S01DCBXXX20-Air - Conditioner - With - Refrigerant - R134a Seat Leon F5 MK3 2013-2020

Service
Workshop Manual
Alhambra 1996 ➤ , Alhambra 2001 ➤ ,
Alhambra 2011 ➤ , Alhambra 2016 ➤ ,
Altea 2004 ➤ , Altea 2009 ➤ ,
Altea XL 2007 ➤ , Altea XL 2009 ➤ ,
Altea XL Freetrack 2008 ➤ ,
Altea XL Freetrack 2009 ➤ ,
Arosa 1997 ➤ , Córdoba 1999 ➤ ,
Córdoba 2003 ➤ , Córdoba Vario 1999 ➤ ,
Exeo 2009 ➤ , Exeo ST 2009 ➤ ,
Ibiza 1999 ➤ , Ibiza 2002 ➤ ,
Ibiza 2008 ➤ , Ibiza 2016 ➤ ,
Ibiza ST 2010 ➤ , Ibiza ST 2016 ➤ ,
León 1999 ➤ , León 2006 ➤ ,
León 2009 ➤ , León 2013 ➤ ,
León ST 2013 ➤ , Mii 2012 ➤ ,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Toledo 2005 ➤ , Toledo 2013 ➤

Air conditioner with refrigerant R134a
Edition 12.2016
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Seat S.A S01DCBXXX20

Alhambra 1996 ➤ , Alhambra 2001 ➤ , Alhambra 2011 ➤ , Alhambra 2016 ➤ , ...
Air conditioner with refrigerant R134a - Edition 12.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Other means of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Basics of air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Coolant agent R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Characteristics of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Refrigerant machine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 How air conditioning worksCopying
Protected by copyright. . . . .for. private
. . . . or. commercial
. . . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. . . . is. not
................. 9
1.10 General aspects regarding
permitted unless authorisedworkplace
by SEAT S.A. SEAT safety . .not
S.A does . .guarantee
. . . . . or. accept
. . . . any. . liability
. . . .with
................ 9
1.11 Safety precautions for working on vehicles with air-conditioning and handling refrigerant
R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.12 Fundamental aspects for working on the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 15
2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Parts of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Refrigerant circuit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Extraction and filling valve for the quick connection of the air-conditioning service station on
the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Switches and senders in the refrigerant circuit and corresponding connections . . . . . . . . 28
2.5 Electrical components not fitted onto the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Pressures and temperatures in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Refrigerant circuit with restrictor and reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.9 Inspection and measurement work which can be carried out with a manometer . . . . . . . . 38
2.10 Equipment for loading and recycling of the refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.11 Repair instructions for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Legal texts and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2 Law regulating waste recycling and management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Refrigerant record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1 Important instructions regarding air-conditioner system repair . . . . . . . . . . . . . . . . . . . . . . 44
5 Working with the service equipment for air conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Working with the service station SAT 4006D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Important notes on working with the air conditioning service station . . . . . . . . . . . . . . . . . . 46
5.3 Connecting the air conditioning service station for carrying out measurements and tests
........................................................................ 46
5.4 Extract the refrigerant circuit using the air conditioning service station. . . . . . . . . . . . . . . . . 47
5.5 Emptying the refrigerant circuit with the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Charging the refrigerant circuit with the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7 Fill the container of the air conditioning service station with refrigerant . . . . . . . . . . . . . . . . 51
5.8 Emptying the service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Check for possible leaks in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1 Locating leaks in the refrigerant circuit with the leak detector SAT 4012 . . . . . . . . . . . . . . 54
6.2 Locating leaks in the refrigerant circuit with the leak detector SAT 4007B . . . . . . . . . . . . 55
6.3 Tracing leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Cleaning the inner side of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.1 Cleaning the refrigerant circuit using the cleaning station SAT 4011 . . . . . . . . . . . . . . . . 62
7.2 Description and operation of the cleaning station SAT 4011 . . . . . . . . . . . . . . . . . . . . . . 65
7.3 Blow through refrigerant circuit with compressed air and nitrogen. . . . . . . . . . . . . . . . . . . 68
Contents i
8 Cleaning refrigerant circuit of impurities using R134a refrigerant . . . . . . . . . . . . . . . . . . . . 71

8.1 Rinsing (cleaning) the refrigerant circuit using the refrigerant R134a . . . . . . . . . . . . . . . . 71
8.2 Application of the flush kit with adapters SAT 4009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3 Adaptation of refrigerant loading machines before SAT 4006D to rinse circuits with the Kit
SAT 4009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.4 Adapters to create rinsing circuits VAS 6338/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.1 Possible complaints regarding the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.2 Odour in the air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10 Connect the air conditioning service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1 To vehicles equipped with a connection on both the high and low pressure sides of the
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
11 Checking the pressures in vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
11.1 Check the pressure in the refrigerant circuit (using the air conditioning service station) . . 106
11.2 Checking pressures with restrictor and reservoir (with internally regulated compressor) . . 109
11.3 Checking the pressures with expansion valve and liquid tank (with internally controlled
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11.4 Checking with expansion valve and liquid tank (without regulating compressor) . . . . . . . . 117
11.5 Pressures with restrictor, reservoir and air conditioner compressor regulating valve N280 :
Check (with externally regulated compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.6 Checking pressures with restrictor, reservoir and air conditioner compressor regulating valve
N280 (with externally regulated compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
11.7 With expansion tank, liquid tank and electric compressor for hybrid vehicles . . . . . . . . . . 131
12 Replacing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12.1 Renewing refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12.2 Replacing the air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
12.3 Replacing liquid tank or collecting tank and choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
13 Quantity of refrigerant R134a, quantity of the refrigerant oil: SEAT vehicles . . . . . . . . . . . . 138
13.1 Top-up quantities of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
13.2 Refrigerant oils and top-up quantities for authorised refrigerant oils . . . . . . . . . . . . . . . . . . 141
14 Verification equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
14.1 List of testers, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
ii Contents
00 – Technical data
1 General notes on air conditioning
systems
(ERL003245; Edition 12.2016)
1.1 Introduction
This repair manual is aimed at providing the operators the basic
knowledge required to enable them to work in a qualified manner.
Note
After studying this manual, the operator should be qualified inSEAT

the S.A does not guarantee or accept any liability with
permitted unless authorised by SEAT S.A.
area of vehicle air-conditioning, and should
respect tobe
the able to apply
correctness the in this document. Copyright by SEAT S.A.
of information
acquired knowledge in practice.
This documentation is also intended for use by the persons in

charge of supervision and/or inspection.
Caution
When using tools or materials that have not been approved

(e.g. sealing additives), damage may be caused to the system
or it may be influenced.
Only tools and materials authorized by the manufacturer must
be used.
Warranty claims are invalid if tools or materials are used that
have not been approved.
1.2 Other means of information

♦ Service and Technical Manual with means of how to solve
current anomalies
♦ Repair manual for repair work specific to each model ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 .
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
♦ Autodidactic programs
♦ Video programmes for training courses
♦ Catalogue of special tools / workshop trials
♦ electronic parts catalogue
♦ Service Organization: Volume 2
1. General notes on air conditioning systems 1

1.3 Basics of air conditioning
1.3.1 Physical basics:

The four known physical states of water also apply to air condi‐
tioning refrigerants.
1- Gas (invisible)
2- Vapour
3- Liquid state
4- Solid
When water is heated in a container (heat absorption), the rising

water vapour is visible. If the vapour is heated by further heat
absorption, the visible vapour becomes invisible gas. This proc‐
ess is reversible. If heat is extracted from water in gaseous state,
it first turns into vapour, then into water, and finally into ice.
A - Heat absorption
B - Heat dissipation
1.3.2 Heat always flows from warmer to colder

material
Every material consists of a mass of moving molecules. The fast
moving molecules of a permitted
hot matter
Protected transfer
by copyright. some
Copying of their
for private energy purposes,
or commercial to in part or in whole, is not
the cooler, slower moving molecules. By doing so, the movement

unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
of the molecules of the hotter matter is slowed down, while the
movement of the molecules of the cooler matter is accelerated.
This process continues until the molecules of both matters move
at the same speed. They have the same temperature, and no
further exchange of heat occurs.
1.3.3 Pressure and boiling point

The boiling points given in the table below are always based on
an atmospheric pressure of 1 bar. Modifying the pressure of a
liquid causes its boiling point to vary.
It is well known that water, for example, reaches its boiling point
at lower temperatures when the pressure is reduced.
From the vapour pressure curves for water and refrigerant R134a,
it can be seen that, for example, with a constant pressure, the
vapour turns into water (in the condenser) if the temperature de‐
creases, and that, for example, by decreasing the pressure, the
2 Rep. gr.00 - Technical data

refrigerant changes from a liquid state into a vapour state (evap‐

orator).
Vapour pressure curve for water
A - Liquid state
B - Gaseous state
C - Vapour pressure curve for water
1 - Pressure on the liquid in bar (absolute)
2 - Temperature in ° C
Vapour pressure curve for refrigerant R134a

