side - air
conditioner service station -
VAS 6338/12-
6338/50-
service station
service station
cuit on high-pressure side - air
conditioner service station -
VAS 6338/3-
6338/50-


vehicles with second evaporator AG. Volkswagen AG d
agen oes
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Note rise nte
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The following connection diagrams were created for the 2.0 l s
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pt
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ility
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❑ Removing and installing es, in part or in w
⇒ Heating, air condi‐
t to the co
tioning; Rep. gr. 87 ;
Refrigerant circuit; Re‐
moving and installing
rrectness of i
expansion valve
l purpos
❑ Qty. 2
nf
ercia
orm
pressure side of rear re‐
m
atio
m
frigerant circuit
o
n in
or c
thi
te
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iva
o
r
rp
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o
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op
C py
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5 - Adapter for connecting re‐ cop Vo
by lksw
frigerant circuit on high-pres‐
cted agen
Prote AG.
sure side - VAS 6338/63-
❑ Only on vehicles with
second evaporator
❑ For connecting front re‐
frigerant circuit on high-
pressure side when this
is to be flushed on vehi‐
cles with second evapo‐
rator
service station
8 - Adapter for connecting refrigerant circuit on low-pressure side - VAS 6338/5-
❑ Only on vehicles with second evaporator
❑ For connecting front refrigerant circuit on low-pressure side when this is to be flushed
9 - Adapter for refrigerant circuit on low-pressure side - air conditioner service station - VAS 6338/3-
10 - Adapter for refrigerant circuit on high-pressure side - air conditioner service station, low-pressure side -
VAS 6338/60-
11 - Adapter for refrigerant circuit on low-pressure side - air conditioner service station - VAS 6338/12-

12 - Adapter for refrigerant circuit on high-pressure side - air conditioner service station - VAS 6338/3-
13 - Expansion valve adapter - VAS 6338/38-
AG. Volkswagen AG d
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11.7.3 Procedure for setting up and flushing refrigerant circuit, vehicles with one by ara
d
rise nte
o
evaporator th eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
equipment required
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Expansion valve adapter - VAS 6338/38-

Note
Setting up
– Unscrew quick-release fastener -1- on refrigerant hoseolks
on
wage es n
ot g
high-pressure side (red) -2-. db
y V ua
ran
e
ris tee
tho or
au ac
ss
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
– Unscrew quick-release fastener -1- on refrigerant hose on rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Note


valve .
– Install expansion valve adapter - VAS 6338/38- .
6338/38- . n AG. Volkswagen A ge G do
swa es
– Remove desiccant bag y V ⇒ Heating, air conditioning system;
olk not
gu
edb
Rep. gr. 87 ; Refrigerant circuit; Removing and installing
ara
des‐
ris nte
iccant bag/desiccant
utho cartridge . eo
r a ac
ss
ce
le
un
pt
an

d
itte
y li

erm
ab

ility
ot p
wit
is n
h re

ole,
spec

-1-.
t to the co

rrectne
-4-.
ss 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.


Flush
station .
Note n AG. Volkswagen AG do

lkswage es n
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yV
ir se
d b ua
ran
flushing, the adapters must be left on the connections. These tho as tee
or
well as components that are still open must be sealed withss
au
clean ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
♦ Expansion valve
spec
es, in part or in w
♦ Desiccant bag
t to the co
pressure side
rrectness of i
♦ Oil seals
l purpos
nform
ercia

m
at
om
io
n
c
in t
or
his
te

a
do
riv

p
cum
for
en
ng
Specified torques
t.
yi Co
Cop py
t. rig
♦ Refrigerant circuit; Assembly overview - refrigerant lines ⇒ yri
gh by
ht
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; As‐ cop Vo
by lksw
sembly overview - refrigerant lines
cted agen
Prote AG.
♦ Air conditioner compressor; Assembly overview - drive unit for

air conditioner compressor ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor; Assembly overview - drive
unit for air conditioner compressor
♦ Front heater and air conditioning unit; Assembly overview -
evaporator housing ⇒ Heating, air conditioning; Rep. gr. 87 ;
Front heater and air conditioning unit; Assembly overview -
evaporator housing
ond evaporator


equipment required
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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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.

♦ Expansion valve adapter - VAS 6338/38-
♦ Adapter for refrigerant circuit on high-pressure side - air con‐
ditioner service station, low-pressure side - VAS 6338/60-
♦ Adapter for connecting refrigerant circuit on high-pressure
side - VAS 6338/63-

Note
♦ If the vehicle has a second evaporator, the rear refrigerant cir‐

cuit (roof air conditioning system) must be rinsed first.
G. Volkswagen AG d
lksw
agen
A
oes
o not
yV gu
db ara
the respective torque. rise nte
ho eo
aut ra
ss c
Setting up
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.


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
Amarok 2011 ➤ , Amarok 2017 aut ➤ , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2o...
h
ra
s c
s R134a - General information - Edition 11.2019
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
nform
• ercia
There must be at least 7 kg of R134a refrigerant.
m
a
com
tio
– Remove expansion valve for air conditioner refrigerant - N697-
n in
r
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
te o
thi
Removing and installing expansion valve .
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.

– Drill out expansion valve for air conditioner refrigerant - N697-

-1- as shown using ∅ 6 mm drill bit -3-.
– Clean drilled out expansion valve for air conditioner refrigerant
- N697- -1- of dirt.
– Install drilled out expansion valve for air conditioner refrigerant
- N697- -1-.
– Connect refrigerant lines to drilled out expansion valve for air
conditioner refrigerant - N697- -1-.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
Note
When unclipping and detaching hydraulic line, be aware of slave

cylinder.
– Undo nuts -1-.

– Disconnect refrigerant lines -2- and -3-.

– Connect refrigerant line on low-pressure side (larger diameter)

-4- to adapter - VAS 6338/3- -3-.
– Connect refrigerant line on high-pressure side (smaller diam‐
eter) -1- to refrigerant circuit adapter high-pressure side - air
conditioner service station low-pressure side - VAS 6338/60-
-2-.

conditioner service station to threaded connection of refriger‐
ant circuit adapter high-pressure side - air conditioner service
station low-pressure side - VAS 6338/60- -2- of refrigerant line
for air conditioner service station on high-pressure side (small‐
er diameter) -1-. agen
AG. Volkswagen AG d
oe
w s no
olks t gu
Flush ed
byV ara
ris nte
– Start first flushing sequence via menu thoof air conditioner service eo
au ra
station . ss c
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
– Remove adapter - VAS 6338/3- and refrigerant circuit adapter
high-pressure side - air conditioner service station low-pres‐
rrectne
sure side - VAS 6338/60- .

ss
– Connect refrigerant line low-pressure side (larger diameter)

o
cial p
-1- to adapter - VAS 6338/5- -2- and nut -3-.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Connect refrigerant line high-pressure side (smaller diameter)

-1- to refrigerant circuit adapter high-pressure side - VAS
6338/63- -2- and nut -3-.
valve .
– Install expansion valve adapter - VAS 6338/38- .
6338/38- .

-1-.
– Connect refrigerant line gofenair
AGconditioner
. Volkswagen Acompressor
G do on low-
pressure side (larger
Volksdiameter)
wa -3- to adapter e-s VAS
not 6338/12-
-4-. ed
by gu
ara
ris nte
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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.


conditioner service station to threaded
en AG. V connection
olkswagen AG of adapter
- VAS 6338/3- -2- of refrigerant
lkswagline for
does
air conditioner service
not
Vo gu
station on high-pressure
ed by side (smaller diameter) -3-. ara
n
is tee
or
– Connect refrigerant
au hose on high-pressure side (red) -6- of air
th or
ac
ss
ce
le

un
pt
an
d
itte
y li
rm
ab
Flush
pe
ility
ot
wit
, is n
h re
service station .
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
♦ Expansion valve
do
r
rp
cum
fo
♦ Expansion valve for air conditioner refrigerant - N697- ,

en
ng
t.
yi Co
op
♦ Desiccant bag C py
t. rig
gh ht
yri by
♦ Evacuating and charging valve, high-pressure side and low- cop Vo
by lksw
pressure side cted agen
Prote AG.
♦ Oil seals
– Check for damage and note correct installation of hydraulic
line of slave cylinder.
Specified torques
♦ Refrigerant circuit; Assembly overview - refrigerant lines ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; As‐
sembly overview - refrigerant lines
♦ Front heater and air conditioning unit; Assembly overview -
evaporator housing ⇒ Heating, air conditioning; Rep. gr. 87 ;
Front heater and air conditioning unit; Assembly overview -
evaporator housing

11.8 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►,
Transporter 2020 ►

one evaporator”, page 143
11.8.1 Connection diagram for flushing circuit, vehicles with one evaporator
e-Line, or may have to be supplemented by additional repair in‐ . Volkswage
structions from ABT e-Line. ksw
agen
AG n AG d
oes
n ol ot g
yV
Please refer to the Electronic Service Information ed System (El‐
b ua
ran
ris
saPro), section “Superstructures and modifications”
ho for relevant tee
ut or
repair manuals regarding modifications byss aABT e-Line. ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Note
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
o
by c lksw
cted agen
Prote AG.

VAS 6338/56-
6338/50-
6338/50-
5 - Adapter - VAS 6338/12-
6338/50-
service station
service station
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
11.8.2 Connection diagram for flushing circuit, vehicles with second evaporator
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p

wit
is n

h re
ole,
spec

t to the co

rrectness o
cial p
f inform
mer
atio
Note
om
n
c
i
or

thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

❑ Removing and installing
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ;
Refrigerant circuit; Re‐ n AG. Volkswagen AG do
swage es n
moving and installing byV
olk ot g
ua
expansion valve ir se
d ran
te
tho eo
4 - Adapter for connecting ss
aure‐ ra
c
frigerant circuit on high-pres‐
ce
e
nl
sure side - VAS 6338/63-
pt
du
an
itte
y li
erm
ab
cuit on high-pressure side - air
ility
ot p
conditioner service station,
wit
, is n
low-pressure side - VAS
h re
hole
6338/60-
spec
es, in part or in w
t to the co
rrectness of i
service station
l purpos

VAS 6338/56-
nf
ercia
or
m
m
atio
6338/50-
om
n in
or c
8 - Adapter - VAS 6338/12-

thi
te
sd
iva

o
r
rp
cu

o
m
f
en
ng
6338/50-
t.
yi Co
Cop py
t. rig
gh ht
yri by
❑ from adapter set for refrigerant circuit - VAS 6338/50- cop Vo
by lksw
cted agen
Prote AG.
11 - Adapter for refrigerant circuit on low-pressure side - air conditioner service station, high-pressure side -
VAS 6338/61-
12 - Adapter for connecting refrigerant circuit on low-pressure side - VAS 6338/62-
13 - Connecting adapter angle piece - VAS 6338/64-
11.8.3 Procedure for setting up and flushing refrigerant circuit, vehicles with one
evaporator

lkswage es n
o ot g
byV ua
d ran
ir se
Amarok 2011 ➤th, Amarok 2017 ➤ , Ameo 2017 ➤ , Arteon 2018
o tee
or ➤ , Atlas 2 ...
u
Air conditioning
ss systems with refrigerant R134a - General information
a ac
- Edition 11.2019
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
equipment required
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.

♦ Connecting adapter angle piece - VAS 6338/64-

Air conditioning systems
wage
n AG. with refrigerant
Volkswagen AG
doe R134a - General information - Edition 11.2019
ks s no
Vol t gu
d by ara
e nte
ris
tho eo
Note au ra
c
ss
ce
le
♦ The following procedure was created for the 2.0 l common railun
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Setting up
ss 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


wage
– Remove expansion valve ⇒ Heating, air conditioning; yV
olks Rep. es n
ot g
gr. 87 ; Refrigerant circuit; Removing and installing
ir se
d b expansion ua
ran
valve . tho tee
or
au ac
s
s
ce
le

un
pt
an
d
itte
y li
erm
ab
6338/56- .
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss
o
cial p
f i
nform
-2-.
mer
atio
m

o
n
c
i
or
n thi
e
-4-.
t
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.


Flush
– Start flushing procedure via menu ofAG
air conditioner
. Volkswagen AG service
agen does
station . Volksw not
g y ua
db ran
rise tee
tho or
Note ss au ac
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
♦ Expansion valve
rrectness of i
♦ Desiccant bag
l purpos

pressure side
nf
ercia
♦ Oil seals orm

m
atio
m

o
n in
or c
thi
e

t
sd
iva

o
r
rp
cu
o
m
f
en
ng

t.
yi Co
frigerant circuit ⇒ Heating, air conditioning; Rep. gr. 87 ; t. Cop py
rig
gh ht
yri by
ation after charging refrigerant circuit . cop Vo
by lksw
cted agen
Prote
Specified torques
AG.

ond evaporator


equipment required
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
♦ Adapter for refrigerant circuit on high-pressure side - air con‐

ditioner service station, low-pressure side - VAS 6338/60-
nform
ercia
♦ Adapter for refrigerant circuit on low-pressure side - air con‐

m
a
com
ti
ditioner service station, high-pressure side - VAS 6338/61-

on in
r
te o
thi
♦ Adapter for connecting refrigerant circuit on low-pressure side

s
iva
- VAS 6338/62-
do
r
rp
cum
fo
♦ Adapter for connecting refrigerant circuit on high-pressure

en
ng
t.
yi
side - VAS 6338/63-
Co
Cop py
t. rig
gh
♦ Connecting adapter angle piece - VAS 6338/64-
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
Setting up
Volkswa
Air conditioner service
swa station with integrated
gen AG
. gen AG
does flushing device
olk not
yV g
– Unscrew ise
d bquick-release fastener -1- on refrigerant
ua
ran hose on
high-pressure
tho
r side (red) -2-. tee
or
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
AG.