A - Liquid state
B - Gaseous state
D - Vapour pressure curve for refrigerant R134a
1 - Pressure on the liquid in bar (absolute)
2 - Temperature in ° C
1.4 Vapour pressure table for refrigerant

R134a
The vapour pressure table for each refrigerant is published in the
literature for refrigeration engineers. This table shows the vapour
pressure exerted on the liquid column in the container for a given
temperature of the container.
Since a characteristic vapour pressure table is known for every
refrigerant, one can determine what refrigerant is present by
measuring pressure and temperature.
Note
Absolute pressure means that 0 bar corresponds to an absolute

vacuum. The normal ambient pressure (positive pressure) corre‐
sponds to 1 bar absolute pressure. In general, most manometer
scales represent atmospheric pressure
Protected as 0Copying
by copyright. bar, meaning
for private or an ab‐ purposes, in part or in whole, is not
commercial
solute pressure of 1 bar (this can be
permitted recognized
unless if there
authorised by SEAT is aS.A
S.A. SEAT -1does
on not guarantee or accept any liability with
the scale). respect to the correctness of information in this document. Copyright by SEAT S.A.
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

Temperature in ° C Pressure in bar (positive pres‐

sure) R134a
-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
50 12.11
55 13.83
60 15.72
65 17.79
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34
1.5 Coolant agent R134a

The evaporation and condensation process is used in air-condi‐
tioners in vehicles. Matter with a low boiling point, called the
refrigerant, is used in this process.
The refrigerant used is tetrafluoroethane R134a, which reaches
its boiling point at a temperature of -26.5 °C with a vapour pres‐
sure of 1 bar.
1.5.1 Physical data of refrigerant R134a

Chemical formula CH2F–CF3 or CF3–CH2F
Chemical designation Tetrafluoroethane
Boiling point at 1 bar - 26.5° C
Freezing point -101.6 °C
Critical temperature 100.6 °C
Critical pressure 40.56 bar (absolute)
1.5.2 Critical point

The critical point (critical temperature and critical pressure) is the
point above which the threshold between liquid and gas disap‐
pears.
Above its critical point, a substance is always gaseous.
At temperatures below the critical temperature, all refrigerants are

found in a liquid phase and gaseous phase in pressurized tanks.
Which means that a cushion of gas is found above the liquid.
As long as there is gas in the pressure vessel alongside the liquid,
the pressure depends directly on the ambient temperature
⇒ page 3 .

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

Only refrigerants specified for the respective air conditioning sys‐
tem may be used.
1.5.3 Environmental aspects of refrigerant

R134a
♦ R134a is a chlorine-free hydrofluorocarbon (FKW)
♦ R134a has a shorter atmospheric persistence than refrigerant
R12.
♦ R134a has no negative impact on the ozone layer.
♦ The greenhouse effect of R134a (Global Warming Potential =
GWP) is about 1300 (the GWP value of carbon dioxide has
been set to 1).
♦ R134a’s influence on the greenhouse effect is 10 times lower
than that of refrigerant R12.
1.6 Characteristics of refrigerant

Protected by copyright. CopyingR134a
for private or commercial purposes, in part or in whole, is not
1.6.1 Commercial names and designations

Refrigerant R134a is currently available under the following com‐
mercial names:
♦ H-FKW 134a
♦ SUVA 134a
♦ KLEA 134a
Note
♦ Other trade designations may be used in other countries.

♦ Among the large selection of various refrigerants, only this one
may be used for vehicles. The designations Frigen and Freon
are trade marks. They apply also to refrigerants which must
not be used in vehicles.
1.6.2 Colour
In liquid or gaseous state, the refrigerant is colourless, like water.
Gases are invisible. Only the boundary layer between gas and
liquid is visible. (Fluid level in indicator tube of charging cylinder
for bubbles in sight glass.) Liquid refrigerant R134a may appear
coloured (milky) in a sight glass. This cloudiness is caused by
partially dissolved refrigerant oil and does not indicate a fault.
1.6.3 Vapour pressure

In a closed container which is not completely full, the refrigerant
volatilizes into vapour state on the surface. The amount that vola‐
tizes is transformed into liquid again due to the aggregation of
vapour particles. This equilibrium develops under pressure and
is often called vapour pressure. The vapour pressure is temper‐
ature-dependant ⇒ page 3 .

1.6.4 Physical properties of R134a

Because the vapour pressure curves of R134a and other refrig‐
erants are in part very similar, unique identification on the basis
of pressure alone is not possible.
In the case of R134a, the compressor is lubricated with special
synthetic refrigerant oils, for example, PAG oils (polyalkylene gly‐
col oils).
1.6.5 Effects on metal

In pure state, the refrigerant R134a is chemically stable and does
not attack iron or aluminium.
However, impurities in the refrigerant, such as chlorinated com‐
pounds, may cause certain metals and plastics to be attacked.
This may lead to blocking, leaks or sedimentation on the com‐
pressor piston.
1.6.6 Critical temperature and critical pres‐

sure
The refrigerant R134a remains chemically stable up to a gas
pressure of 39.5 bar (which corresponds to a temperature of 101
°C). The refrigerant decomposes at higher temperatures (see
Flammability).
1.6.7 Water content

Only very small amounts of water are soluble in the refrigerant.
On the other hand, refrigerant vapour and water vapour mix in
any proportion.
Any water present in the refrigerant circuit is transported in drop
form. The dryer, dryer bags or dryer cartridges can absorb around
7g water, after which point they are saturated and cannot absorb
any more water. If any water remains in the refrigerant circuit, it
will flow to the nozzle of the expansion valve or throttle valve and
freeze.
The air-conditioner will then stop cooling.
Water destroys the air conditioner because at high pressures and
temperatures it combines with other impurities to form acids.
1.6.8 Combustibility
Refrigerant is non-flammable. On the contrary, it has a fire re‐
tarding and extinguishing effect. Refrigerant decomposes when
exposed to flames or incandescent surfaces. UV light can also
decompose refrigerants (UV is emitted by electric arc welding).
This produces toxic decomposition products which must not be
inhaled. Mucus irritation generally provides sufficient warning.
1.6.9 Charge factor

There must be space both for liquid and vapour in a container. As
the temperature rises, the liquid expands. The space occupied by

the vapour becomes smaller. At a certain moment, only liquid will
remain in the container. After that time, even a small increase in
temperature will result in a very large increase in pressure, since
the liquid is seeking to expand further but there is no space for it
to do so. The resulting forces are sufficient to burst the container.
To prevent containers from being overcharged, regulations gov‐
erning the storage of compressed gases specify how many kilo‐
grams may be charged into a container for every litre of container
volume. This charge factor multiplied by the internal volume gives
the permissible charge quantity. For the refrigerant used in vehi‐
cles, the filling factor is 1.15 kg/l.

1.6.10 Detecting leaks

External damage can cause leaks in the refrigerant circuit. Due
to the small amount of refrigerant which may leak, small leaks
may be detected, for example, with an electronic leak detector or
a leak detection additive which is added to the refrigerant circuit.
Electronic leak detectors can detect leakage rates of less than 5
grams loss of refrigerant per year. (For each different refrigerant,
an electronic leak detector specifically designed to detect the
composition of the refrigerant in question must be used. For ex‐
ample, leak detectors for refrigerant R12 are not suitable to be
used for refrigerant R134a, seeing as it contains no chlorine
atoms, causing the detector not to react).
1.7 Refrigerant machine oil

The refrigerant oil is mixed with the refrigerant (at a proportion
from 20 to 40%, depending on the kind of compressor and the
amount of refrigerant), after which it circulates through the circuit
and lubricates the mobile parts.
Special synthetic refrigerant oils, for example, polyalkylene glycol
(PAG) oil, are use in combination with the refrigerant in air-con‐
ditioners which use R134a. This is necessary as mineral oil does
not mix with R134a. Moreover, the materials used in air-condi‐
tioners which use R134a may be attacked when the mixture flows
through the refrigerant circuit under high pressures and temper‐
atures, or if the lubricating film in the compressor is broken. The
use of unauthorized oils may cause the air-conditioner to break
down, and therefore only approved oils must be used.
⇒ Electronic parts catalogue (ETKA)
Type of oil for R134a in vehicles: PAG
Note
♦ Do not store refrigerant oil in open containers, as it is very

hygroscopic (water absorbent).
♦ Keep oil containers closed at all times.
♦ Do not reuse refrigerant oil. Dispose of as used oil from un‐
known source (see Waste, Environmental protection, Refrig‐
erant regulatory legislation (EC) 2037/2000).
♦ Diester oils are only for use in larger installations (not for air-
conditioners in vehicles).
1.7.1 Properties of refrigerant oil

The most important properties are its great capacity to dissolve
in refrigerants, good lubricating properties, the absence of acids,
and very low water content. Therefore, only specific types of oils
must be used. Consult the list of authorized refrigerant oils and
filling amounts ⇒ Rep. gr. 87 .
The PAG oils suitable for refrigerant
Protected R134a
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purposes, in part or in whole, is not
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from moisture. Refrigerant oil ages due to the effect of humidity

and acids, turning dark and viscous, and becomes aggressive to
metals.

Note
♦ In refrigerant circuits designed for refrigerant R134a, only oil

authorized for use with the compressor must be used. (See ⇒
Rep. gr. 87 for charge quantities).
♦ Due to its chemical properties, refrigerant oil must not be dis‐
posed of with engine or gear oils ⇒ Waste, Environmental
protection; Article 17 of Regulation (EC) 2037/2000 .
1.8 Comfort
A basic requirement for concentrated and safe driving is the feel‐
ing of comfort in the passenger compartment. This feeling of
comfort can only be achieved by using the air-conditioner, espe‐
cially under extreme temperatures and high air humidity. Obvi‐
ously, the feeling of comfort can also be increased
respect by opening
to the correctness thein this document. Copyright by SEAT S.A.
of information
windows and the sunroof or by turning up the fan. However, this
may cause inconvenience inside the vehicle, for example, addi‐
tional noise, draughts, exhaust fumes entering the vehicle, and
unfiltered air containing pollen (which is rather unpleasant for
those who suffer from allergies).
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 can be done both with the vehicle stopped or in
motion.
Other important advantages of the air-conditioner are:
♦ The purity of the air that enters the vehicle (the humid fins of
the evaporator retain dust, for example, and expose of it to‐
gether with the condensed water).
♦ Temperatures in a mid-range vehicle (Example: after driving
for a short while, exterior temperature of 30 °C in the shade,
and vehicle exposed to direct sunlight).
with air conditioning without air condi‐
system tioning system
Head region 23 °C 42 °C
Chest area 24 °C 40 °C
Footwell 30 °C 35 °C
1.8.1 Environmental aspects

Since about 1992, the air conditioning systems of newly manu‐
factured cars have been successively changed to refrigerant
R134a. This refrigerant contains no chlorine and thus does not
damage the ozone layer.
Up until about 1992, air conditioning systems were charged with
refrigerant R12. As it contains chlorine atoms, this CFC is ex‐
tremely prone to destroying ozone, and also to contributing to the
greenhouse effect.
There are programs for exchanging old air conditioning systems
containing the ozone-damaging refrigerant R12.
For environmental protection reasons, refrigerant must not be re‐
leased in the atmosphere (Legal texts and guidelines).
⇒ page 41

1.9 How air conditioning works

The temperature in the passenger compartment depends on the
amount of heat radiated through the windows and conducted by
the metal parts of the body. In order to maintain comfortable tem‐
peratures for the occupants on very warm days, part of the
available heat must be pumped away.
Since heat spreads towards cooler bodies, a unit that can create
low temperatures is fitted in the vehicle interior. Refrigerant is
constantly being evaporated in it. The latent heat of evaporation
is taken from the air passing through the evaporator.
The refrigerant, with the absorbed heat, is pumped away by the
compressor. Due to compression by the compressor, the heat
content and temperature of the refrigerant is increased. It is now
higher than the ambient air temperature.
The hot refrigerant flows with its heat content to the condenser.
There the refrigerant looses its heat through the condenser to the
surrounding air due to the temperature gradient between the re‐
frigerant and the surrounding air.
Thus, the refrigerant is a means of heat transport. Because it will
be needed again, it returns to the evaporator.
All air conditioning systems basically depend on the circulation of
refrigerant. However, there are differences in the construction of
the system.
1.10 General aspects regarding workplace

safety
♦ According to the current regulations and dispositions of the
legislation and professional trade unions.
♦ Observe the operating instructions regarding the work post ⇒
Environmental protection; Article 17 of Regulation (EC)
2037/2000 and Workplace safety (Service organization, Vol.
2, Chapter 6.12) , which must be on display at the refrigerant
work post.
1.10.1 Product characteristics
The refrigerant used in automotive air-conditioners belongs to the
new generation of refrigerants based on chlorine-free partially
fluorinated hydrocarbons (H–CF, R134a).
In regard to their physical behaviour, they are refrigerants which
can be liquefied under pressure. They are subject to regulations
for pressurised containers and may be charged only into ap‐
proved and identified pressurised gas containers.
Specific conditions which apply for safe and proper use must be
maintained.
1.10.2 Handling refrigerants
WARNING
There is a freezing hazard.

The refrigerant can emerge as liquid or as vapour.
Do not open containers in which this refrigerant is present.
When opening tanks or containers which contain refrigerant, their

content may escape in liquid or vapour state. This emergence will
be more energetic, the higher the pressure in the container.

How high the pressure is depends on two factors:

• The type of refrigerant inside the container. “The following rule
applies: The lower the boiling point, the higher the pressure.”
• How high is the temperature. “The following rule applies: The
higher the temperature, the higher the pressure.”
1.10.3 Use protective goggles

Put on protective glasses. They prevent refrigerant from coming
into contact with the eyes, which may cause serious injury due to
freezing.
1.10.4 Wear protective gloves and apron

Refrigerants dissolve fats and oils very well. Therefore, if they
come into contact with the skin, they eliminate the protective
greasy layer. Skin from which the natural oil and fat have been
removed is vulnerable to cold and germs.
1.10.5 Do not allow liquid refrigerant to come in

contact with the skin
The refrigerant will draw its latent heat of evaporation from its
surroundings. That can be your skin. This can result in very low
temperatures. This leads to localised areas of freezing (boiling
point of R134a -26.5°C at atmospheric pressure).
1.10.6 Do not inhale refrigerant vapours
Note
In high concentrations, refrigerant vapours which escape mix with

the ambient air and displace the oxygen in the air needed when
breathing.
1.10.7 Absolutely NO SMOKING

Refrigerant can decompose in the burning cigarette. The resulting
substances are poisonous and must not be breathed in.
1.10.8 Welding and soldering on refrigeration

systems
Before welding on vehicles (close to air-conditioner parts), the
refrigerant must be extracted by means of suction, and any re‐
mains must be eliminated by blowing with nitrogen.
The decomposition products of the refrigerant formed by the ef‐
fect of heat are not only toxic, but are also extremely corrosive
and may attack the piping and other parts of the installation. This
refers primarily to hydrogen fluoride.
1.10.9 Pungent smell

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

• In the event of contact with the eyes or mucus, immediately
rinse with abundant running water and see an ophthalmolo‐
gist.

• In the event of contact with the skin, immediately remove all

wet clothing and rinse the affected parts of the skin with abun‐
dant water.
• In the event of inhaling refrigerant vapours in high concentra‐
tions, immediately take the affected person outdoors. Seek
medical assistance. In case of respiratory problems, adminis‐
ter oxygen. If the affected person has trouble breathing or
cannot breathe at all, tilt the head backwards placing one hand
behind the neck and apply artificial respiration.
1.10.11 Handling pressurized containers and

vessels
• Secure the containers to prevent them from falling.
Bottles stored upright must be secured to prevent them from fall‐
ing, and those lying flat must be secured to prevent them from
rolling.
• Do not drop or knock the containers over.
If dropped, the containers may be damaged, causing them to
break. The refrigerant will then evaporate rapidly, liberating con‐
siderable forces. Flying fragments of the bottle may cause serious
injury.
If transported improperly, the valves of the bottles may break. In
order to protect the valve, the bottles must always be transported
with the protective cap in position.
• The bottles must never be placed close to heating radiators.
Very high temperatures may be found in the vicinity of heating
radiators. High temperatures also mean high pressures, which
may exceed the admissible pressure of the container.
1.10.12 Do not expose to temperatures above

50 °C
In order to eliminate all hazards, the regulations regarding pres‐
surized vessels state that these vessels must not be exposed to
temperatures above 50 °C.
1.10.13 Do not heat in uncontrolled manner

Never heat the container with a flame. Localized overheating may
cause alterations in the material of the container, causing it to lose
resistance to pressure. Moreover, there is a risk that the refriger‐
ant may decompose due to localized overheating.
1.10.14 Seal empty containers

Empty refrigerant containers must always be closed to prevent
humidity from entering. Moisture in metal containers leads to for‐
mation of rust, weakening the container wall material. Moreover,
the rust particles which enter the air-conditioning installation from
the container affect its operation.
1.10.15 Safety precautions for handling suction

and filling equipment
• Before connecting the filling equipment to the air conditioner,
ensure that all shut-off valves are completely closed.
• Before disconnecting the filling equipment from the air condi‐

tioner, ensure that the process has been completed, in order
prevent any refrigerant from escaping into the atmosphere.
• Once the refined refrigerant has been transferred from the fill‐
ing equipment to an external pressurized gas bottle, the man‐

ual shut-off valves on both the bottle and the filling equipment
must be closed.
• Do not expose the filling equipment to humidity or use it in wet
or humid environments.
• Ensure that the electrical power of the filling equipment is dis‐
connected before carrying out any maintenance work.
• Avoid using electrical power extension cords, in order to min‐
imize the risk of fire. If it is necessary to use an extension cord,
use a cable with a minimum cross-section of 2.5 mm2.
• In the event of fire, move the external bottle away.
• If oil sucked out from the air-conditioner is transferred from the
suction accumulator to the graduated container supplied, en‐
sure that it is later deposited in a container which can be
closed, seeing as the oil contains a small amount of refriger‐
ant. The refrigerant must not be dumped or disposed of into
the environment.
• When storing the service station, ensure that the wheels are
blocked.