Note


• There must be at least 7 kg ofG.R134a
Volkswagrefrigerant.
e nA n AG d
wage oe
– Remove expansion y V valve ⇒ Heating, air conditioning;
olks s no
t gu Rep.
gr. 87 ; Refrigerant
ised b circuit; Removing and installing expansion
ara
nte
valve . ut
hor eo
ra
sa c
– Install expansion
s valve adapter - VAS 6338/56- from adapter
ce
le

un
pt
an
d
itte
y li
rm
ab
6338/56- .
pe
ility
ot
wit
, is n

Rep. gr. 87 ; Refrigerant circuit; Removing and installing des‐ h re
hole
spec
es, in part or in w
t to the co

– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
rrectness of i
– Remove right headlight ⇒ Electrical system; Rep. gr. 94 ;

l purpos
Headlights; Removing and installing headlights .

– Disconnect refrigerant line in area of angle piece.
nform
mercia
a
com
– Install connecting adapter angle piece - VAS 6338/64- -3- on

ion in
nuts -1- and refrigerant lines -2-.

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.
– Disconnect refrigerant lines on high-pressure side (smaller di‐

ameter) -1- and -5-.
– Connect refrigerant lines high-pressure side (smaller diame‐
ter) -1- to refrigerant circuit adapter high-pressure side - VAS
6338/63- -2- and nut -4-.
– Connect refrigerant lines on high-pressure side (smaller di‐
ameter) -5- to refrigerant circuit adapter high-pressure side -
air conditioner service station low-pressure side - VAS
6338/60- -3- and nut -4-.


pressure side (smaller diameter) -1- to adapter
agen
AG-. VAS
Volksw6338/3-
agen AG
does
-2-. Volksw not
g by ua
ed ran
– Connect refrigerant line of airhoconditioner
ris compressor on low- tee
pressure side (larger diameter)
aut -3- to adapter - VAS 6338/12- or
ac
-4-. ss
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
ercia

m
at
om
io
n
c
in t
or
his
ate
do
riv

p
cum
for
en
g

n
t.
yi Co
station on low-pressure side (larger diameter) -3-. Cop py
ht. rig
rig ht
Flush
py by
co Vo
by lksw
cted agen
– Start first flushing sequence via menu of air conditioner service
Prote AG.
station .
Note

– Connect refrigerant line low-pressure side (larger diameter)

-1- to refrigerant circuit adapter low-pressure side - VAS
6338/62- -2- and nut -3-.
– Connect refrigerant line on low-pressure side (larger diameter)
-1- to refrigerant circuit adapter low-pressure side - air condi‐
tioner service station high-pressure side - VAS 6338/61- -4-
and nut -5-.
ant circuit adapter low-pressure side - air conditioner service
station high-pressure side - VAS 6338/61- -4- of refrigerant
line for air conditioner service station on low-pressure side
(larger diameter) -1-.

Note
Disregard items 1, 2 and 4.

ant circuit adapter high-pressure side - air conditioner service
station low-pressure side - VAS 6338/60- -3- of refrigerant line
on high-pressure side (smaller diameter) -5-.
– Remove rear expansion valve ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; Removing and installing ex‐
pansion valve .
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.

Note
olkswagen AG
en AG. V
– Drill out expansion valve -1- as shown using ∅ol6 mm
ksw
ag bit -3-. does
not
V gu
by ara
– Clean drilled out expansion valve -1- of rdirt.
ise
d
nte
ho eo
ut
– Install drilled out expansion valve -1-.
ss
a ra
c
ce
le
– Connect refrigerant lines to drilled out expansion valve -1-.

un
pt
an
d
itte
y li
Flush
erm
ab
ility
ot p
wit
is n
service station .
h re
ole,
spec
Note
t to the co
rrectne
ss o
cial p
f in
form
mer
atio
m

o
n
c
i
or
n thi
♦ Front expansion valve
te
sd
iva
o
pr
c
♦ Rear expansion valve
um
r
fo
en
ng
t.
♦ Desiccant bag
yi Co
Cop py
t. rig
gh ht
yri by
pressure side
cop Vo
by lksw
cted agen
Prote AG.
♦ Oil seals
Specified torques

12 Complaints
12.1 Possible complaints about refrigerant

circuit G. Volkswage
A n AG d
agen oes
olksw not
yV gu
db ara
Note rise nte
tho eo
s au ra
c
♦ The air conditioning
s system is operating
correctly if the air
ce
le
emerging from the vent on the dashboard is at a temperature

un
pt
an
d
of 7 °C or less.
itte
y li
erm
ab
♦ Set the Climatronic to: “LO”.
ility
ot p
wit
is n
♦ Set the air conditioning system: “A/C” on; “max”; “cold”.
h re
ole,
spec
12.1.1 Conditions for testing:
t to the co
• Self-diagnosis of the air conditioning system with the Vehicle
diagnosis, testing and information system - VAS 5051A- using
rrectne
“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
ss
system” is fitted with self-diagnosis).
o
cial p
f inform
⇒ Rep. gr. 87
mer
atio
12.1.2 Possible complaints
om
n
c
i
or
n thi
te
sd
iva
Note
pr
cum
r
fo
en
ng
t.
yi
For all complaints marked with * ⇒ page 161 .
Co
Cop py
t. rig
gh ht
yri by
♦ The cooling has failed completely. *
cop Vo
by lksw
cted agen
Prote AG.
♦ Insufficient cooling output at all vehicle or engine speeds. *
♦ No or insufficient cooling after driving a few miles. *
♦ The air conditioner compressor, the air conditioning system
magnetic clutch - N25- or the air conditioner compressor reg‐
ulating valve - N280- have been switched off by low-pressure
switch for magnetic clutch - F73- , high-pressure switch for
magnetic clutch - F118- , air conditioning system pressure
switch - F129- or by operating and display unit for Climatronic
air conditioning system - E87- or Climatronic control unit -
J255- because pressure was too high or too low.* *
♦ No fresh air flow, or very much reduced fresh air flow after
driving some distance (evaporator iced up). *
In addition, the following problems may occur:
The air conditioner compressor is noisy
– Tighten the securing screws for the air conditioner compressor
and the air conditioner compressor bracket using a torque
wrench.
– Check routing of refrigerant pipes; they must not touch other
components and must be installed without tension (adjust if
necessary).

Noises (refrigerant hammering) occur immediately after the air

conditioning is switched on and/or in a curve or when the brakes
are applied:
– Discharge, evacuate and re-charge refrigerant circuit (too
much refrigerant in circuit).
Note
♦ Excess refrigerant oil in the circuit may also cause this problem
(e.g. if the refrigerant oil level was not checked after the air
conditioner compressor was renewed). In case of this com‐
plaint, the refrigerant circuit must be purged with R134a re‐
frigerant ⇒ page 70 .
♦ The refrigerant must be drained from the air conditioning com‐
pressor. To facilitate this process, turn the air conditioner
compressor over by hand at the poly V-belt pulley or coupling
disc of the magnetic gcoupling.
AG. VolksThen
wagenfill
AGrefrigerant circuit with
a en
total amount ofVorefrigerant
lksw oil (50 g direct into
does
notair conditioner
compressor) ed according to ⇒ vehicle-specific workshop
by gu
ara man‐
ual . tho ris nte
e or
au ac
ss
Water sprays out of the vents (in dash panel or footwell) although ce
le
un
pt
air conditioning system is otherwise functioning properly: an
d
itte
y li
– Check proper routing of condensate drain; it must not be
erm
ab
ility
crushed or kinked.
ot p
wit
is n
– The condensed water drain valve must not be hindered in its

h re
ole,
operation by wax or underbody sealant and must open and

spec
close properly.
t to the co
– Check the plenum chamber cover; it must be undamaged and

be installed correctly (no water must flow into the evaporator).
rrectne
– Check water drains in plenum chamber; they must not be

blocked (e.g. by leaves).
ss
12.2 Odours from heater and air conditioner

o
cial p
f in
unit
form
mer
atio
om
n
c
i
or
12.2.1 Does the odour emanate from the evap‐

thi
te
sd
va
orator or heat exchanger?

i
o
pr
cum
r
fo
en
ng
♦ Fishy smell
t.
yi Co
Cop py
.
– Due to leak in engine's cooling system or in heat exchanger of
ht rig
rig ht
by
heater and air conditioner unit. copy Vo
by lksw
cted agen
Prote AG.
Note
If the fishy smell is weaker when the temperature is set to “cold”

or stronger when the temperature is set to “warm”, check the heat
exchanger for leaks.
♦ Smell of a burnt clutch

♦ Vapours from foot mats, retrospectively installed seat covers
etc.
♦ Putrid, mouldy smell
– Caused by accumulation of debris, pine needles etc. in plenum
chamber
12. Complaints 157

Note
Clean plenum chamber.
– Stagnant water that cannot flow out of plenum chamber.
Note
Check water drains in plenum chamber.
♦ Smell from heater and air conditioner unit
Note
Smells that originate from the heater and air conditioner unit can
be detected in fresh air mode and in recirculation mode.
wage e
– Due to too much condensatey Vinolkthe
s
heater and air conditioner
s no
t gu
unit ised b ara
n r tee
ho
aut or
ac
ss
Note
ce
e
nl
pt
du
an
itte
Check the condensation water drains ⇒ Rep. gr. 87 as indicated y li

erm
in the vehicle-specific repair manual. ab

ility
ot p
wit
, is n
h re
– Due to an old or very dirty dust and pollen filter
hole
spec
es, in part or in w
t to the co
Note
Check the dust and pollen filter ⇒ Rep. gr. 80 as indicated in the
rrectness of i
vehicle-specific repair manual.

l purpos
– Due to deposits on the fins of the evaporator

nf
ercia
orm
m
Note
atio
om
n in
or c
Clean the evaporator, using the ultrasonic air conditioner cleaning

thi
te
sd
a
unit - VAS 6189A- ⇒ page 158 or the suction feed spray-gun -

iv
o
r
rp
cu
V.A.G 1538- and corresponding spray lance ⇒ page 159 .

o
m
f
en
ng
t.
yi Co
op
12.2.2 Ultrasonic air conditioner cleaning unit -
C py
t. rig
gh ht
yri
VAS 6189A-
p by
co Vo
by lksw
cted agen
Prote AG.
– The ultrasonic air conditioner cleaning unit - VAS 6189A- must
be placed in the front-passenger footwell and sprays the agent
Aero-Clean. Aero-Clean neutralises microbes and bacteria in
the heater and air conditioner unit.
The device is provided with instructions for use.
Current equipment ⇒ Electronic parts catalogue .

olkswagen AG
en AG. V
12.2.3 Spraying the evaporator with the suctionyV
olks
wag does
not
gu
feed spray-gun - V.A.G 1538- and ed spray
b ara
ris nte
ho eo
lance ss
au
t ra
c
ce
le
Directly spray the evaporator with cleaning solution using a spray
un
pt
an
lance (approx. 10 bar). The cleaning solution neutralises mi‐
d
itte
y li
crobes and bacteria directly on the evaporator.
rm
ab
pe
ility
In order to enable access to the evaporator, preparatory work and
ot
wit
, is n
different spraying lances are necessary, e.g. V.A.G 1538/5; V.A.G
h re
1538/6 or V.A.G 1538/7.
hole
spec
es, in part or in w
Vehicle-specific instructions for user are provided with the evap‐
t to the co
orator cleaning solution “D 600 100 A2”.
Current devices and spray lances ⇒ Electronic parts catalogue .
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.
12. Complaints 159

13 Connecting the air conditioning serv‐

ice station lksw
agen
AG. Volkswagen AG d
oes
n o ot g
yV ua
edb ran
ris tee
tho
13.1 For vehicles that have connections on
or
au ac
ss
both low-pressure and high-pressure
ce
le
un
pt
an
d
sides of refrigerant circuit

itte
y li
rm
ab
pe
ility
ot
wit
, is n
13.1.1 Connecting a air conditioner service sta‐
h re
hole
spec
tion for measuring and testing
es, in part or in w
t to the co
rrectness of i
ply.
l purpos
– Connect quick-release coupling adapters to filler hoses of air

conditioner service station (handwheels not turned inwards,
i.e. manual stop valves not open).
nform
ercia
– Switch on air conditioner service station in this state and evac‐

m
a
uate charging hoses (necessary only if air is in the charging
com
tion in
hoses).
r
te o
thi
– Switch off air conditioner service station .
s
iva
do
r
rp
– Unscrew sealing cap from service connections (with valve). cum

fo
en
ng
t.
yi Co
– Connect air conditioner service station via service connections t. Cop py
to vehicle refrigerant circuit using quick-release coupling
rig
gh ht
yri by
adapters. op Vo
by c lksw
cted agen
Prote
– Turn handwheel of quick-release coupling adapter inwards
AG.
only far enough to ensure that valves on service connections

are open (check using a pressure gauge; do not overstress
valves).
– Perform the intended measuring and checking work.