1.11 Safety precautions for working on vehi‐

cles with air-conditioning and handling
refrigerant R134a
Air-conditioner service equipment A/C charging station - SAT
4006D-
WARNING
♦ It is recommended that you always have an eye-bath

ready for use in case it is needed.
♦ If the refrigerant comes into contact with the eyes, imme‐
diately rinse them thoroughly for at least 15 minutes. Then,
apply eye drops and seek medical assistance immediate‐
ly, even if the eyes do not cause any pain.
♦ The medical assistance must be informed of the fact that
the freezing was caused by refrigerant R134a. If, despite
taking these safety precautions, other parts of the body
come into contact with the refrigerant, also rinse thor‐
oughly with cold water for at least 15 minutes.
♦ Work may only be carried out on the refrigerant circuit of
the air-conditioner in well ventilated areas. All air-extrac‐
tion installations in the workshop must be turned on.
♦ Do not store the refrigerant in deep or underground en‐
closures (e.g. basements), or on staircases leading down
to them, or window sills.
• Do not weld, braze or soft-solder any parts of the charged air

conditioning
Protected bysystem. The same
copyright. Copying applies
for private to welding
or commercial orpart
purposes, in soldering
or in whole, is not
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permitted of the vehicle
unless authorised which
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not guarantee theanyair-
accept liability with
conditioning to be heated. If any parts are to be removed due
to the correctness of information in this document. Copyright by SEAT S.A.
to repairs in the paint oven or in its preheating area, the parts

may not reach temperatures in excess of 80°C.
Reason:
Excessive heat causes extremely high pressures in the installa‐
tion, which may cause the pressure relief valve to open.
Solution:
– Empty the refrigerant circuit with the service station.
Note
Do not repair any damaged or leaking parts of the air-conditioner

by means of welding. They must always be replaced.
Always prevent heating containers (e.g. filling cylinders of the

service station) with refrigerant excessively, and do not expose
them to direct sunlight.
Solution:
– Never fill the container completely with liquid refrigerant. If too
little space is left for expansion (gas cushion), the container
will burst if the temperature rises, possibly with disastrous
consequences ⇒ page 5 .
Equipment and containers which contain air must under no cir‐
cumstances be filled with refrigerant.

Solution:
– Vacuum the equipment and containers before filling them with
refrigerant.

1.12 Fundamental aspects for working on the

refrigerant circuit
• Observe the instructions regarding the workplace ⇒ see En‐
vironmental protection, Regulations on fluorinated gases 492
(11/08/03), Service organization (30/11/02) . Refrigerant from
air conditioning systems / refrigerant oils - to be displayed at
refrigerant designated working area.
• Work with absolute cleanliness.
• When handling refrigerant and nitrogen, always wear protec‐
tion goggles and gloves.
• All air-extraction installations in the workshop must be turned
on.
• Only empty the refrigerant circuit using the air conditioning
service station; then the screw connection can be opened or
defective components can be replaced.
• Close any open units or flexible hoses with plugs, in order to
protect them from humidity and dirt. Plugs of different diame‐
ters can be found in the equipment kit - T20017A- .
• Use only tools and materials specially designed for refrigerant
R134a.
• Protect the refrigerant oil against humidity by closing the open
containers.
– Rinse the refrigerant circuit with nitrogen and the specific sol‐
vent for refrigerant R134a: ⇒ page 62
The refrigerant circuit must be rinsed with R134a in event of the
following: ⇒ page 71
In vehicles without electromagnetic coupling on the compressor:
♦ Humidity or dirt have entered the refrigerant circuit (e.g. after
an accident).
♦ The refrigerant oil has turned dark or viscous.
♦ After permitted
replacing unlessthe air-conditioner
authorised compressor,
by SEAT S.A. SEAT thereorisaccept
S.A does not guarantee too any liability with
much refrigerant machine oil in the refrigerant circuit.
♦ The compressor has been replaced due to “internal” damage

(e.g. noise or lack of power).
In vehicles without electromagnetic coupling on the compressor:

Note
♦ The engine should only be started once the refrigerant circuit

has been assembled completely.
♦ If possible, start engine only with refrigerant circuit charged.
♦ The air conditioner compressor is driven permanently by the
poly V-belt pulley or elastic drive coupling (it is not fitted with
a magnetic clutch).
♦ If the air-conditioner compressor locks, the overload protection
will come off the compressor shaft. Even if no buckling is visi‐
ble on the Poly-V belt pulley / overload protection, the com‐
pressor may still be locked. Another possibility is that there is
abrasive dust in the area of the pulley / overload protection.
♦ The compressor is equipped with a protected oil supply to
prevent any damage if the refrigerant circuit were to be empty.
This means that approx. 40 to 50 cm3 of refrigerant oil remains
in the air-conditioner compressor.
♦ Do not start the engine unless the refrigerant circuit has been
properly assembled. If, for example, the refrigerant piping has
not been connected to compressor, the compressor may over‐
heat if the engine is running (due to internal heating), and may
eventually be destroyed.
♦ The air-conditioner compressor regulating valve - N280- does
not work when the refrigerant circuit is empty and the com‐
pressor is operating at idling speed with the engine.
♦ Should it be necessary to start the engine with an empty re‐
frigerant circuit, please observe the following:
♦ The refrigerant circuit must be fully assembled.
♦ There must be at least a quarter of the refrigerant oil required
by the refrigerant circuit in the compressor.
♦ The engine speed must not exceed 2,000 rpm.
♦ The engine must run for about < 10 minutes.
1.12.1 O-rings
♦ Use only O-rings which are resistant to refrigerant R134a and
to the corresponding refrigerant oils. The O-rings are no longer
colour coded. Either black or colour-coded O-rings may now
be used, without distinction.
♦ Ensure that the interior diameter of the O-rings
authorisedisbycorrect.
permitted unless SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ Rep. gr. 87
♦ The O-rings may only be used once.
♦ Before assembly, lubricate the O-rings slightly with refrigerant
oil (PAG oil).

Note
♦ When blowing out the parts with compressed air and nitrogen,
always use an appropriate device (workshop extraction sys‐
tem) to suck up the mixture of gas from the parts.
♦ Once the repair work has been completed, screw plugs (with
seals) into all the valve connections and service connections.
Putting the air-conditioner into service. Check the vehicle-specific

charge quantities ⇒ Rep. gr. 87 .
Do not top up a charged refrigerant circuit; discharge refrigerant
present and recharge system.
1.12.2 Before operating the air conditioning

system after recharging with refrigerant
– When a new compressor is mounted or the refrigerant oil is
replaced (e.g. after blowing out the refrigerant circuit with com‐
pressed air), the compressor pulley must be turned 10 full
turns by hand before stating the engine. This will prevent dam‐
age to the air conditioner compressor.
– In 5 and 10 cylinder diesel engines, turn the compressor 10
full turns by hand at the overload protection. Then, mount the
compressor. This will prevent damage to the air conditioner
compressor.
– With the air-conditioner turned off ( electromagnetic coupling
for air-conditioner - N25- and regulating valve for air-condi‐
tioner compressor - N280- are not activated), start the engine.
– Once the engine starts idling at a stable speed, turn on the air-
conditioner and let it run for at least 10 minutes at maximum
cooling power.

2 General information on refrigerant

circuit
2.1 Parts of the refrigerant circuit
Caution

be used.
• All refrigerant circuit components which are sent for quality

control must always be closed (use the original plugs from the
spare part).
• Replace any damaged or leaking components of the refriger‐
ant circuit. ⇒ page 132
• Up to now, all spare parts (compressor, collecting tank, liquid
tank, evaporator and condenser) have been filled with nitro‐
gen. This method is now being eliminated so that the pressure
compensation when the cap on a replacement part is un‐
screwed is only slight, if present at all.
2.1.1 Layout of the refrigerant circuit compo‐

nents and its influence on the high and
low pressure sides
The liquid tank condenser is found on the high pressure side, to‐
gether with the choke or expansion valve, as separation between
the high pressure side and the low pressure side of the liquid.
The highpermitted
pressureunlessisauthorised
caused by due
SEAT to
S.A.the
SEAT choke
S.A doesor
notexpansion valve
guarantee or accept any liability with
forming a narrowing where
respect to the the ofrefrigerant
correctness is document.
information in this accumulated, thus
Copyright by SEAT S.A.
leading to an increase in pressure and temperature.
Excessive pressure is produced if the circuit is filled with too much
refrigerant or refrigerant oil, the condenser is dirty, the radiator
breaks down, the system is blocked, or there is humidity in the
refrigerant circuit (freezing of the choke or expansion valve).
The evaporator, the collector tank and the evaporator tempera‐
ture sensor are found on the low pressure side, together with the
compressor, as separation between the high pressure side and
the low pressure side of the gas.
A drop in pressure may occur in the system due to a loss of re‐
frigerant, a fault in the choke or expansion valve (no narrowing),
a fault in the compressor, or freezing of the evaporator.