14 Checking pressures on vehicles
14.1 Checking pressures in the refrigerant

circuit (using a air conditioning service
station )
Note
♦ Check cooling output. The air conditioning system is operating

correctly if the air emerging from the vent on the dashboard is
at a temperature of 7 °C or less.
♦ Set the Climatronic to: “LO”.
♦ Set the air conditioning system: “A/C” on; “max”; “cold”.
♦ Connections with valve and service connections for measure‐
ment and testing
14.1.1 Conditions for testing

• Radiator and condenser clean (clean if necessary)
• The heat insulation on expansion valve is OK and properly
installed. See vehicle-specific repair manual ⇒ Rep. gr. 87 .
• The poly V-belt is OK and properly tensioned. The V-belt agen for
AG. Volkswagen AG d
oes
air conditioner compressor and alternator is in ygood
olkswcondition not
V gu
and correctly tensioned. See vehicle-specific
isedrepair
b
manual ⇒ ara
nte
Rep. gr. 87 ut
hor eo
ra
sa c
• All air ducts, covers and seals are OK
s and properly installed.
ce
e
nl
pt
du
• Fault-finding on the electrical systems and vacuum system
an
itte
y li
has found no faults. See vehicle-specific repair manual ⇒ Rep.
erm
ab
gr. 87
ility
ot p
wit
, is n
• Self-diagnosis of the air conditioning system with the vehicle

h re
diagnosis, testing and information system - VAS 5051A- using
hole
“guided fault finding” cannot detect any faults; no switch-off spec

es, in part or in w
conditions for the air conditioner compressor are set in the

t to the co
measured value block (only when the vehicle “air conditioning

system” is fitted with self-diagnosis).
rrectness of i
• The passage of air through the dust and pollen filter is not im‐
paired by dirt. See vehicle-specific repair manual ⇒ Rep. gr.
l purpos
87
• The heater and air conditioner does not draw any secondary
nf
ercia
air at highest fresh air blower speed. evaporator and heater

orm
not drawing in secondary air at maximum fresh-air blower

m
atio
m
speed See vehicle-specific repair manual ⇒ Rep. gr. 87

o
n in
or c
thi
• The air duct flaps in the heater and air conditioner reach their
te
sd
a
stop positions. See vehicle-specific repair manual ⇒ Rep. gr.

iv
o
r
rp
cu
87
o
m
f
en
ng
t.
yi
• The fresh air intake ducts under the bonnet and in the pas‐
Co
op py
senger compartment and their water drain valves are in good
t. C rig
gh ht
yri
condition. See vehicle-specific repair manual ⇒ Rep. gr. 87 p by
o Vo
by c lksw
cted agen
• Engine warm. Prote AG.
• Vehicle not exposed to sunlight

• Ambient temperature is above 15°C.
• All dash panel vents open
14. Checking pressures on vehicles 161

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Amarok 2011 ➤ , Amarok 2017 ➤ ris , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas
ed
nte2 ...
o eo
Air conditioning systems withaurefrigerant
th R134a - General information - Edition r a11.2019
ss c
ce
e
• Engine running and air conditioner set to maximum cooling
nl
pt
du
an
output
itte
y li
erm
ab
⇒ Rep. gr. 87
ility
ot p
wit
, is n
Set maximum cooling output
h re
hole
Settings on operating and display unit for Climatronic air condi‐
spec
es, in part or in w
tioning system - E87-
t to the co
– Select “Auto” mode (air conditioner compressor switched on).
– Select temperature setting “LO” for driver and front passenger.
rrectness of i
Setting on heating control:
l purpos
– A/C button and Rec or recirculate buttons should be pressed.
nf
ercia
– Set rotary temperature control to Cold stop.
orm
m
atio
– Set rotary fresh air blower control to position 4.
om
n in
or c
• The radiator fan(s) should be running radiator fan - V7- (at
thi
e
least at speed 1).

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
With some versions, the fan is not switched on until the pressure
py by
co Vo
by lksw
in the refrigerant circuit has exceeded a specified value. Prote
cted AG.
agen
• The fresh air blower - V2- should be running at maximum

speed.
• The air flap for fresh air and air recirculation moves to the “re‐
circulation” position or the air flow flap closes and the recircu‐
lation flap opens (within 1 minute of starting the vehicle).
• The coolant shut-off valve is closed.
• The valves for the pump valve unit are closed (and the coolant
circulation pump is not pumping).
14.1.2 Checking pressures

– Connect the air conditioner service station ⇒ page 160 .
– Read pressures off pressure gauges; there may be two re‐
sults.
Ambient temperature (in de‐ Pressure in the refrigerant cir‐
grees C) cuit in bar positive pressure
+15°C 3.9
+20°C 4.7
+25°C 5.6
+30°C 6.7
+35°C 7.8
+40°C 9.1
+45°C 10.5

Note
♦ The temperature of the components of the refrigerant circuit

should be the same as the ambient temperature.
AG. Volkswagen AG d
agen oes
♦ If individual components of the refrigerant circuit are ywarmer
Vol
ksw not
gu
or colder, the pressure will deviate from the values edshown in
b ara
nte
the tables. oris eo
th
au ra
♦ Absolute pressure means that 0 bar corresponds to an abso‐
ss c
ce
e
lute vacuum. The normal ambient pressure corresponds to 1
nl
pt
du
bar absolute pressure. On the scales of most pressure
an
itte
y li
gauges, 0 bar corresponds to an absolute pressure of 1 bar
erm
ab
(indicated by -1 bar mark below 0).
ility
ot p
wit
, is n
♦ Where vehicles have a high-pressure sender - G65- which in‐
h re
dicates the measured pressure in the measured values block,
hole
spec
the measured pressure should agree with the values in the
es, in part or in w
tables.
t to the co
⇒ Rep. gr. 87
rrectness of i
The pressure in the refrigerant circuit is lower than indicated in
l purpos
the table
Too little refrigerant in circuit.
nf
ercia
o
– Check for leaks in the refrigerant circuit ⇒ page 60 .
rm
m
atio
m
– Check the high-pressure safety valve.

o
n in
or c
thi
If the high-pressure safety valve has blown off:
te
sd
iva
o
r
– Check activation of radiator fan.

rp
cu
o
m
f
en
ng
– Check refrigerant pipes and refrigerant hoses for restrictions

t.
yi Co
op
in cross-section at bends that have too tight radius.
C py
ht. rig
rig ht
py by
– Check refrigerant pipes and refrigerant hoses for external co Vo
by lksw
damage.
cted agen
Prote AG.
– If no defects are found, blow through refrigerant circuit with

compressed air and nitrogen.
The pressure in the refrigerant circuit is equal to or greater than
that in the table
– Start engine.
– On vehicles with electrical air conditioner compressor, switch
off ignition.
electric shock.
voltage cables.
tools.



system .
warning instructions for work on the high-voltage system”
n AG. ⇒
VolElec‐
kswagen AG
wage
trical system; Rep. gr. 93 ; General warning Vinstructions for work
does
olks not
gu
on the high-voltage system . ed
by ara
n is tee
or
– Set air conditioning system for maximum
au
th cooling output. or
ac
ss
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
If when connected to the air conditioner service station the low-
ot p
wit
pressure switch had been removed, bypass the electrical con‐
, is n
h re
nections in the respective pressure measurement plug.
hole
spec
es, in part or in w
• The air conditioner compressor is driven by the engine via the
t to the co
air conditioning system magnetic clutch - N25- .
• The air conditioner compressor regulating valve - N280- is ac‐
rrectness of i
tivated by the Climatronic control unit - J255- .
l purpos
⇒ Rep. gr. 87
If the air conditioner compressor is not driven or the regulating
nf
ercia
valve not activated when the engine is running:
orm
m
atio
– Determine the cause, e.g. by reading the event memory for
om
n in
the air conditioning system, and rectify it.
or c
thi
te
– Observe the test prerequisites.
sd
iva
o
r
rp
cu
– Check power supply for air conditioning system magnetic
o
m
f
en
ng
clutch - N25- . If this is OK, repair magnetic clutch.

t.
yi Co
Cop py
.
– Check actuation of air conditioner compressor regulating valve
ht rig
rig ht
by
- N280- . copy Vo
by lksw
cted agen
Prote
⇒ Rep. gr. 87 .
AG.
14.1.3 Continuation of checking pressures

♦ Where vehicles have a restrictor and reservoir, check these
(with internally regulated air conditioning system compressor)
⇒ page 165 .
♦ Where vehicles have an expansion valve and receiver, check
these (with internally regulated air conditioner compressor)
⇒ page 169 .
♦ Where vehicles have an expansion valve and receiver, check
these (without internally regulated air conditioner compressor)
⇒ page 173 .
♦ Where vehicles have a restrictor and reservoir and air condi‐
tioning system compressor regulating valve - N280- (external‐
ly regulated air conditioning system compressor)
⇒ page 174 .

14.2 Checking systems with a restrictor agen

and
AG. Volkswagen AG
does
collector (with internally by V regulated air
olksw not
gu
ara
conditioner compressor) ed
ris nte
tho eo
au ra
c
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ Connect the air conditioner service station ⇒ page 160 .
ility
ot p
wit
♦ Observe the test prerequisites ⇒ page 161 .
, is n
h re
hole
spec
– Raise engine speed to 2000 rpm.
es, in part or in w
t to the co
– Observe pressure gauge of the air conditioner service station .
rrectness of i
Note
l purpos
♦ Switching pressures for refrigerant circuit switches are vehi‐

cle-specific.
nf
ercia
or
♦ The connection with a valve for the low-pressure switch or on
m
m
atio
the evaporator should only be used where the vehicle does
om
n in
not have a service connection on the low-pressure side and
or c
access to the connection on the air conditioner compressor or
thi
te
sd
a
reservoir is not possible (measurement accuracy). This only

iv
o
r
rp
cu
applies to certain vehicles.
o
m
f
en
ng
t.
yi Co
op
⇒ Rep. gr. 87 C py
ht. rig
rig ht
py by
14.2.1 Specifications:
co Vo
by lksw
cted agen
Prote AG.
High-pressure side:
Rising from starting pressure (when pressure gauge is connec‐
ted) to maximum 20 bar.
Low-pressure side:
Falling from starting pressure (when pressure gauge is connec‐
ted) to diagram value.
A - High pressure (measured at the service connection) in bar
positive pressure.
B - Low pressure (measured at the connection with the valve at
the air conditioner compressor or at the reservoir) in bar positive
pressure.
C - Permitted tolerance range.
D - Low pressure (measured at the connection with the valve for
the low-pressure switch or at the service connection) in bar pos‐
itive pressure.
E - Permitted tolerance range.

AG. Volkswagen AG d
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Air conditioning systems with refrigerant R134a horis- General information - Edition 11.2019 nte
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Possible deviation from specification Possible cause of fault Rectifying fault
ce
le
un
pt
an
d
• High pressure remains constant or in‐ Too little refrigerant in circuit. – Look for leaks and rectify them.
itte
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creases only slightly (above the pres‐
erm
ab
ility
sure measured when the engine is – Re-charge refrigerant circuit.
ot p
stopped).
wit
is n
h re
ole,
• Low pressure falls quickly to the dia‐
spec
gram value or lower,
t to the co
• Required cooling output is not at‐
tained.
rrectne
• High pressure normal
• Low pressure matches the diagram
ss o
value,
cial p
f inform
mer
tained.
atio
om
n
c
i
or
n
thi
te
sd
va
• Low pressure is too low (see dia‐

i
o
pr
cum
r
gram),
fo
en
ng
t.
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• Required cooling output is not at‐ Cop py
tained.
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
Note
If no fault can be found for this complaint, purge (clean) refrigerant

circuit with refrigerant R134a ⇒ page 70 . If this is not possible in
your workshop, blow through refrigerant circuit with compressed
air and dry with nitrogen ⇒ page 68 .

• High pressure only increases slightly The air conditioner compressor is de‐ – Flush refrigerant circuit
above pressure with engine stop‐ fective. ⇒ page 70 .
ped,
– Renew the air condi‐
• Low pressure falls only slightly, tioner compressor.
tained.


• High pressure increases above Constriction or obstruction in refrigerant cir‐ – Run hand over re‐
specification cuit frigerant circuit to
check for differen‐
• Low pressure falls quickly to the di‐ ces in temperature.
agram value or lower,
• Required cooling output is not at‐ • At one component a
tained. temperature gradi‐
ent will be detected:
– If a hose or pipe is
kinked or crushed,
renew it.
– Flush refrigerant
circuit with com‐
pressed air and ni‐
trogen in the event
of an obstruction.
– Repeat the check; if

the system does not
operate correctly.
– Purge (clean) refrig‐

erant circuit
⇒ page 70 .
• High pressure and low pressure are Moisture in refrigerant circuit – Blowing through re‐
normal at first, but after a time, frigerant circuit with
compressed air and
• The high pressure increases beyond nitrogen.
the specified value,
• The low pressure falls to the diagram – Renew receiver.
value or lower,
• The cooling power called for is not the system does not
delivered. operate correctly.
agen
AG. Volkswagen AG d
oes – Purge (clean) refrig‐
yV
olksw not
gu erant circuit
ised b ara
nte ⇒ page 70 .
or eo
h
ut
ss a ra
c – Re-charge refriger‐
ant circuit.
ce
e
nl
pt
du
an
– Repeat test.
itte
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erm
ab
• High pressure normal The air conditioner compressor is defec‐ – Purge (clean) refrig‐
ility
ot p
tive. erant circuit

wit
, is n
• Low pressure is too low (see dia‐ ⇒ page 70 .

h re
gram),
hole
spec
– Renew the air con‐

es, in part or in w
• The cooling power required is deliv‐

ditioner compres‐
t to the co
ered.
sor.
rrectness of i
Note
l purpos
♦ If the fault is “high pressure normal, low pressure too low ”

nf
ercia
please note the following:

orm
m
♦ In this case, the evaporator may be iced up or the low-pressure

atio
m
switch for air conditioning system - F73- has switched off the
o
n in
or c
air conditioning system compressor, although the correct

thi
te
quantity of refrigerant is present in the refrigerant circuit.

sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
167
by lksw
cted agen
Prote AG.
14. Checking pressures on vehicles
Possible deviation from specifica‐ Possible cause of fault Rectifying fault

tion
• High pressure normal or too Too much refrigerant in circuit. – Extract some refrigerant from
high the refrigerant circuit.
• Low pressure too high (see dia‐ • If quantity of refrigerant extrac‐
gram), ted roughly corresponds to
• The air conditioner compressor specified capacity:
is noisy (especially immediately – Renew the air conditioner com‐
after being switched on), pressor.
• Required cooling output is not
attained. • The quantity of refrigerant ex‐
tracted is significantly greater
than the prescribed charge
quantity.
– Re-charge refrigerant circuit.
– Repeat test.

• High pressure and low pressure Too much refrigerant oil in circuit. – Drain refrigerant cir‐
normal wage
e
cuit.
ks s no
Vol t gu
• Required cooling output is noted at‐
by ara – Purge (clean) refrig‐
tained. thoris nte
eo erant circuit
au ra
c ⇒ page 70 .
ss
ce
• High pressure and low pressure

le
un
pt
normal
an
d
itte
y li
erm
ab
• The air conditioner compressor is

ility
ot p
noisy (especially immediately af‐

wit
is n
ter being switched on),

h re
ole,
spec
• The cooling power required is de‐

livered.
t to the co
rrectne
Note
s
♦ Overfilling with refrigerant oil can occur if the refrigerant oil

s o
level was not checked after the air conditioner compressor

cial p
f in
was renewed.
form
mer
♦ If the air conditioner compressor is not to be replaced, drain

atio
om
refrigerant oil from air conditioner compressor via the block

n
c
i
or
connections. From the total amount of refrigerant oil, fill 50 g

thi
te
direct into air conditioner compressor and fill remainder in re‐

sd
iva
o
r
frigerant circuit according to ⇒ vehicle-specific workshop man‐

p
cum
r
fo
ual .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

14.3 Checking systems with an expansion

valve and reservoir (with internally regu‐
lated air conditioner compressor)
Note


gen AG
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– Observe pressure
db
ygauge
Vo set. gu
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ris
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a
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Switching pressures and design of refrigerant circuit switches are
itte
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vehicle-specific.
erm
ab
ility
ot p
wit
, is n
Pressures must be measured at service connections; fitting loca‐
h re
tions of these connections are vehicle-specific.
hole
spec
es, in part or in w
⇒ Rep. gr. 87
t to the co
rrectness of i
High-pressure side:
l purpos

ted) to maximum 20 bar.
nf
ercia
Low-pressure side:
orm
m
atio

om

n in
or c
thi
e
A - High pressure in bar positive pressure.

t
sd
iva
o
r
rp
cu
B - Low pressure in bar positive pressure.

o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


tion
• High pressure remains constant Not enough refrigerant in circuit or – Extract some refrigerant from
or increases only slightly (above expansion valve defective the refrigerant circuit.
the pressure measured when
the engine is stopped). • If quantity of refrigerant extrac‐
ted roughly corresponds to
• Low pressure falls quickly to the specified capacity:
diagram value or lower,
– Renew the expansion valve.
attained. – Re-charge refrigerant circuit.
– Repeat test.
• Low pressure matches the dia‐
gram value, • The quantity of refrigerant ex‐
tracted is significantly less than
• Required cooling output is not the prescribed charge quantity.
attained.
– Locate leak with leak detector
and eliminate.
– Re-charge refrigerant circuit.
– Repeat test.
Note
If no fault can be determined and the function of the air condi‐

tioning system is not OK when the test is repeated, purge refrig‐
erant circuit with refrigerant R134a (clean) ⇒ page 70 . If this is
not possible in your workshop, blow through refrigerant circuit with
compressed air and dry with nitrogen ⇒ page 68 .
AG. Volkswagen AG d
agen oes
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Possible deviation from specifica‐ Possible cause dofbyfault
V Rectifyingt fault
gu
ara
tion orise nte
eo
h
ut ra
• High pressure increases above ♦ Constrictionssor obstruction in re‐ – Run hand over refrigerant circuit
a c
specification frigerant circuit to check for differences in tem‐
ce
le
un
pt
perature.
an
d
• Low pressure falls quickly to the ♦ Expansion valve defective

itte
y li
rm
diagram value or lower,

ab
• At one component a tempera‐

pe
ility
ture gradient will be detected:

ot

wit
, is n
attained.
h re
– If a hose or pipe is kinked or

hole
spec
crushed, renew it.

es, in part or in w
t to the co
– In the event of an obstruction,

flush refrigerant circuit with com‐
pressed air and nitrogen and re‐
rrectness of i
place expansion valve.

l purpos
• If no fault can be detected:

– Purge (clean) refrigerant circuit
nform
ercia
⇒ page 70 .
m
a
com
ti
– Repeat test.
on 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
cted agen
Prote AG.

Note
If the air conditioning system is still not operating correctly after

the refrigerant circuit has been purged with compressed air and
nitrogen, the expansion valve must be renewed.

• High and low pressure normal at ♦ Expansion valve defective – Examine expansion
first, valve for dirt or cor‐
♦ Moisture in refrigerant circuit rosion and replace if
• After a while, the high pressure necessary
increases beyond the specifica‐
tion, and the low pressure falls to – Blowing through re‐
the diagram value or lower, frigerant circuit with
• The cooling power called for is compressed air and
not delivered. nitrogen.
– Renew receiver.
AG. Volkswagen AG d
agen o–
es n Repeat the check; if
olksw ot g
ed by V
theuasystem
ran does not
horis operate teecorrectly.
t or
au ac
ss – Purge (clean) refrig‐
ce
e
erant circuit
nl
pt
du
an
⇒ page 70 .
itte
y li
erm
ab
– Re-charge refriger‐
ility
ot p
ant circuit.
wit
, is n
h re
hole
– Repeat test.
spec
es, in part or in w
t to the co
Note
rrectness of i
Always replace receiver if this fault occurs.
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.


• High pressure normal or too high ♦ Too much refrigerant in circuit. – Extract some refrig‐
(see diagram), erant from the re‐
♦ Expansion valve or air conditioner com‐ frigerant circuit.
• Required cooling output is not at‐ pressor defective.
tained. • If quantity of refrig‐
• The air conditioner compressor is erant extracted
noisy (especially immediately af‐ agen
AG. Volkswagen AG doroughly corre‐
ter being switched on), Volksw sponds
es n
ot g to specified
ed by capacity:ua
ra
ris nte
utho – Renew the expan‐
or e
a ac
ss sion valve.
ce
e
nl
pt
du
an
itte
y li
ant circuit.
erm
ab
ility
ot p
– Repeat test.
wit
, is n
h re
hole
• The quantity of re‐
spec
frigerant extracted
es, in part or in w
t to the co
is significantly
greater than the
prescribed charge
quantity.
rrectness of i
l purpos
ant circuit.
nf
ercia
– Repeat test.
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
o
If the air conditioning system is still not operating correctly when
r
rp
cu
o
m
the test is repeated, refit the expansion valve and purge the re‐
f
en
ng
t.
frigerant circuit with compressed air and nitrogen. Then replace
yi Co
op py
the air conditioner compressor and receiver. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

• High pressure only increases ♦ The air conditioner compressor is defec‐ – Flush refrigerant cir‐
slightly above pressure with en‐ tive. cuit ⇒ page 70 .
gine stopped,
– Replace the air con‐
• Low pressure falls only slightly, ditioner compressor
• The required cooling power is not and receiver.
delivered.
Possible deviation Possible cause of fault Rectifying

from specification fault
• High pressure ♦ Expansion valve or air – Renew
normal conditioner compres‐ the expan‐
sor defective. sion valve.
• Low pressure is
too low (see dia‐ – Re-
gram), charge re‐
• The cooling pow‐ frigerant
er required is de‐ circuit.
livered.
– Repeat
test.

Note
♦ If repeated check results in air conditioning system still not

operating correctly, purge (clean) the refrigerant circuit
⇒ page 70 . Then replace the air conditioner compressor and
receiver.
♦ In this case, the evaporator may ice up although the correct

• High pressure and low pressure Too much refrigerant oil in circuit. – Drain refrigerant cir‐
normal cuit.
• Required cooling output is not at‐ – Purge (clean) refrig‐
tained. agen
AG. Volkswagen AG d
oes erant circuit
ksw
y Vol ⇒gpage
not
ua 70 .
db ran
• High pressure and low pressure rise
tee
normal tho or
s au ac
s
• The air conditioner compressor is
ce
le
un
pt
noisy (especially immediately af‐
an
d
itte
y li
ter being switched on),
erm
ab
ility
ot p
• The cooling power required is de‐
wit
livered.
is n
h re
ole,
spec
t to the co
Note
rrectne
was renewed.
ss o
cial p
f in
form
mer
atio
om
n
c
i
or
n
ual .
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
valve and reservoir (without regulated
py by
co Vo
by lksw
cted
air conditioner compressor)
agen
Prote AG.
14.4.1 Conditions for testing

• Radiator and condenser clean (clean if necessary)
• The V-belt for air conditioner compressor and alternator is
correctly tensioned.
• All air ducts, covers and seals are OK and properly installed.
• The flaps reach their end positions.
• Engine warm.
• The evaporator and heating do not draw any uncooled air at
highest fresh air blower speed.

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”.
• Ambient temperature above 15°C.
• The temperature switch for evaporator - E33- is correctly fitted
and its switching temperatures are correct.
14.4.2 Check
Check pressures in refrigerant circuit with ignition switched off.
– Check pressures in refrigerant circuit (using air conditioning
service station ) ⇒ page 162 .
Check pressures in refrigerant circuit with air conditioner com‐
pressor being driven.
– Connect the air conditioner service station ⇒ page 160 .
AG. Volkswagen AG d
– Start engine. ksw
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not
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– Raise engine speed to 2000 rpm. ise
d b ara
nte
or eo
h
– Observe pressure gauge of air conditioner service
s aut
station . ra
c
s
– Check actual values against specifications ⇒ page 174 .
ce
e
nl
pt
du
an
itte
14.4.3 Specified values
y li
erm
ab
ility
ot p
High-pressure side
wit
, is n
h re
Pressure rising from initial pressure to 20 bar max.
hole
spec
Low-pressure side
es, in part or in w
t to the co
Pressure falling from initial pressure to diagram value.
A - High pressure in bar positive pressure.
rrectness of i
B - Low pressure in bar positive pressure.
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
14.5 Checking systems with a restrictor and Cop py
t. rig
gh ht
reservoir and air conditioner compres‐ pyri by
Vo
co lksw
by
sor regulating valve - N280- (with exter‐
cted agen
Prote AG.
nally regulated air conditioner compres‐

sor)
Note


wage e
– Observe pressure gauge of the
yV
oair
lks conditioner service station
s no
.t gu
b ara
ed nte
oris e
th or
Note au ac
ss
ce
e
nl
pt
du
Switching pressures for the air conditioner compressor regulating
an
itte
y li
valve - N280- and the radiator fan - V7- are vehicle-specific.
erm
ab
ility
ot p
wit
⇒ Rep. gr. 87
, is n
h re
hole
spec
es, in part or in w
t to the co
High-pressure side:
ted) to 20 bar.
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
o
by c lksw
cted agen
Prote AG.

Low-pressure side:
Falling from starting pressure (when pressure gauge iswaconnec‐
olks
ge es n
ot g
ted) to diagram value. d byV ua
ran
ir se tee
A - Low pressure (measured at the serviceutconnection)
ho in bar ab‐ or
solute pressure. ss
a ac
ce
le
un
B - Control current for the air conditioner compressor regulating
pt
an
d
valve - N280- .
itte
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rm
ab
C - Permitted tolerance range. pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high atmospheric humidity), the pressure on the high
pressure side can increase to a maximum of 29 bar.
rrectness of i
♦ The control current -B- is indicated in the measured values
l purpos
block.
♦ The high pressure is indicated in the measured values block
nform
ercia
⇒ Rep. gr. 87 .
m
a
♦ The low pressure is adjusted to within tolerances within the
com
tion in
output range for the air conditioner compressor depending on
r
te o
the control current for the air conditioner compressor regulat‐
thi
s
iva
ing valve - N280- .
do
r
rp
cum
fo
en
ng
t.
tures, high humidity), the output may not always be sufficient
yi Co
op py
to attain the specified value. t. C rig
gh ht
pyri by
♦ The set working current for the regulating valve must be great‐
co Vo
by lksw
cted
er than 0.3 A to ensure that the regulating valve is reliably
agen
Prote AG.
activated.
♦ At the setting for “maximum cooling power”, the control current
should be approx. 0.8 A (indicated in the measured values
block) ⇒ Rep. gr. 87 .
bar absolute. On the scales of most pressure gauges, 0 bar
corresponds to an absolute pressure of 1 bar (indicated by -1
bar mark below 0).