2.1.2 Air conditioning system compressor with

magnetic clutch:
The air-conditioner compressor is driven by the vehicle engine
using a Poly-V belt.
An electromagnetic coupling on the air-conditioner compressor
provides direct transmission between the belt pulley and the air-
conditioner compressor (crankshaft) when the air-conditioner is
turned on.
A short-circuit fuse mounted on the compressor pulley activates
the electromagnetic coupling if the compressor turns with difficul‐
ty, protecting the belt transmission against excessive load.
The air conditioner compressor draws refrigerant gas from the
evaporator, compresses it and sends it to the condenser.
Note
♦ The air-conditioner compressor contains refrigerant oil which

may be mixed with refrigerant R134a at any temperature.
♦ The manufacturer’s label specifies the refrigerant to be used
for the specific air-conditioner compressor installed. A regu‐
lating valve adjusts the pressure in the low pressure side within
the specified technical range (characteristic regulation curve).
♦ In order to prevent the air-conditioner compressor from being
damaged if the refrigerant circuit is empty, the electromagnetic
coupling is disconnected, and the air-conditioner compressor
regulating valve - N280- is not activated (the compressor op‐
erates at idling speed with the engine).
2. General information on refrigerant circuit 19

2.1.3 Air conditioner compressor without

magnetic clutch
The air-conditioner compressor is driven by the vehicle engine
using a Poly-V belt.
An overload protection device mounted on the air-conditioner
compressor pulley is activated if the compressor turns with diffi‐
culty, protecting the belt transmission against excessive load.
Note

♦ The refrigerant should be specified on the model label that has
to be used for the respective air conditioner compressor fitted.
A regulating valve adjusts the pressure in the low pressure
side within the specified technical range (characteristic regu‐
lation curve).
♦ On this air-conditioner compressor, the regulating valve is ac‐
tivated from the exterior.
has been assembled completely. ⇒ page 15
♦ The compressor is equipped with a protected oil supply to
prevent any damage if the refrigerant circuit were to be empty.
This means that approx. 40 to 50 cm3 of refrigerant oil remains
in the air-conditioner compressor.
2.1.4 Electric compressor for hybrid vehicles
WARNING
♦ High voltage on high-voltage system of hybrid vehicle!

Health risk for persons with life-sustaining systems.
♦ Following procedure also requires work on high-voltage
system. All work on vehicles with high-voltage systems
must only be carried out by qualified personnel. Work must
be advised by a high-voltage technician.
♦ Observe general warning notices about work on high-volt‐
age system ⇒ Electric drive, Repair group
Protected 93; General
by copyright. Copying for private or commercial purposes, in part or in whole, is not
warning notices for work on high-voltage system.
♦ Ensure there is no voltage in high-voltage system ⇒ Elec‐
tric drive, Repair group 93; Ensuring there is no voltage in
high-voltage system.

Electrical air conditioner compressor
WARNING
Danger of short circuit

The air conditioner compressor operates with 288 Volts in a
speed range of 800 to 8,600 rpm.
Do not touch the air conditioner compressor when commis‐
sioning, risk of short circuits.

Note

♦ The refrigerant should be specified on the model label that has
to be used for the respective air conditioner compressor fitted.
The power is controlled using the speed.
has been assembled completely ⇒ page 15
♦ 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 remains in the air-conditioner
compressor.
♦ The air-conditioner compressor is fitted with an overpressure
valve.
2.1.5 Condenser
The condenser transfers heat from the compressed refrigerant
gas to the surrounding air.
This allows the refrigerant gas to condense into liquid form.

2.1.6 Evaporator
The liquid refrigerant evaporates in the tubes of the evaporator.
The heat required for this process is extracted from the air which
flows past the evaporator fins. The air is cooled down. The refrig‐
erant evaporates, and is sucked in by the compressor, together
with the heat absorbed.
A choke or expansion valve is used to control the amount of re‐
frigerant which enters the evaporator. In systems with an expan‐
sion valve, the flow is regulated such that only gaseous refrigerant
exits the evaporator.
2.1.7 Reservoir
In order to ensure that the compressor only sucks in gaseous re‐
frigerant, the collecting tank collects the mixture of gas and va‐
pour which comes from the evaporator. Gaseous refrigerant is
formed from the vapour.
The refrigerant oil which constantly flows through the refrigerant
circuit does not remain inside the collecting
Protected tank,
by copyright. as there
Copying isoracommercial purposes, in part or in whole, is not
for private
suction hole for the oil. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Any humidity which may have entered the refrigerant circuit dur‐
ing assembly is retained by a filter (desiccant bag) located in the
tank.
The compressor sucks in gaseous refrigerant with oil.
Note
♦ The collecting tank must be replaced if the refrigerant circuit

has remained open for a prolonged period of time (longer than
the repair time) and humidity has entered, or if required due to
any other circumstance.
♦ Plugs -A- and -B- must only be removed immediately before
assembly.
♦ If the collecting tank remains open, the desiccant bag is soon
saturated with humidity, rendering it useless.
♦ During assembly, also take note of the arrow indicating the
flow direction.

2.1.8 Throttle
The restrictor creates a restriction. This restriction limits the flow,
separating the high-pressure and low-pressure sides in the re‐
frigerant circuit. Upstream of the restrictor, the refrigerant is warm
due to the high pressure. Downstream of the restrictor, the refrig‐
erant is cold due to the low pressure. There is a strainer before
the narrowing to collect any dirt. There is also a fine mesh after
the narrowing which atomizes the refrigerant before it reaches the
evaporator.
Note
♦ Arrow -A- on the restrictor points to the evaporator.

♦ It must be replaced whenever the circuit is opened.
♦ Take note of the different versions.
⇒ Rep. gr. 87
⇒ electronic parts catalogue
2.1.9 Receiver
The receiver collects the droplets of liquid and conveys them in a
continuous flow to the expansion valve. Moisture which has en‐
tered the refrigerant circuit during assembly is collected by the
dryer bag in the receiver.
Note
♦ Replace the fluid tank in case the refrigerant circuit had been
opened for a longer period (longer that the usual repair period)
and humidity has entered or in event a replacement is neces‐
sary due to a certain complaint. ⇒ page 132
♦ The plugs must only be removed immediately before assem‐
bly.
♦ If the liquid tank remains open, the desiccant bag is soon sa‐
turated with humidity, rendering it useless.
♦ During assembly, also take note of the arrow indicating the

flow direction.
New tanks are mounted directly onto the condenser, and are
equipped with a desiccant cartridge.
Note
♦ Replace the desiccant cartridge in case the refrigerant circuit

had been opened for a longer period (longer that the usual
repair period) and humidity has entered or in event a replace‐
ment is necessary due to a certain complaint. ⇒ page 132
♦ The desiccant cartridge must only be removed from its pack‐
aging immediately before assembly.
♦ If the packaging remains open, the desiccant cartridge is soon
saturated with humidity, rendering it useless.

2.1.10 Expansion valve

The expansion valve controls the flow and atomizes the refriger‐
ant as it passes through, such that the vapour turns into gas until
it leaves the evaporator, according to its heat content.
2.1.11 Quick-release couplings on refrigerant

line
WARNING
Only release and open the quick-release couplings after com‐

pletely discharging the refrigerant circuit.
Note
♦ To remove refrigerant line -D- use release tool for air condi‐
tioner pipes -T40149/- to open retaining ring -A- ⇒ Air condi‐
tioning; Rep. gr. 87 .
♦ After removing the corresponding refrigerant line it is neces‐
sary to replace the quick-release coupling connections -B- and
-G- together with the associated support ring -E- or -H- and O-
ring -F- or -J-. ⇒ Air conditioning system; Rep. gr. 87 and ⇒
Electronic parts catalogue .
A - Retaining ring (in quick-release coupling, high-pressure side)

B - Quick-release coupling with retaining ring (“high-pressure
side”)
C - Refrigerant line with internal heat exchanger
D - Refrigerant line (“high-pressure
Protected by copyright. side”) purposes, in part or in whole, is not
Copying for private or commercial
E - Support ring
respect (“high-pressure
to the side”)
correctness of information in this document. Copyright by SEAT S.A.
F - O-ring (“high-pressure side”)

G - Quick-release coupling with retaining ring (“low-pressure
side”)
H - Support ring (“low-pressure side”)
J - O-ring (“low-pressure side”)

2.1.12 O-rings
These rings seal the joints between the individual components of
the refrigerant circuit.
Only O-rings which are resistant to refrigerant R134a and to the
corresponding refrigerant oils must be used. This is guaranteed
by using genuine spare parts.
O-rings:
• Use once only.
• Note the correct diameter -a- and -b-.
• Lubricate with refrigerant oil before assembly.
Note
O-rings for circuits using refrigerant R134a are no longer colour

coded. Either black or colour-coded O-rings may now be used,
without distinction.
⇒ Rep. gr. 87 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

2.1.13 Piping and flexible hoses of the refriger‐

ant circuit
The mixture of refrigerant oil and refrigerant R134a attacks certain
metals (e.g. copper) and alloys, and dissolves certain materials
used in flexible hoses. For this reason, only genuine spare parts
must be used.
Piping and flexible hoses are joined by means of screw joints or
special plug-in couplings.
Note
Observe the specified tightening torque for the screw joints, and
use the release tools supplied for the plug-in couplings.
2.1.14 Pressure relief valve

The pressure relief valve is located on the compressor or on the
liquid tank.
The valve opens at a pressure above approx. 38 bar and closes
again when the pressure has dropped (approx. 30 bar).
Not all the refrigerant is lost from the system.
Depending on the version, it is equipped with a transparent plastic
disc which is broken when the valve reacts.

2.2 Refrigerant circuit configuration

2.2.1 Refrigerant circuit with expansion valve
and evaporator
1- Evaporator
2- Expansion valve
3- Suction, charging and measuring valve
4- Liquid tank with desiccant bag / desiccant cartridge
5- Condenser
6- Air conditioner compressor
Note
The arrows indicate direction of refrigerant flow.
2.2.2 Refrigerant circuit with restrictor and

reservoir
1- Air conditioner compressor
2- Condenser respect to the correctness of information in this document. Copyright by SEAT S.A.
3- Throttle
4- Evaporator
5- Collecting tank with desiccant bag
Note
2.2.3 Refrigerant circuit with expansion valve

and two evaporators
1- Evaporator
2- Expansion valve
3- Suction, charging and measuring valve
4- Inspection hole
5- Liquid tank with desiccant
6- Condenser
7- Supercharger
8- Solenoid valve for refrigerant circuit
9- Expansion valve
10 - Second evaporator
Note

2.3 Extraction and filling valve for the quick

connection of the air-conditioning serv‐
ice station on the refrigerant circuit
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783- (2 … 10 Nm) with "insertable
ratchet 1/4 Inch" - VAS 6234-
WARNING

If refrigerant circuit has not been evacuated, refrigerant may
escape.
Extract refrigerant before opening refrigerant
permitted unless authorisedcircuit. If the
by SEAT S.A. SEATre‐
S.A does not guarantee or accept any liability with
frigerant circuit is not opened within
respect 10
to theminutes after
correctness of it has
information in this document. Copyright by SEAT S.A.
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
• Only valves and connections which are resistant to refrigerant

R134a and to the corresponding refrigerant oils must be used.
• Different connections (exterior diameter) for high and low
pressure sides.
• Always replace plugs.
Position in the vehicle.
See the repair manual of the respective vehicle ⇒ Rep. gr. 87 .
2.3.1 Suction and charging valve with Schrad‐

er valve
Note
♦ Torque wrench - V.A.G 1783- with "insertable ratchet 1/4 Inch"

- VAS 6234-
♦ Socket - T10364- for releasing the element of the Schrader
valve ⇒ page 154
A - Service connection (welded)

B - Element of the Schrader valve (2.4 ± 0.2 Nm)
C - O-ring (belonging to the valve)
D - Sealing cap with seal

2.3.2 Suction and charging valve, high pres‐

sure side
Note

- VAS 6234-
♦ Socket - T10364- for releasing the valve element
⇒ page 154
1- Base with external or internal thread

2- O-ring: 10.8 mm, 1.8 mm Code: black or coloured
3- Suction and charging valve with groove for O-ring, and ex‐
terior or interior thread M8 x 1 for cap
4- O-ring for cap: 10.8 mm, 1.8 mm Code: black or coloured
5- Cap
2.3.3 Suction and charging valve, low pres‐

sure side
Note

- VAS 6234-
♦ Socket - T10364- for releasing the valve element
⇒ page 154 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1- Connection with external thread and groove for O-ring
2- O-ring: 7.6 mm, 1.8 mm Code: black or coloured

3- Suction and charging valve with interior thread M8 x 1 for
cap
4- O-ring for cap: 7.6 mm, 1.8 mm Code: black or coloured
5- Cap
2.4 Switches and senders in the refrigerant

circuit and corresponding connections
Note
Switching pressures, disassembly and assembly of switches, as

well as layout of switches and versions. See specific refrigerant
circuit for vehicle.
⇒ Rep. gr. 87

2.4.1 High-pressure switch for air conditioning

system - F23-
Function:
Increases the refrigerant liquid fan speed if the refrigerant circuit
pressure increases (approx. 16 bars).
2.4.2 High-pressure switch for magnetic

clutch - F118-
Function:
Turns therespect
air-conditioner compressor
to the correctness of information in off if the pressure
this document. Copyright byin theS.A.
SEAT re‐
frigerant circuit is excessive (approx. 32 bar).
2.4.3 Air-conditioner low pressure switch -

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

2.4.4 Valve connections for switches in refrig‐

erant circuit
WARNING

escape.
Extract the refrigerant before disassembling valve -C-. If the
refrigerant circuit is not opened within 10 minutes after it has
been evacuated, pressure may develop in coolant circuit due
to re-evaporation. Extract refrigerant again.
• Different thread for switches on high and low pressure sides.

• Only valves and O-rings which are resistant to refrigerant
R134a and to the corresponding refrigerant oils must be used.
A - Connection (welded)
B - O-rings
C - Valve (with O-ring)
2.4.5 Air-conditioner pressure switch - F129-

This pressure switch has 3 functions:
1. Increases the refrigerant liquid fan speed if the refrigerant cir‐
cuit pressure increases (approx. 16 bars).
2. Switches off the air-conditioner if thebypressure
Protected is too
copyright. Copying for high (ap‐
private or commercial purposes, in part or in whole, is not
prox. 32 bar) (e.g. due to a lackpermitted
of engine cooling).
3. Switches off the air-conditioner if the pressure is too low (ap‐

prox. 2 bar) (e.g. due to a loss of coolant).
Note
The air-conditioner pressure switch - F129- replaces the air-con‐

ditioner high pressure switch - F23- , the air-conditioner low
pressure switch - F73- and the high pressure switch for the elec‐
tromagnetic coupling - F118- .

2.4.6 High-pressure sender - G65-

This high pressure sender - G65- is installed instead of the air-
conditioner pressure switch - F129- .
The high pressure sender generates a rectangular signal or a da‐
tagram when voltage is applied. This signal changes according
to the pressure in the installation.
With this signal, the connected control units (refrigerant fan con‐
trol unit, engine control unit air-conditioner control unit and dis‐
play, Climatronic - E87- , or else the Climatronic control unit -
J255- , etc.) calculate the pressure of the refrigerant circuit, and,
according to this pressure, activate the refrigerant and engine
fans, the air-conditioner electromagnetic coupling - N25- , or ad‐
just the activation of the air-conditioner compressor regulating
valve - N280- .
2.4.7 Refrigerant pressure and temperature

sender - G395-
WARNING

escape.
Extract the refrigerant before disassembling the refrigerant
pressure and temperature sender - G395- . If the refrigerant
circuit is not opened within 10 minutes after it has been evac‐
uated, pressure may develop in coolant circuit due to re-
evaporation. Extract refrigerant again.
This refrigerant pressure and temperature sender - G395- is in‐

stalled instead of the high pressure sender - G65- or the air-
conditioner pressure switch - F129- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The pressure signal is continuously monitored, while
respect the
to the temper‐
ature signal is only monitored if the temperature rises above 0 °
C.
This information is used by the Climatronic control unit - J255- to
accordingly activate the refrigerant fans and the air-conditioner
compressor regulating valve - N280- .
2.4.8 Regulating valve for compressor of air

conditioning system - N280-
The regulating valve is mounted onto the compressor. It is acti‐
vated by the air-conditioner control unit and display, Climatronic
- E87- , or else by the Climatronic control unit - J255- . The reg‐
ulating valve is used to control the pressure in the low pressure
side, thereby regulating the temperature in the evaporator.
Note
The air-conditioner compressor regulating valve - N280- forms

part of the air-conditioner compressor, and cannot be replaced
separately.

2.5 Electrical components not fitted onto the

refrigerant circuit
2.5.1 Fan control unit - J293-
Note
Different models exist.
This control unit connects and disconnects the electromagnetic

coupling, and thereby the air-conditioner compressor. It connects
the refrigerant fans, and calculates the pressure of the refrigerant
circuit in vehicles equipped with a high pressure sender - G65- or
a refrigerant pressure and temperature sender - G395- .
2.5.2 Evaporator outlet temperature sender -

G263- or evaporator temperature sen‐
sor - G308-
Function:
The evaporator outlet temperature sender - G263- or the evapo‐
rator temperature sensor - G308- calculate the temperature after
the evaporator. This value is sent to the air-conditioner control
unit, and serves as reference signal for controlling the compres‐
sor. This prevents that the evaporator ices-up
2.5.3 Fan control unit - J293- respect to the correctness of information in this document. Copyright by SEAT S.A.
Note
There are different models; the control units can be connected to

the radiator fan -arrows-.
This control unit connects and disconnects the electromagnetic

coupling, and thereby the air-conditioner compressor. Connect
the radiator fan and determine the pressure of the refrigerant cir‐
cuit on the vehicle using the high-pressure sender - G65- or
refrigerant pressure and temperature sender - G395-

2.6 Pressures and temperatures in the re‐

frigerant circuit
WARNING
When working on the refrigerant circuit, the current general

safety regulations and pressurized vessel regulations must be
observed.
The refrigerant circuit pressures and temperatures depend on the

current service states (e.g. engine speed, refrigerant fan speed
1, 2 or 3, engine temperature, compressor on or off), as well as
on the effects of environmental factors (e.g. ambient temperature,
air humidity, cooling power required).
In vehicles equipped with a air-conditioner compressor regulating
valve - N280- , the pressure in the low-pressure side is regulated
by activating the valve.
For this reason, the values specified in the following table are
merely approximations. They are calculated based on an engine
speed of between 1500 and 2000 rpm for 20 minutes, and an
ambient temperature of 20 °C.
The connections supplied for the manometer bank used to meas‐
ure the pressure are located on the specific refrigerant circuit of
the vehicle.
⇒ Rep. gr. 87
At a temperature of 20 °C and with the engine stopped, a pressure
of 4.7 bar is set in the refrigerant circuit.
2.7 Refrigerant circuit with expansion valve

A – Low-pressure side of refrigerant circuit.
B – High-pressure side of refrigerant circuit.