. Volkswage
Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo 2017 wag➤
en ,AG
Arteon 2018 ➤ o, eAtlas
n AG d
s no 2 ...
olks
Air conditioning systems with refrigerant R134ad -byGeneral information - Edition 11.2019
V t gu
ar
e an
ris tee
tho or
Possible deviation Possible cause of fault Rectifying
ss
fault
au ac
from specification
ce
le
un
pt
• High pressure ♦ Actuation of air con‐ – Check ac‐
an
d
itte
y li
remains con‐ ditioner compressor tuation of air
rm
ab
stant or increa‐ regulating valve - conditioner
pe
ility
ot
ses only slightly N280- is defective. compressor
wit
, is n
(above the pres‐ regulating
h re
sure measured ♦ Too little refrigerant
hole
valve -
spec
when the engine in circuit. N280- .
es, in part or in w
t to the co
is stopped).
– Locate leak
• Low pressure with leak de‐
falls quickly to
rrectness of i
tector and
the diagram val‐ eliminate.
ue or lower,
l purpos
• Required cooling – Re-charge
refrigerant
nform
output is not at‐ ercia
tained.
m circuit.
a
com
tion in
• High pressure
r
te o
normal
thi
s
iva
do
• Low pressure
r
rp
cum
fo
matches the dia‐
en
ng
t.
gram value,
yi Co
Cop py
ht. rig
• Required cooling rig ht
py by
output is not at‐
co Vo
by lksw
cted
tained.
agen
Prote AG.
• High pressure
normal
• Low pressure is
too low (see dia‐
gram),
• Required cooling
output is not at‐
tained.
• High pressure
normal
• Low pressure is
too low (see dia‐
gram),
• Required cooling
output is not at‐
tained.
Note
If no fault can be found for this complaint, purge (clean) refrigerant

circuit with refrigerant R134a ⇒ page 70 . If this is not possible in
your workshop, blow through refrigerant circuit with compressed
air and dry with nitrogen ⇒ page 68 .


tion
• High pressure only increases ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
slightly above pressure with en‐ ulating valve - N280- is defective. air conditioner com‐
gine stopped, pressor regulating
♦ The air conditioner compressor is defective. valve - N280- .
• Low pressure falls only slightly,
• Required cooling output is not – Purge (clean) refrig‐
attained. erant circuit
⇒ page 70 .

ditioner compres‐
sor.
• High pressure increases above ♦ Constriction or obstruction in refrigerant cir‐ – Run hand over re‐
specification cuit frigerant circuit to
• Low pressure falls only slightly, ces in temperature.
attained. • At one component a
temperature gradi‐
kinked or crushed,
renew it.
circuit with com‐
trogen in the event
of an obstruction.
• If no fault is found:
AG. Volkswagen AG d
agen oes – Purge (clean) refrig‐
ksw
gu erant circuit
o l not
byV ara
ris ed ⇒ntpage
ee
70 .
ho
• High pressure and low pressure ♦ ut
Moisture in refrigerant circuit – Blowing c through re‐
or
a a
are normal at first, but after a ss frigerant circuit with
ce
le
while, the high pressure increa‐ compressed air and

un
pt
an
d
ses beyond the specification, nitrogen.

itte
y li
rm
ab
• The low pressure falls to the di‐

pe
ility
– Renew reservoir.
agram value or lower,
ot
wit
, is n
h re
• The cooling power called for is – Repeat the check; if

hole
the system does not

spec
not delivered.
operate correctly.
es, in part or in w
t to the co

erant circuit
rrectness of i
⇒ page 70 .
l purpos
ant circuit.
nform
ercia
– Repeat test.
m
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.


tion
• High pressure normal ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
ulating valve - N280- is defective.
G. Volkswagen AG d air conditioner com‐
• Low pressureksiswatoo low
gen A (see di‐ oes pressor regulating
agram), by V ol
♦ Thenair ot g conditioner compressor is
ua defective. valve - N280- .
ed ran
ris
• Thethocooling power required is tee
delivered.
au or
ac – Purge (clean) refrig‐
ss erant circuit
ce
e
⇒ page 70 .
nl
pt
du
an
itte
y li
erm
ab
ditioner compres‐
ility
ot p
sor.
wit
, is n
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
the following: if faulty the evaporator could ice up or the re‐
l purpos
quired cooling output is not delivered.

nform
ercia

m
at
om
i
♦ Check the measured value of the evaporator output tempera‐
on
c
in t
ture sender - G263- or evaporator temperature sensor -

or
his
e
G308- .
at
do
priv
♦ Check the actuation of the air conditioner compressor regu‐

um
for
en
g
lating valve - N280- .

n
t.
yi Co
Cop py
ht. rig
⇒ Rep. gr. 87
rig ht
py by
co Vo
by lksw
cted agen
Possible deviation from specifi‐
Prote
Possible cause of fault Rectifying fault
AG.
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:
• Required cooling output is not – Renew the air condi‐

attained. tioner compressor.
frigerant extracted is
significantly greater
than the prescribed
charge quantity:
ant circuit.
– Repeat test.
• High pressure and low pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
sure normal cuit.
• Required cooling output is not – Purge (clean) refrig‐
attained. erant circuit
⇒ page 70 .

Possible deviation from specifi‐ Possible cause of fault Rectifying fault

cation
• High pressure and low pres‐
sure normal
• The air conditioner compres‐
sor is noisy (especially imme‐
diately after being switched
on),
• The cooling power required is
delivered.
Note
. Volkswagen AG
gen AG
♦ Overfilling with refrigerant oil Vcan
olks occur if the refrigerant oil
wa oes d
not
level was not checked after d bthe air conditioner compressor
y gu
ara
was renewed. rise nte
tho eo
au ra
♦ If the air conditionerss compressor is not to be replaced, drain c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ual .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
valve, receiver and air conditioner com‐ rrectness of i
pressor regulating valve - N280- (with
l purpos
externally regulated air conditioner com‐

pressor)
nform
mercia
a
com
Note
ion in
r
te o
thi

s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
op py
– Raise engine speed to 2000 rpm. t. C rig
gh ht
pyri by
– Observe pressure gauge of the air conditioner service station .
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Switching pressures for the air conditioner compressor regu‐

lating valve - N280- and the radiator fan - V7- are vehicle-
specific.
♦ Pressures should be measured at the service connections; the
location of these connections is vehicle-specific ⇒ Rep. gr.
87 .
High-pressure side:
ted) to 20 bar.

Low-pressure side:
A - Low pressure (measured at the service connection) in bar ab‐
solute pressure.
B - Control current for the air conditioner compressor regulating
valve - N280- .
Note

tures, high atmospheric humidity), the pressure on the high
pressure side can increase to a maximum of 29 bar.
♦ The control current -B- is indicated in the measured values
block.
♦ The high-pressure value measured by the high-pressure
sender - G65- is indicated in the measured values block ⇒ gen AG. Volkswagen AG d
Rep. gr. 87 . Vol
ksw
a oes
not
y gu
db ara
♦ The low pressure is adjusted to within tolerances
or
isewithin the nte
output range for the air conditioner compressor au depending on
th eo
ra
the control current for the air conditioner compressor
ss regulat‐ c
ing valve - N280- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
tures, high humidity), the output may not always be sufficient
ility
ot p
to attain the specified value.
wit
, is n
h re
♦ The set working current for the regulating valve must be great‐
hole
er than 0.3 A to ensure that the regulating valve is reliably
spec
activated.
es, in part or in w
t to the co
♦ At the setting “maximum cooling power”, the control current
should be approx. 0.65 A to 0.8 A (vehicle-specific, indicated
in the measured values block) ⇒ Rep. gr. 87 .
rrectness of i
l purpos

bar absolute. On the scales of most pressure gauges, 0 bar
nf
ercia
corresponds to an absolute pressure of 1 bar (indicated by -1

bar mark below 0). 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.

Possible deviation Possible cause of fault Rectifying fault

from specification . Volkswagen AG
gen AG
waair does
• High pressure ♦ Actuation o lksof con‐ – Check ac‐ not
yV gu
remains con‐ ditioner
ed b compressor tuation of air ara
nte
stant or increa‐ oris
regulating valve - conditioner eo
th
ses only slightly a N280- is defective.
u compressor ra
c
ss
(above the pres‐ regulating
ce
le
sure measured ♦ Too little refrigerant valve -

un
pt
in circuit.
an
d
when the engine N280- .

itte
y li
erm
is stopped).
ab
ility
– Locate leak
ot p
• Low pressure
wit
with leak de‐
is n
falls quickly to
h re
tector and
ole,
the diagram val‐
spec
eliminate.
ue or lower.
t to the co
• Required cool‐ – Re-charge
ing output is not refrigerant
attained. circuit.
rrectne
• High pressure
ss
normal.
o
cial p
f in
• Low pressure
form
mer
matches the di‐
atio
agram value.
om
n
c
i
or
n
• Required cool‐
thi
te
ing output is not

sd
iva
o
r
attained.
p
cum
r
fo
en
ng
t.
yi
• High pressure • Too little refrigerant – Extract some
Co
Cop py
normal. in circuit. refrigerant
t. rig
gh ht
yri
from the re‐
p by
o Vo
• Low pressure is
c by lksw
cted frigerant cir‐ agen
too low (see dia‐ Prote
cuit.
AG.
gram).
• Required cool‐ • The quantity
ing output is not of refrigerant
attained. extracted is
significantly
less than the
prescribed
charge
quantity.
– Locate leak
with leak de‐
tector, elimi‐
nate.
– Re-charge
refrigerant
circuit.
– Repeat test.
• If quantity of
refrigerant
extracted
roughly cor‐
responds to
specified ca‐
pacity:

Possible deviation Possible cause of fault Rectifying fault

from specification
• Expansion valve de‐ – Renew the
fective expansion
valve.
– Re-charge
refrigerant
circuit.
– Repeat test.
Note
♦ If no fault can be found for this complaint, purge (clean) re‐

frigerant circuit with refrigerant R134a ⇒ page 70 . If this is not
possible in your workshop, blow through refrigerant circuit with
compressed air and dry with nitrogen ⇒ page 68 .
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- or evaporator temperature sensor -
G308- and actuation of the air conditioner compressor
regulating valve - N280- . If the measured value of the evap‐
orator output temperature sender - G263- or the evaporator
temperature sender - G308- is faulty, the evaporator may ice
up or the cooling output will not be achieved.
♦ If a repeat test after the expansion valve has been renewed
indicates that the air conditioning system is still not operating agen AG. Volkswagen AG do
correctly, refit the expansion valve and flush the refrigerantyV
olks
w es n
ot g
circuit with compressed air and nitrogen. Then replaceisethed air
b ua
ran
conditioner compressor and receiver. thor tee
o
au ra
♦ In this case, the evaporator may ice up althoughssthe correct
c
ce
le

un
pt
an
d
itte
♦ If the expansion valve is defective (always closed or not open‐
y li
rm
ab
ing wide enough) the air conditioner compressor regulating
pe
ility
valve - N280- will be set to maximum power and the low-pres‐
ot
wit
, is n
sure value will fall to the diagram value or less (the air condi‐
h re
tioner compressor is drawing the refrigerant out of the low-
hole
spec
pressure side). However, since no refrigerant can flow through
es, in part or in w
the expansion valve, the required cooling power is not deliv‐
t to the co
ered, and it can be that the high-pressure value does not rise
at all or not enough, since no energy exchange is occurring.
rrectness of i
l purpos

tion
nform
ercia
• High pressure only increases ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
slightly above pressure with en‐ ulating valve - N280- is defective. air conditioner com‐
m
a
com
gine stopped. pressor regulating

ion in
valve - N280- .
r
te o
• Low pressure falls only slightly.

thi
s
iva
do

r
rp
cum
fo
attained.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


tion
♦ The air conditioner compressor is defective. – Extract refrigerant.

erant circuit
⇒ page 70 .

ditioner compres‐
sor.
AG. Volkswagen AG d
agen
not – Re-charge refriger‐
oes
o lksw
by
V gu ant circuit.
d ara
rise nte
• High pressure increases above ♦ Actuation
ut
ho of air conditioner compressor reg‐ – Check eo
r a actuation of
specification. ulating
ss a valve - N280- is defective. air conditioner
c com‐
pressor regulating
ce
le
• Low pressure falls quickly to the

un
pt
valve - N280- .
an
d
diagram value or lower.

itte
y li
rm
ab
pe
ility
ot
attained.
wit
, is n
h re
hole
♦ Constriction or obstruction in refrigerant cir‐ – Run hand over re‐
spec
cuit frigerant circuit to
es, in part or in w
t to the co
ces in temperature.
rrectness of i
• At one component a
temperature gradi‐
l purpos

nform
ercia
kinked or crushed,
renew it.
m
a
com
tion in
r
te o
thi
circuit with com‐
s
iva
do
r
rp
cum
trogen in the event

fo
en
g
of an obstruction.
n
t.
yi Co
Cop py
t. rig
gh ht
yri by
ant circuit.
op Vo
by c lksw
cted agen
Prote AG.
– Repeat test.
• If no fault is found:
erant circuit
⇒ page 70 .
ant circuit.

the system does not
operate correctly.
♦ Expansion valve defective – Extract refrigerant.
– Renew the expan‐

sion valve and re‐
ceiver.
ant circuit.