Component Overall state Pressure (bar positive pressure) Temperature in °C

of the refriger‐
ant
-1- Evaporator, from inlet to Vapour approx. 1.2 bar approx. -7 °C
outlet
(approx. 1.8 bar) (approx. -1 °C)
-2- air-conditioner compres‐ Gas approx. 1.2 bar approx. -1 °C
sor, side A
(approx. 1.8 bar) approx. +1 °C
-3- air-conditioner compres‐ Gas approx. 14 bar approx. 65 °C
sor, side B
-4- Condenser Gas, vapour, approx. 14 bar At the output approx. +55 °
liquid C
-5- Receiver Liquid approx. 14 bar approx. 55 °C
-6- Extraction and filling valve, Liquid approx. 14 bar approx. 55 °C
side B
-7-Expansion valve Liquid, expan‐ approx. 14 bar approx. 55 °C, is reduced to
sion into va‐ -7 °C
pour
-8- Extraction and filling valve, Gas approx. 1.2 bar approx. -7 °C
side A

Component Overall state Pressure (bar positive pressure) Temperature in °C

of the refriger‐
ant
(approx. 1.8 bar) approx. -1 °C
1) 1. The pressure is maintained at approx 2 bar absolute pressure in the refrigerant circuits by the regulating compressor, in spite of the
changing transfer of heat and the different engine speeds. However this applies only for the compressor output range. If the performance
limits of the compressor are exceeded, the pressure increases.
2) 2. The temperature is maintained within the regulation range of the compressor in the refrigerant circuits by the regulating compressor,
in spite of the changing transfer of heat and the different engine speeds. However this applies only for the compressor output range. If the
performance limits of the compressor are exceeded, the temperature increases.
Note
♦ Air conditioning compressors that do not regulate their power

by themselves will be switched off by the respective controller
at an evaporation temperature less than 0°C via the compres‐
sor regulation valve of the air conditioning - N280- .
♦ In vehicles equipped with a air-conditioner compressor regu‐
lating valve - N280- , the pressure in the low-pressure side is
regulated by activating the valve.

HD - High pressure side of the refrigerant circuit.
ND - Low pressure side of the refrigerant circuit.

1 - Evaporator
2 - Expansion valve
3 - High pressure switch/sen‐
sor
❑ The versions are differ‐
ent depending on the
vehicle.
4 - Service connection for the
high-pressure side
5 - Receiver
vehicle.
6 - Condenser
7 - Pressure relief valve
8 - Compressor, high-pressure
side
9 - Compressor, low-pressure
side
10 - Primary volume
❑ Not fitted on all vehicles
11 - Service connection for the
low-pressure side
2.8 Refrigerant circuit with restrictor and reservoir

A – Low-pressure side of refrigerant circuit.

B – High-pressure side of refrigerant circuit.
Component Overall state of Pressure (bar positive pres‐ Temperature in °C

the refrigerant sure)
-1- air-conditioner compressor, Gas up to 20 bar up to 70 °C
side B
-2- Condenser from gas up to 20 bar up to 70 °C
through vapour
to liquid
-3- Restrictor From liquid to Side B up to 20 bar, side A Side B up to 60 °C, side
vapour over 1.5 bar A over -4 °C
-4- Evaporator From vapour to over 1.5 bar over -4 °C
gas
-5- Reservoir Gas
-6- air-conditioner compressor, Gas
side A
On side A, the pressure is retained at approx. 2 bar by the “reg‐
ulating” compressor, even with different engine speeds. However,
this is only valid within the power range of the compressor. If the
power limits of the air-conditioner compressor are exceeded.
⇒ page 106

Note
In vehicles equipped with a air-conditioner compressor regulating

valve - N280- , the pressure in the low-pressure side is regulated
by activating the valve.
2.9 Inspection and measurement work

which can be carried out with a manom‐
eter
Manometer reading
1- Temperature scale for refrigerant R134a, CF3–CH2F or
CH2F–CF3.
2- Pressure scale
The manometers may have one or more temperature scales to‐
gether with the pressure scale. The values for the R134a scale
are assigned according to the vapour pressure table. As different
refrigerants produce different vapour pressures at the same tem‐
perature, each temperature scale is identified for the correspond‐
ing refrigerant.
2.9.1 Manometers allow the following inspec‐

tion and measurement work to be car‐
ried out
a – Pressure and temperature measurement in the refrigerant cir‐
cuit
♦ The high-pressure manometer is used to measure the pres‐
sure and temperature which, while the air-conditioner is con‐
nected, evenly spread from the compressor outlet, through the
condenser, up to the narrowing (choke or expansion valve).
♦ The low-pressure manometer is used to measure the pressure
and temperature which, while the air-conditioner is connected,
evenly spread from the narrowing (choke or expansion valve),
through the evaporator, up to the compressor inlet.
Note
The relationship between pressure and temperature specified on

the manometers is only valid for the areas of the refrigerant circuit
which contain liquid or vapour, not gas. In gaseous state, the
temperature is approx. between 10 °C and 30 °C greater than that
stated by the manometer.
b – Checking for presence of refrigerant in closed container

A closed container or a refrigerant circuit contains
Protected by copyright.refrigerant
Copying for private or commercial purposes, in part or in whole, is not
R134a if the temperature stated by permitted
the manometer is equal
unless authorised by SEAT toS.A.the
SEAT S.A does not guarantee or accept any liability with
temperature of the refrigerant (the liquidrespect
present adopts the tem‐
perature of the environment).

A closed container or a disconnected refrigerant circuit is empty
if the temperature stated by the manometer is below the temper‐
ature of the refrigerant.

Note
The relationship between pressure and temperature specified on

the manometers is no longer valid when no liquid is present, and
the only pressure created is due to the presence of gas.
2.10 Equipment for loading and recycling of

the refrigerant
Different equipment is available on the market for the extraction
by vacuum, cleaning and filling of the refrigerant of vehicle air
conditioners.
2.10.1 Classification of suction systems into

groups
Group 3:
Mobile suction and charging systems for charging pressurized
gas tanks fixed to the system.
The refrigerant or the mixture of refrigerant and refrigerant oil is
charged into the pressurized gas tanks which are permanently
joined or fixed to the mobile systems. According to Regulation
COM (2003) 492 regarding fluorinated gases (11/08/03), in this
case, the pressurized gas tanks must be equivalent to pressur‐
ized tanks.
The charging systems do not require:
♦ a permit
♦ or an inspection by experts, seeing as the gas is charged into
pressurized gas tanks equivalent to pressurized tanks. (None‐
theless, the system used to charge the pressurized gas tanks
to be delivered to third parties from these pressurized tanks
does require the corresponding permit and is subject to com‐
pulsory inspections).
Note
In the case of service and recycling equipment used in automotive

workshops, these suction and charging equipment do not require
a permit (Group 3), but may only be handled by duly qualified
personnel. The handling and maintenance of the equipment is
described in the corresponding manufacturer’s documentation.
2.10.2 Charging systems which do not require

a permit
Charging systems which do not require a permit are charging
systems in which the pressurized gases are charged into mobile
pressurized gas tanks which are exclusively used by the company
itself.
Note:
Certain service equipment is charging systems which do not re‐
quire a permit. When working with this equipment, the refrigerant
is not charged into mobile pressurized gas tanks, but into a fixed
charging cylinder with a visible level gauge and float switch.

Recommendation:
When charging surplus refrigerant to cover own demand, it is ad‐
visable to use a portable charging cylinder with a visible level
gauge and a pressure relief valve.
When charging pressurized gases into other pressurized gas
tanks, observe the TRG 402 (Technical Regulations regarding
Pressurized Gases).
2.11 Repair instructions for refrigerant circuit
WARNING
When working on the refrigerant circuit, the current general

safety regulations and pressurized vessel regulations must be
observed.
Caution
When using tools or materials that

Protected have Copying
by copyright. not been approved
(e.g. sealing additives), damage mayauthorised
permitted unless be causedby SEAT toS.A.
theSEAT
system
or it may be influenced. respect to the correctness of information in this document. Copyright by SEAT S.A.

be used.
Special tools and accessories:

In order to guarantee a correct and professional repair of an air-
conditioner system:
• special tools and material are required (see the list under
⇒ page 147 ).
• The basic notes on the leak detector device must be taken into
account ⇒ page 53 .
• Special knowledge is required.
Note
Refrigerant may not be released into the environment

⇒ page 41 .