Note


tion
• High pressure and low pressure ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
are normal at first, but after a ulating valve - N280- is defective. air conditioner com‐
while, the high pressure increa‐ pressor regulating
ses beyond the specification. valve - N280- .
• After a time, the low pressure
falls to the diagram value or low‐
er.
• The cooling power called for is
not delivered.
• High pressure and low pressure ♦ Moisture in refrigerant circuit – Extract refrigerant.
are normal at first, but after a agen AG. Volkswagen AG d
oes
longer drive, the low pressure ksw not – Blowing through re‐
Vol gu
by
falls to below the specification ed ara
nte frigerant circuit with
ris
(evaporator iced up). ut
ho eo
r
compressed air and
a ac nitrogen.
ss
ce
le
un
pt
– Renew receiver to‐

an
d
itte
gether with dryer.

y li
erm
ab
ility
ot p
– Evacuate refriger‐
wit
is n
ant circuit for at

h re
least 3 hours.
ole,
spec
t to the co
ant circuit.

rrectne
the system does not

operate correctly.
ss o

cial p
f in
erant circuit
form
mer
⇒ page 70 .
atio
om
c
i
or
ant circuit.
thi
te
sd
iva
o
pr
– Repeat test.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note
♦ If this complaint occurs after a longer period of operation or

only occasionally (the low pressure falls below the specifica‐
tion and the evaporator ices up) it is sufficient only to renew
the dryer (fitted within the receiver). Check the quantity of re‐
frigerant oil. Refrigerant circuit is then to be evacuated for at
least 3 hours.
♦ In case of this complaint, it is not initially necessary to purge
the refrigerant circuit with compressed air and nitrogen, since
as a rule only a small quantity of moisture will have accumu‐
lated in the system, which can be removed by a longer evac‐
uation period.

tion
• High pressure normal, low pres‐ ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
sure too low (see diagram), and ulating valve - N280- is defective. air conditioner com‐
the cooling performance is at‐ pressor regulating
tained. valve - N280- .
♦ Expansion valve defective – Extract refrigerant.

n AG. Volkswagenerant
AG do circuit
swage es
by Volk
⇒ pagen70 ot g .
ua
d ran
ir se tee
utho – Renew the expan‐ or
ss
a sion valve and re‐ ac
ceiver.
ce
le
un
pt
an
d
itte
y li
rm
ab
ant circuit.
pe
ility
ot
wit
, is n
h re
the system does not
hole
spec
operate correctly.
es, in part or in w
t to the co
ditioner compres‐
sor.
rrectness of i
♦ The air conditioner compressor is defective. – Extract refrigerant.
l purpos

erant circuit
nform
ercia
⇒ page 70 .
m
a
com
tio

n in
ditioner compres‐
r
te o
thi
sor.
s
iva
do
r
rp
cum
fo
en
ng
t.
Cop
yi
ant circuit. Co
py
t. rig
gh
– Repeat test.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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.
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- or evaporator temperature sensor -
G308- and actuation of the air conditioner compressor
regulating valve - N280- . If the measured value at the high-
pressure sender - G65- is faulty, the evaporator can ice up or
the required cooling
swa
power
gen AG. Volksiswanot
gen delivered.
AG do
es
k not
Vol
♦ If the defect
by is in the air conditioner compressor
ua regulating
g
ed ran
valve ho - N280- (the regulating valve is not activated,
ris tee but the air
aut
conditioner compressor still runs), it is not
or
necessary ac to blow
ss
through the refrigerant circuit. If this fault occurs, it is sufficient
ce
le
to renew the air conditioner compressor (check the refrigerant

un
pt
an
d
oil quantity in the air conditioner compressor).

itte
y li
rm
ab
pe
ility
ot

wit
, is n

h re
hole
sure value will fall to the diagram value or less (the air condi‐ spec
es, in part or in w
t to the co
rrectness of i
l purpos
⇒ Rep. gr. 87
nform
ercia
cation
m
a
com
ti
• High pressure normal or too ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
on in
high. ulating valve - N280- is defective. air conditioner com‐

r
te o
thi
pressor regulating
s
iva
• Low pressure too high (see di‐ ♦ Too much refrigerant in circuit.
do
valve - N280- .
r
rp
agram).
um
fo
en
g
– Extract some refrig‐

n
t.
yi
Co
op
erant from the refrig‐
py
sor is noisy (especially imme‐
t. C rig
erant circuit.
gh ht
diately after being switched
pyri by
Vo
o
by c
on).
lksw
cted
agen
Prote AG.
• Required cooling output is not frigerant extracted is
attained. about equal to the
prescribed charge
quantity:
tioner compressor.
than the prescribed
charge quantity:
ant circuit.
– Repeat test.

lkswage es n
o ot g
byV u
Amarok 2011 ➤ , Amarok ir se
d 2017 ➤ , Ameo 2017 ➤ , Arteonar2018 an
tee ➤ , Atlas 2 ...
o
Air conditioning asystems
uth with refrigerant R134a - General information or
ac - Edition 11.2019
ss
ce
e
nl
pt
du
an
cation
itte
y li
erm
ab
♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
ility
ot p
cuit.
wit
, is n
h re
hole
• If quantity of refriger‐
spec
ant extracted roughly
es, in part or in w
t to the co
corresponds to
specified capacity:
rrectness of i
erant circuit
⇒ page 70 .
l purpos
nf
ercia
ant circuit.
orm
m
atio
– Repeat test.
om
n in
c
♦ Expansion valve defective – Drain refrigerant cir‐

or
thi
e
cuit.
t
sd
iva
o
r
rp
cu
o
– Renew the expan‐
m
f
en
ng
t.
op
yi Co
sion valve and re‐
ceiver.
C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote
ant circuit.
AG.

the system does not
operate correctly.

tioner compressor.
♦ The air conditioner compressor is defective. – Drain refrigerant cir‐
cuit.

erant circuit
⇒ page 70 .
tioner compressor.

than the prescribed
charge quantity.
ant circuit.
– Repeat test.

Note
♦ If the defect is in the air conditioner compressor regulating

valve - N280- (the regulating valve is not activated, but the air
conditioner compressor still runs), it is not necessary to blow
through the refrigerant circuit. If this fault occurs, it is sufficient
to renew the air conditioner compressor (check the refrigerant
oil quantity in the air conditioner compressor).
was renewed.
ual .

cation agen
AG. Volkswagen AG d
oes
lksw not
• High pressure and low pres‐d by
Vo
♦ Actuation of air conditioner gu compressor
ara reg‐ – Check actuation of
sure are normal. orise ulating valve - N280- is defective.
nte
eo
air conditioner com‐
ut
h
r pressor regulating
• Required coolingssoutput is not ♦ Too much refrigerant oil in circuit.ac
a
valve - N280- .
attained.
ce
e
nl
pt
du

an
itte
y li
erant circuit
erm
ab
⇒ page 70 .
ility
ot p
wit
• High pressure and low pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
, is n
h re
sure are normal. cuit.

hole
spec

es, in part or in w

t to the co
sor is noisy (especially imme‐ erant circuit

diately after being switched ⇒ page 70 .
on).
rrectness of i
• The cooling power required is – Re-charge refriger‐

ant circuit.
l purpos
delivered.
– Repeat test.
nf
ercia
♦ Expansion valve defective – Renew the expan‐

orm
sion valve.
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.

Note

was renewed.
ual .
♦ If the expansion valve is defective (always open) the evapo‐
rator temperature will no longer be regulated so that only
gaseous refrigerant exits the evaporator. It is then possible
that under certain operating conditions, drops of liquid will be
drawn into the air conditioner compressor, which will hen
cause noise (because liquid is incompressible).
lkswage es n
o ot g
byV ua
d ran
ir se
14.7 With expansion valve, receiver and utho tee
or
electrical air conditioner compressor
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
Note
ab
ility
ot p
wit
is n
The electrical air conditioner compressor does not have an air
h re
conditioner compressor regulating valve - N280- . Regulation
ole,
spec
takes place via the speed of the air conditioner compressor. The
air conditioner compressor contains the control electronics and a
t to the co
G-supercharger that impels the refrigerant.
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.

15 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). en AG. V
olkswagen AG
ag does
ol ksw n
• The genuine parts of air conditioner
yV compressor, reservoir, ot gua
db
receiver, evaporator and condenser
ris
e are charged with nitrogen ran
tee
before shipment. Thisaufilling
tho is being gradually discontinued, or
ac
or the pressure of the
ss nitrogen filling is so low that escaping
gas is no longer perceptible when the part is initially opened.
ce
le
un
pt
an
d
itte
• Where vehicles are fitted with an air conditioner compressor
y li
erm
ab
without a magnetic clutch, the engine should be started only
ility
ot p
when the refrigerant circuit has been fully assembled (since
wit
the air conditioner compressor will always run when the engine
is n
h re
is running) ⇒ page 18 .
ole,
spec
• The air conditioner compressor with air conditioner compres‐
t to the co
sor regulating valve - N280- (without magnetic clutch) has an
internal oil circuit to ensure that the air conditioner compressor
is not damaged when the refrigerant circuit is empty. This
rrectne
means that approx. 40 to 50 cm3 of refrigerant oil remain in
the air conditioner compressor ⇒ page 18 .
ss o
cial p
f in
Note
form
mer
atio
m
♦ Since genuine parts are sometimes stored for long periods in

o
n
various places, it can well be that gas will escape from some
c
i
or
n thi
parts when first opened but not from others (even among those
te
sd
a
having the same part number). Therefore, be careful when

iv
o
pr
unscrewing the sealing caps from the genuine part connec‐ cum
r
fo
en
ng
tions and allow the nitrogen gas to escape slowly.

t.
yi Co
op py
♦ Either a restrictor with a reservoir or an expansion valve with
t. C rig
gh ht
yri
a receiver is built into the refrigerant circuit. p by
o Vo
by c lksw
cted agen
♦ Seal open connections and pipes (to prevent absorption of Prote AG.
moisture).
♦ Always renew the restrictor.
The reservoir / receiver or desiccant bag / cartridge need not be

renewed under the following circumstances.
• After an accident in which there was no damage to the reser‐
voir or receiver.
• Repairs are performed quickly (no more delay than during a
normal repair time) and there was no moisture intrusion. The
vehicle is no more than 5 years old.
The reservoir or receiver or dryer cartridge should be renewed
under the following circumstances>
• The refrigerant circuit was opened and the vehicle is more than
5 years old.
• The refrigerant circuit has been opened for in indeterminate
period (seepage leak).
• Repairs take longer than a normal repair time and there has
been moisture intrusion.
• Always renew collector/reservoir or dryer cartridge after blow‐
ing through with compressed air or purging with refrigerant
R134a. Keep genuine parts sealed for as long as possible to
keep the ingress of moisture as low as possible.
• The air conditioner compressor seizes.
15. Renewing components 191

AG. Volkswagen AG d
agen oes
lksw not
• The reservoir or receiver
by V is damaged (e.g. in an accident).
o gu
ara
ed
ris nte
ho eo
CAUTIONaut ra
c
ss
Risk of chemical burns from atomised refrigerant oil. Eyes and
ce
le
un
pt
other parts of the body could be injured.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Never inhale atomised refrigerant oil.
h re
ole,
spec
15.1 In the event of leaking or damaged com‐
t to the co
ponents (apart from the air conditioner
compressor, receiver or reservoir)
rrectness
15.1.1 If the refrigerant circuit was completely
o
cial p
f inform
empty
mer
atio
m
– Remove defective part.

o
n
c
i
or
n thi
– Remove air conditioner compressor.* ⇒ Heating, air condi‐
te
sd
a
tioning; Rep. gr. 87 ; Air conditioner compressor; Removing

iv
o
pr
and installing air conditioner compressor . cum

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

– Unscrew oil drain plug -B- / -D- from air conditioner compres‐
sor -A-.*
Note
♦ The design of the oil drain plug -B- / -D- and seal -C- / -E- may
vary (depending on the manufacturer of the air conditioner
compressor) ⇒ Heating, air conditioning; Rep. gr. 87 ; Air
conditioner compressor (vehicle-specific workshop manual).
♦ When installing the oil drain plug -B-/-D-, observe the corre‐
sponding torque specification (depending on the manufacturer
of the air conditioner compressor and the design of the oil drain
plug). Please note that the oil drain plug of air conditioner
compressors manufactured by “Denso” and “Delphi” is equip‐
ped with an oil seal ⇒ Heating, Air conditioning; Rep. gr. 87 ;
Air conditioning compressor, Assembly overview - drive unit
of air conditioner compressor (currently valid specified agen torque:
AG. Volkswagen AG d
oes
30 Nm for “Denso” and 15 Nm for “Delphi” compressors).
y Volksw The not
gu
oil drain plug of air conditioner compressors ise
d b
manufactured by ara
nte
“Sanden” and “Zexel- / Valeo” may be thoequipped
r
with an O-ring eo
or an oil seal (depending on the vehicle
ss au
equipment; currently ra
c
valid specified torque: 10 Nm, respectively).
ce
le
un
pt
an
d
♦ On the Denso air conditioner compressor, for example, the oil

itte
y li
drain plug -D- has an oil seal -E-; renew ⇒ Heating, air con‐
rm
ab
pe
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
ility
ot
specific workshop manual) and ⇒ Electronic parts catalogue .
wit
, is n
h re
♦ On the Sanden air conditioner compressor, for example, the
hole
spec
oil drain plug -B- has a seal -C-; renew ⇒ Heating, air condi‐
es, in part or in w
tioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
t to the co
specific workshop manual) and ⇒ Electronic parts catalogue .
♦ If a seal (oil seal or O-ring) fitted to the oil drain plug is not
rrectness of i
available as a replacement part, the removed old part can be
reused (as an exception to the general rule of using new seals
l purpos
only). The old seal, however, must always be checked for

damage prior to installation. If any damage or deformation is
nform
ercia
detected on the old seal, it must be renewed with a commer‐

cially available new part.
m
a
com
tio
♦ After filling the refrigerant circuit, check the installed oil drain
n in
r
plug for leaks using e.g. an electronic leak detector.

te o
thi
s
iva
do
♦ To speed up draining of the refrigerant oil, rotate the shaft of

r
rp
cum
the air conditioner compressor e.g. using the belt pulley or the
fo
en
g
magnetic clutch pulley.

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

Note
♦ To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor by hand using the poly V-
belt pulley or the magnetic clutch.
♦ Pour old refrigerant oil out of air conditioner compressor, han‐
dling refrigerant oil ⇒ Volkswagen ServiceNet; Service hand‐
oils .
♦ Then fill the air conditioner compressor with the quantity of
new refrigerant oil corresponding to the quantity
wage
n Ain
G.a
Vogenuine
lkswagen AG
does
air conditioner compressor ⇒ Rep. gr.y V87
olks . not
gu b ara
ed
♦ Different types and quantities ofthorefrigerant
ris oils are required nte
e
for different air conditioner compressors
sa
u ⇒ Rep. gr. 87 . or
ac
s
♦ To ensure proper lubrication of the air conditioner compressor
ce
e
nl
pt
du
when it runs for the first time, the air conditioner compressor
an
itte
y li
must be filled with at least 80 cm3 of refrigerant oil; the re‐
erm
ab
mainder can be poured into the new reservoir or receiver ⇒
ility
ot p
Rep. gr. 87 .
wit
, is n
h re
♦ If dirt enters the air conditioner compressor whilst the refrig‐
hole
spec
erant circuit is open (e.g. after an accident), the air conditioner
es, in part or in w
compressor should be renewed.
t to the co
♦ Blow through refrigerant circuit with compressed air and re‐
move moisture with nitrogen ⇒ page 68 .
rrectness of i
l purpos
– Replace receiver or reservoir and restrictor.

– Assemble the refrigerant circuit, evacuate it and charge it.
nform
ercia
15.1.2 If there is still refrigerant in the refriger‐

m
at
om
io
ant circuit
n
c
in t
or
his
ate
– Drain refrigerant circuit.

do
priv
cum
or
– Remove the defective part, blow through with compressed air

f
en
ng
t.
yi
and collect any escaping refrigerant oil.
Co
Cop py
t. rig
gh
– The refrigerant oil that is blown out (plus 20 cm3 for the evap‐
ht
pyri by
Vo
o
orator, plus 10 cm3 for the condenser, refrigerant lines and
c by lksw
cted agen
Prote
refrigerant hoses) should be poured into the new component
AG.
as fresh refrigerant oil.

– Replace restrictor. Depending on vehicle.
– Assemble, evacuate and charge refrigerant circuit.
15.2 Renew the air conditioner compressor
Note
On vehicles equipped with an electrical air conditioner compres‐

sor, de-energise the high-voltage system before removing the air
conditioner compressor. ⇒ Electric drive; Rep. gr. 93 ; Electric
drive; De-energising high-voltage system
15.2.1 Without needing to flush refrigerant cir‐

cuit of contaminants (cleaning), e.g. in

cases of external damage after an acci‐

dent
– Remove air conditioner compressor.
Note
If a different air conditioner compressor with other refrigerant oil

is fitted, purge the refrigerant circuit with R134a refrigerant
⇒ page 70 .

If an electrical air conditioner compressor is renewed without hav‐
ing a mechanical fault (e.g. defective printed circuit board), the
amount of refrigerant oil from this electrical air conditioner com‐
pressor must be determined.
Note
♦ The air conditioner compressor must be purged in order to

extract the refrigerant oil which needs to be determined.
♦ Purge the air conditioner compressor in normal direction of
flow (from low-pressure inlet to high-pressure outlet).
♦ In order to purge as much refrigerant oil from the air condi‐
tioner compressor as possible make sure that the high-pres‐
sure outlet of the air conditioner compressor is in the lowest
position possible. wage
e ks s no
Vol t gu
♦ If an air conditioning service station without purging
ed
by pro‐ ara
gramme is used, the sequence has to be tcarried
ho
ris out manually nte
eo
(evacuate, purge 3 times with at least 2s akg of refrigerant each
u ra
c
time and extract refrigerant again, evacuate).
s
ce
e
nl
pt
du
an
itte
Determined amount e.g. 50 cm³ y li

erm
ab
ility
Then, remove as much refrigerant oil from the new air conditioner
ot p
wit
compressor as is necessary to ensure that only the same amount
, is n
h re
of refrigerant oil which has been purged from the old air condi‐
hole
spec
tioner compressor remains in the new one (plus 10 cm 3). If, for
es, in part or in w
example, the new original air conditioner compressor is filled with

t to the co
e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
rrectness of i

l purpos

oils .
nf
ercia
orm
m
atio
Note
om
n in
or c
thi
If the amount of refrigerant oil which can be removed from the

te
sd
a
new air conditioner compressor is not sufficient, the new air con‐
iv
o
r
rp
cu
ditioner compressor must be purged. After the new air conditioner

o
m
f
en
compressor has been purged, fill the amount of refrigerant oil

ng
t.
yi Co
which has been determined when purging the old air conditioner t. Cop py
compressor.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Mechanically driven air conditioner compressor: Drain refrigerant Prote AG.
oil via block connections.

– To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor using the magnetic clutch
poly V-belt pulley. Not applicable for electrical air conditioner
compressor.
book; Environmental protection; Waste disposal; Current n AG. Volkswagen AG do
lkswage es n
situation; Disposal channels; Disposal of used oils; RefrigerantbyV
o ot g
ua
oils . ir se
d ran
te
ho eo
ut
– Only refill with fresh refrigerant oil equivalent to volume
ss
a of oil ra
c
that was removed (from defective air conditioner compressor).
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ If for instance 70 cm3 refrigerant oil was poured out of the de‐
h re
hole
fective air conditioner compressor, and 220 cm3 oil was pour‐
spec
ed out of the genuine air conditioner compressor (a small
es, in part or in w
t to the co
quantity of refrigerant oil remains in the air conditioner com‐
pressor), pour 70 cm3 refrigerant oil into the genuine air con‐
ditioner compressor (the refrigerant oil previously poured out
rrectness of i
of the genuine air conditioner compressor part may be used).
l purpos
♦ Different air conditioner compressors require different types

and quantities of refrigerant oils ⇒ Rep. gr. 87 .
nform
ercia
♦ If a large quantity of refrigerant oil (more than about 80 cm3)

was poured from the defective air conditioner compressor, the
m
at
om
remaining refrigerant oil can also be poured into the evapora‐
ion
c
tor or the reservoir or receiver ⇒ Rep. gr. 87 .
in t
or
his
ate
do
riv
– Replace restrictor. Depending on vehicle.

p
cum
for
en
ng

t.
yi Co
Cop py
. rig
15.2.2 Leaks or internal damage (e.g. noises or
t
gh ht
pyri by
Vo
o
lack of power)
c by lksw
cted agen
Prote AG.

Note
♦ For internal damage or leak (in or from air conditioner com‐

pressor), flush refrigerant circuit with refrigerant R134a
⇒ page 70 .
♦ If a different air conditioner compressor with other refrigerant
oil is fitted, purge the refrigerant circuit with R134a refrigerant
⇒ page 70 .
15.3 Replace receiver or reservoir and re‐

strictor
15.3.1 After flushing contaminants from refrig‐

erant circuit, e.g. due to moisture intru‐
sion (because refrigerant circuit was

open for a longer period of time) or due

to soiling
The reservoir/receiver or desiccant bag/cartridge need not be re‐
newed under the following circumstances:
• After an accident in which there was no damage to the reser‐
voir or receiver.
• Repairs are performed quickly (no more delay than during a
normal repair time) and there was no moisture intrusion. The
vehicle is no more than 5 years old.
The reservoir or receiver or dryer cartridge should be renewed
under the following circumstances>
AG. Volkswagen
• The refrigerant circuit was opened
wage
n
and the vehicle
AG do
is
es more than
olks not
5 years old. d by V gu
a
e ran
ris t
• The refrigerant thcircuit
o has been opened for in indeterminateee or
period (seepage
s au leak). ac
s
ce
le
• Repairs take longer than a normal repair time and there has
un
pt
an
d
been moisture intrusion.

itte
y li
rm
ab
• Always renew collector/reservoir or dryer cartridge after blow‐
pe
ility
ot
ing through with compressed air or purging with refrigerant
wit
, is n
R134a. Keep genuine parts sealed for as long as possible to
h re
hole
keep the ingress of moisture as low as possible.
spec
es, in part or in w
• The air conditioner compressor seizes.
t to the co
• The reservoir or receiver is damaged (e.g. in an accident).
rrectness of i
l purpos

– Rectify cause of fault.
nform
ercia
– Renew the expansion valve.

m
a
com
– Drain refrigerant oil from air conditioner compressor via block

ion in
connections.
r
te o
thi
s
iva
– To speed up the draining of the refrigerant oil, rotate the shaft

do
r
rp
of the air conditioner compressor using the magnetic clutch

um
fo
poly V-belt pulley.

en
ng
t.
yi Co
op py
. C rig
ht ht
rig
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐ py by
o Vo
by c lksw
cted agen
Prote AG.
oils .
– Then fill the air conditioner compressor with a quantity of new
refrigerant oil equal to the quantity in a genuine air conditioner
compressor ⇒ Rep. gr. 87 .

AG. Volkswagen AG d
agen oes
olksw not
V
Note d by gu
ara
rise nte
tho eo
♦ Types and quantities of refrigerant oils which should be used
au ra
ss c
for different air conditioner compressors ⇒ Rep. gr. 87 .
ce
e
nl
pt
du
an
♦ To ensure proper lubrication of the air conditioner compressor
itte
y li
when it runs for the first time, the air conditioner compressor
erm
ab
must be filled with at least 80 cm3 of refrigerant oil; the re‐
ility
ot p
wit
mainder can be poured into the new reservoir or receiver ⇒
, is n
h re
Rep. gr. 87 .
hole
spec
♦ If dirt enters the air conditioner compressor whilst the refrig‐
es, in part or in w
t to the co
erant circuit is open (e.g. after an accident), the air conditioner
compressor should be renewed.
rrectness of i
– Replace receiver or reservoir and restrictor.
l purpos
15.3.2 Without needing to flush contaminants
nform
ercia
from refrigerant circuit (e.g. damage in

m
at
om
an accident); no refrigerant has escaped
ion
c
in t
or
and no moisture or dirt has entered re‐
his
ate
do
riv
frigerant circuit
p
cum
for
en
ng

t.
yi Co
Cop py
t. rig
– Replace restrictor. Depending on vehicle. opyri
gh by
Vo
ht
c
– Remove receiver or reservoir.
by lksw
cted agen
Prote AG.
– Clean any dirt out of receiver or reservoir.
– Weigh removed receiver or reservoir.
Note
♦ Fill enough refrigerant oil into the new reservoir or collector so

that it has the same weight as the container which was re‐
moved.
♦ Install new receiver or reservoir.

Air conditioning systems with refrigerant R134a n AG. Volkinformation
a-geGeneral
swagen AG
doe-s Edition 11.2019
ksw n ol ot g
yV ua
edb ran
ris tee
16 Testing equipment and stools au
tho or
ac
s
ce
e
nl
pt
du
an
itte
16.1 List of test equipment, tools and materi‐
y li
erm
ab
als
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
This list is an overview of the test equipment, tools and materials
necessary for professional repairs to the refrigerant circuit.
rrectness of i
16.1.1 Tools and materials available from re‐
l purpos
gional sales centre or importer
nform
ercia
Overview Page
m
at
om
i
Air conditioner service station ⇒ page 201
on
c
in t
or
Leak detector - V.A.G 1796- ⇒ page 202
his
ate
do
riv
Leak detecting system - VAS 6196- ⇒ page 202

p
cum
or
Leak detection additive - VAS 6196/1- Not illustrated

f
en
ng
t.
yi Co
op
Leak detecting system - VAS 6201- or later ⇒ page 203 C py
ht. rig
model rig ht
py by
co Vo
Air conditioner service station with purging Not illustrated
by lksw
cted agen
Prote
device or air conditioner service station with
AG.
purging device - VAS 6337- (latest available

air conditioner service stations ⇒ V.A.G
workshop equipment catalogue ).
♦ With integrated program for purging re‐
frigerant circuit using refrigerant R134a.
Purging device for refrigerant circuits - VAS ⇒ page 202

6337/1- , (other available refrigerant circuit
purging devices ⇒ V.A.G workshop equip‐
ment catalogue .
♦ For purging refrigerant circuit using re‐
frigerant R134a. May also be used on
older air conditioner service stations
(purging procedure must then be carried
out manually) with a reservoir volume of
at least 10 kg refrigerant R134a.
Purging device for refrigerant circuits - VAS ⇒ page 202

6336/1- , (other available refrigerant circuit
purging devices ⇒ V.A.G workshop equip‐
ment catalogue .
♦ For purging refrigerant circuit using re‐
frigerant R134a. May also be used on
older air conditioner service stations
(purging procedure must then be carried
out manually) with a reservoir volume of
at least 10 kg refrigerant R134a.
Adapter case VW/Audi passenger vehicle Not illustrated

set VAS 631 for refrigerant circuits with re‐
frigerant R134a.
♦ For connection of air conditioner service
station to refrigerant circuit and to bridge
certain components during purging with
refrigerant R134a or blowing through with
compressed air or nitrogen.
16. Testing equipment and tools 199

Overview Page
AG. Volkswagen AG d
agen
Adapter case commercial vehicle set o-
lksw Not illustrated oes not
VAS 6338/50- for refrigerant circuits by Vwith re‐ gu
ara
d
se
frigerant R134a. hori nte
eo
aut
♦ For connection of air conditioner service ra
s c
station to refrigerant circuit and to bridge
s
ce
le
certain components during purging or
un
pt
an
d
blowing through.
itte
y li
rm
ab
pe
ility
Ultrasonic air conditioner cleaning unit - VAS Not illustrated
ot
wit
6189A-
, is n
h re
♦ To remove unpleasant odours originating
hole
spec
from air conditioning system.
es, in part or in w
t to the co
Suction feed spray-gun - V.A.G 1538- Not illustrated
♦ V.A.G 1538/5, probe for evaporator
cleaning, short
rrectness of i
l purpos
cleaning, long
nform
ercia
cleaning, 700 mm (CV)

m
a
com
♦ Cleaner D 600 100 A1
tion in
r
te o
♦ Cleaning solution for evaporator D 600
thi
s
100 A2
iva
do
r
rp
cum
fo
♦ To remove unpleasant odours from evap‐

en
ng
t.
orator Cop
yi Co
py
ht. rig
ht
Release tools case - VAS 6127- ⇒ page 203
rig by
opy Vo
♦ To open refrigerant pipes.
by c lksw
cted agen
Prote AG.
Release tools - VAS 6127/1-3- ⇒ page 203

♦ To open refrigerant pipes.
Counter-hold tool - V.A.G 1616- ⇒ page 204

♦ For coupling plate (air conditioner com‐
pressor made by “Sanden”).
Puller - V.A.G 1616/1- for magnetic clutch ⇒ page 204

(Sanden air conditioner compressor).
Magnetic clutch puller - V.A.G 1719- (Zexel ⇒ page 204
air conditioner compressor).
Adapter set for refrigerant circuit - V.A.G ⇒ page 204
1785/1-10- R134a.
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 205
connections on HP/LP side of refrigerant cir‐
cuit.
16.1.2 Tools and materials commercially available

Overview Page
Fin comb ⇒ page 205
Charging hoses 5/8"-18 UNF with valve opener ⇒ page 206
Connector piece for pressure bottles for refrigerant and sealing ring with quick- ⇒ page 206
release coupling or threaded connector 5/8"-18 UNF

Overview Page
AG. Volkswagen AG d
agen oes
Valve caps 5/8" -18 UNF V olksw not ⇒ page 206
gu
by a
Manifold gauge with pressure limiter for nitrogen orised
⇒rapage
nte 206
h eo
Quick connector adapter for service connections,
aut 2 × included with the air ⇒ page r a 207
ss c
conditioner service station .
ce
e
nl
pt
du
Open ring spanners of widths matching those of the threaded connections on Not illustrated
an
itte
y li
the refrigerant pipes.
erm
ab
ility
Valve opener for charging hoses Not illustrated
ot p
wit
, is n
Connection nipple for tapered seal 5/8"-18 UNF Not illustrated
h re
Compressed air gun with rubber nozzle hole Not illustrated
spec
es, in part or in w
Hand shut-off valve 5/8" - 18 UNF Not illustrated
t to the co
Recycling bottle for refrigerant R134a Not illustrated
Digital thermometer Not illustrated
rrectness of i
Safety gloves Not illustrated
l purpos
Safety glasses Not illustrated

Refrigerant R134a with pressure bottle (contents as required) Not illustrated
nform
ercia
Nitrogen in pressure bottle Not illustrated

m
at
om
i
Strap wrench (oil filter) as counterhold for poly V-belt pulley Not illustrated
on
c
in t
or
his
ate
do
priv
cum
or
16.1.3 Tools to be made locally

f
en
ng
t.
yi Co
op py
Overview Page t. C rig
gh ht
pyri by
Charging hose with connection to workshop ⇒ page 207
o Vo
by c lksw
cted
compressed air system
agen
Prote AG.
16.1.4 Tools and materials available from re‐

gional sales centre or importer
Air conditioner service station
⇒ Workshop equipment
♦ The procedures for testing, extracting (recycling), evacuating
and charging should be carried out in accordance with the re‐
spective user's manual.
♦ The installed filter and dryer must be renewed at the latest at
the end of the period of use specified in the operating instruc‐
tions and every time that the station is emptied (keep replace‐
ment filter on hand. They can be ordered from the manufac‐
turer of the device, see user's manual.
♦ Air conditioner service stations or purging devices approved
by VW but not shown here may also be used.
⇒ Workshop equipment
Note
♦ This air conditioner service station incorporates the following

familiar individual devices: charging cylinder, manifold gauge,
vacuum pump, shut-off valves and charging hoses.
♦ This air conditioner service station includes one of each type
of quick-release connector (for high-pressure and low-pres‐
sure side service connections).

Purging device for refrigerant circuits - VAS 6337/1- from “Behr”

or later model.
Note
♦ With filter -1- and two large cylindrical sight glasses

♦ The filter in the purging device for refrigerant acircuits
gen AG should n AG do
. Volkswage
be changed after about 2 purging cycles yV
o(depending
lksw on the es n
ot g
level of contamination from the purged ed b refrigerant circuits). If ua
ran
a heavily contaminated refrigerant ris
ho circuit is purged (the refrig‐
tee
t or
erant oil from the refrigerant circuit
ss
au is black and viscous or ac
there are large amounts of shavings in the refrigerant circuit)
ce
le
renew filter after purging refrigerant circuit.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
Purging device for refrigerant circuits - VAS 6336/1- from “Waeco”
wit
or later model.
is n
h re
ole,
spec
Note
t to the co
♦ With filter -1- and one sight glass
rrectne
♦ The filter in the purging device for refrigerant circuits should
be changed after about 2 purging cycles (depending on the
s
level of contamination from the purged refrigerant circuits). If
s o
a heavily contaminated refrigerant circuit is purged (the refrig‐
cial p
f in
erant oil from the refrigerant circuit is black and viscous or
form
mer
there are large amounts of shavings in the refrigerant circuit)
atio
renew filter after purging refrigerant circuit.
om
n
c
i
or
n thi
te
sd
a
Leak detector - V.A.G 1796-

iv
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.
Leak detecting system - VAS 6196-

Air conditioning systems with refrigerant R134a - .General
en AG Volkswageinformation
n AG - Edition 11.2019
ag does
ksw not
y Vol gu
Leak detecting system - VAS 6201- or later model ed
b ara
nte
oris eo
th
au ra
c
ss
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
Release tool - VAS 6127- case comprising release tool - VAS
6127/1- release tool - VAS 6127/2- and release tool - VAS 6127/3-
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
Release tool - VAS 6127/1- release tool - VAS 6127/2-
c by lksw
cted agen
Prote AG.
♦ Blue 1/2 inch
♦ Black 5/8 inch
♦ Red 3/8 inch
♦ White 3/4 inch
Release tool - VAS 6127/3-

♦ Green NW 8 for high-pressure line
♦ Black NW 13 for low-pressure line

Counterhold - V.A.G 1616- for clutch pulley (for “Sanden” air con‐
ditioner compressors)
Puller - V.A.G 1616/1- for clutch pulley (for “Sanden” air condi‐
tioner compressors)
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
Magnetic clutch puller - V.A.G 1719- (for “Zexel” air conditioner
, is n
h re
compressors)
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
Adapter set for refrigerant circuit - V.A.G 1785/1-10-

thi
te
sd
iva
o
♦ Adapter to clean refrigerant circuit (flushing with refrigerant
r
rp
cu
o
R134a) ⇒ page 70 or blowing through with compressed air or

f
en
ng
t.
nitrogen ⇒ page 68
yi Co
Cop py
t. rig
A - 5/8"-18 UNF thread for conical surface seal gh ht
pyri by
Vo
o
by c lksw
B - Cap nuts (for connection with O-ring) with thread Prote
cted AG.
agen
♦ M 18x1.5 V.A.G 1785/1

♦ M 20x1.5 V.A.G 1785/2
♦ M 24x1.5 V.A.G 1785/3
♦ M 28x1.5 V.A.G 1785/4
A - 5/8"-18 UNF thread for conical surface seal
B - Threaded union for O-ring

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♦ M 28x1.5
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Valve adapter
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B - Internal thread with valve opener M 10x1.25 V.A.G 1785/9 (for
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V.A.G 1785/10 (for connections on the low-pressure side)
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Socket insert - T10364- for valves of service connections on HP/
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16.1.5 Tools and materials commercially avail‐

able
Fin comb

Charging hoses
5/8"-18 UNF thread
Note
♦ Use charging hoses in different colours, 1800 mm long.

♦ Maintain a stock of valve openers and spare seals.
Connector piece for pressure bottles for refrigerant with sealing

ring, quick-release coupling or threaded connector 5/8"-18 UNF
Valve caps with replacement seals (for 5/8''-18 UNF threads)

Seals can also be used for charging hoses.
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Manifold gauge with pressure reducer for nitrogen (maximum re‐

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duction pressure: 15 bar)

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2- Pressure hose (internal diameter 5 mm, length 2 m) with

hose junctions
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coupling adapter for service connections to refrigerant circuit.

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Quick-release coupling adapter for service connections

♦ High-pressure side with nominal diameter of 16 mm
♦ Low-pressure side with nominal diameter 13 mm
Note
These quick-release couplings are supplied with the air condi‐

tioner service station .
16.1.6 Tools to be made locally

Charging hose with connection to workshop compressed air sys‐
tem
A - Charging hose 5/8" - 18 UNF** (version with large internal
diameter)
B - Connector for workshop compressed air system** (use only
with filter and dryer for compressed air)
** Tools and materials commercially available
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Service

Golf 1998 tho

Golf 2015 ➤ , Golf 2016 ➤ ,

Golf 2017 ➤ , Golf Cabriolet 2012 ➤ ,

Golf MEX 2018 ➤ , Golf Plus 2005 ➤ ,

Golf Plus 2009 ➤ ,

Golf Sportsvan 2015 ➤ ,

Golf Sportsvan 2018 ➤ ,

Golf Variant 2007 ➤ ,

Golf Variant 2010 ➤ ,

Golf Variant 2014 ➤ ,

Golf Variant 2015 ➤ ,

Golf Variant 2017 ➤ , Jetta 2005 ➤ ,

Jetta 2011 ➤ , Jetta 2013 ➤ ,

Jetta 2015 ➤ , Jetta 2018 ➤ ,

LT 1997 ➤ , Lupo 1999 ➤ ,

Service Department. Technical Information

Lupo 3L 1999 ➤ , Multivan 2004 ➤ ,

Polo 2018 ➤ , Polo Classic 1996 ➤ ,

Polo Lim IN 2011 ➤ ,

Polo Lim IN 2016 ➤ ,

Polo Lim MY 2014 ➤ ,

Polo Lim MY 2016 ➤ ,

Polo Lim RUS 2016 ➤ ,

Polo Variant 1998 ➤ , Scirocco 2009 ➤ ,

Scirocco 2015 ➤ , Sharan 1996 ➤ ,

Sharan 2011 ➤ , Sharan 2016 ➤ ,

T-Cross 2019 ➤ , T-Roc 2018 ➤ ,

TGE 2017 ➤ , The Beetle 2017 ➤ ,

The Beetle Cabriolet 2012 ➤ ,

The Beetle Cabriolet 2017 ➤ ,

Tiguan 2008 ➤ , Tiguan MEX 2017 ➤ ,

Service Department. Technical Information

Tiguan RUS 2017 ➤ , Touareg 2003 ➤ ,

e-TGE 2019 ➤ , e-up! 2014 ➤ ,

Service Department. Technical Information

matter of course, be observed.

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8027068B

1.1 Safety precautions when working on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Safety precautions when working on a high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 1

4 General information on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.2 Basics of air conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.3 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.5 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8.8 Emptying air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

12.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1.1 Safety precautions when working on air conditioning systems

– If more than 10 minutes have passed since the refrigerant was pt

extracted, repeat the extraction process before opening the y li

circuit from continued evaporation.

Risk of damage to refrigerant lines

the inner foil.

– Never bend refrigerant lines to a radius less than 100 mm.

1.2 Safety precautions when working on a high-voltage system

Danger to life from high voltage

The high-voltage system is under high voltage. Severe or fatal

gesic pumps, implanted defibrillators, pacemakers, insulin

Risk of injury from engine starting unexpectedly

Risk of damage to high-voltage cables

tionally. Risk of limbs becoming trapped or drawn in by the

radiator fan starting automatically.