3 Legal texts and regulations
Note
♦ The laws and regulations applicable in each case are those of

each particular country, or else, the following in the case of the
European Union.
♦ Different and/or additional laws and regulations may be appli‐
cable in other countries or continents.
♦ Please refer to the responsible authorities.
♦ The affects to the changes in the climate are apparent through‐
out the world. This is why environmental protection represents
one of the most important tasks of mankind. However, this task
is a huge challenge for participants.
♦ The global objectives concerning the topic environmental pro‐
tection have been defined in the Kyoto protocol, amongst
others. Next to the objectives for
Protected by reducing
copyright. carbon
Copying for privatedioxide, this
or commercial purposes, in part or in whole, is not
protocol also determines the objectives for reducing green‐
house gasses (fluorinated gases), such as, e.g. for refrigerant

R134a due to the increased possibility of the greenhouse ef‐

fect.
3.1 Laws and regulations

On a European level, a large number of relevant directives have
been legislated for the automobile industry. In Germany, for ex‐
ample, at a national level from the 1st August 2008, as an en‐
hancement to the European legislation, the Chemicals Climate
Protection Ordinance has come into effect.
Regulation (EU) No. 2037/2000
(1) The use and sale of CFCs is forbidden.
(2) Calendar for banning the use and manufacture of HCFC
equipment.
(3) CFCs and HCFCs will be recovered for destruction or recycling
during service or maintenance operations on the equipment, or
before its disassembly or destruction.
(4) Member states will take measures to promote the recovery,
recycling or destruction of CFCs and HCFCs.
(5) Member states will determine the minimum qualification re‐
quired by the personnel involved.
(6) All feasible measures will be taken to prevent CFCs and
HCFCs from leaking or escaping. In particular, fixed equipment
with a refrigerant load greater than 3 kg will be controlled.
Training and certification programmes will be established for per‐
sonnel involved in the carrying out of leak inspections, recovery,
recycling and destruction of refrigerants
♦ Regulation (EU) No. 1005/2009
♦ Guideline 2006/40/EC
♦ Royal Legislative Decree 795/2010 for Spain
3. Legal texts and regulations 41

♦ Chemicals Climate Protection Ordinance, recycling and refuse

law (for the destination country of the vehicle)
Maintenance and repair work on the refrigerant circuit of the air
conditioning system
All of those persons who carry out the maintenance and repair
work on air conditioning systems of vehicles must have completed
a training course and have been instructed (training certificate).
Other legislation may apply outside the European Union.
TRG 402 (Using the filling stations)
• over the age of 18 years,
• who possess the required knowledge and experience,
• and who can be expected to carry out their tasks in a reliable
manner.
The personnel must be trained before commencing their activi‐
ties, and periodically thereafter, at least once a year, in matters
regarding
• special hazards involved with handling pressurized gases,
• safety regulations, in particular the relevant TRG,
• measures to be taken in case of faults, disasters or accidents,
• handling fire extinguishing equipment and protective equip‐
ment,
• handling and maintenance of charging stations, based on the
handling instructions.
Transformation of a refrigerant R12 circuit into a refrigerant
R134a circuit, and repair (Retrofit)
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Due to the situation of the environment and the resulting laws

derived, the manufacture of refrigerant R12 will be suspended,
and it will no longer be available. Refrigerant R134a was de‐
veloped as a replacement for R12.
♦ Air-conditioner systems designed and built to operate with re‐
frigerant R12 cannot and must not simply be charged with
refrigerant R134a. In order to guarantee that the air-condition‐
er operates perfectly after a transformation, certain compo‐
nents of the refrigerant circuit must be replaced.
Refrigerant record
According to the environmental statistics law, it is compulsory to
keep a record of refrigerants used.
For this reason, automotive workshops will have to inform the re‐
spective National Statistical Institute on the use of refrigerants.
Therefore, it is advisable to keep a record sheet ⇒ Service Or‐
ganisation Manual
Note
Due to a guideline of the European Parliament from 2005, in‐

spection sheets are no longer required in the EC. Other guidelines
may apply for countries that do not belong to the EC.

3.2 Law regulating waste recycling and

management
The legal regulations regarding the handling and elimination of
refrigerant and refrigerant oil waste must be included in the pro‐
tection law on waste emissions, recycling and management.
⇒ Environmental Protection (EC) No. 2038/2000 (see Page 25
of Official Journal) Consult the competent authorities.
3.2.1 Elimination of refrigerants and refriger‐

ant oils
Refrigerant
The refrigerant to be eliminated must be placed in appropriate
containers, which must be duly marked, for its recycling, taking
into account the admissible filling mass.
Refrigerant machine oil
Used refrigerant Protected
oils from installations
by copyright. which
Copying for privatecontain halogenated
hydrocarbons must beunless
permitted disposed
authorisedof as waste
by SEAT S.A. SEATsubject
S.A does to specialor accept any liability with
not guarantee
control. They may not be mixed with other oils or materials. They
must be stored and eliminated correctly in compliance with the

national directives.
Sources in other countries may be obtained from the responsible
authorities.
3.3 Refrigerant record
Note
♦ The following laws and guidelines listed apply for the member
states of the EC. Other or extended guidelines may apply in
countries outside the European Union.
♦ Please refer to the responsible authorities.
The quantities used for the operating and maintenance must be

documented (Refrigerant manual, ⇒ SEAT-ServiceNet, Guide‐
lines, Service Guidelines; Environment Protection; Emission Pro‐
tection ), so that you are able to provide proof when requested by
the responsible authorities. Due to a guideline of the European
Parliament from 2005, inspection sheets are no longer required
in the EC. Other guidelines may apply for countries that do not
belong to the EC.
3. Legal texts and regulations 43

4 Refrigerant circuit
4.1 Important instructions regarding air-con‐

ditioner system repair
• An air-conditioner system designed to operate with refrigerant
R12 cannot be used with refrigerant R134a, without first car‐
rying out modifications to the refrigerant circuit.
• Refrigerant oils specially designed for refrigerant circuits
which use R134a and for those which use R12 must never be
mixed.
• Service stations which come into contact with a specific re‐
frigerant must only be used with that specific refrigerant.
• Circuit components designed for use with refrigerant R134a
are marked by means of inscriptions and/or green labels, or
are manufactured (e.g. using different threads) in such a way
that it is impossible to confuse them with components de‐
signed to operate with refrigerant R12.
• There is an information plate in the engine compartment, lock
carrier plate or plenum chamber which specifies the refrigerant
used.
• Different refrigerants must under no circumstances be mixed.
If work is to be carried out on the refrigerant circuit, take into ac‐

count the information contained in chapters “Safety measures”
and “Basic aspects for working on the refrigerant circuit”.

5 Working with the service equipment

for air conditioners
Caution
♦ If there is a suspicion that chemical substances have been

filled into the refrigerant circuit of the vehicle for the pur‐
pose of sealing leaks, the vehicle must not be connected
to the air conditioning service station and the refrigerant
must not be extracted.
♦ Chemical substances used to seal leaks build up deposits
in the refrigerant circuit which impair the function of the air
conditioner and lead to malfunction of the air conditioner
(and your air conditioning service station).
♦ The client must be informed that their air conditioning sys‐
tem contains substances that have not been authorised
by SEAT. You are not permitted to extract nor repair such
air conditioning systems.
Note
♦ SEAT refuses the use of chemical substances for sealing the

leaks in refrigerant systems.
♦ The chemical substances used to seal leaks in refrigerant cir‐
cuits usually react with the ambient air or the humidity con‐
tained in the ambient air. Solid deposits of chemical substan‐
ces build up in refrigerant circuits (and in your air conditioning
service station) and cause malfunctions at valves and other
components if they come into contact with them. These de‐
posits cannot be completely removed from the components.
♦ In most cases, you are not able to see if chemical substances
are used for sealing the leaks in refrigerant systems. In most
cases, the necessary sticker that should be applied for the
purpose of informing about this substance is usually not at
hand. Therefore great care is required on vehicles where the
past records are unknown.
♦ Containers are available at accessory dealers that should sep‐
arate the chemical substances (for sealing leaks). As SEAT
refuses the use of such substances, they cannot provide any
information to the use of suchProtected
filtersbyand theirCopying
copyright. efficiency atorthis
for private commercial purposes, in part or in whole, is not
point. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5. Working with the service equipment for air conditioners 45

5.1 Working with the service station SAT

4006D
5.2 Important notes on working with the air
conditioning service station
When working with the service stations (e.g. air-conditioner serv‐
ice station - 4006D- ), the following must be taken into account:
• The installed filters and desiccants must be replaced at the
latest when the service time stated in the respective instruc‐
tions manual is reached.
• Only refrigerant oils authorized for the specific refrigerant cir‐
cuit of the vehicle must be used.
Under the following circumstance, the refrigerant sucked out must
not be reused in the station, even after it has been purified.
• If the compressor was damaged, leading to the refrigerant de‐
composing due to overheating.
• If there are dark and sticky sediments in the refrigerant circuit
(which can only be detected after opening the installation).
• If there is any doubt about the composition of the refrigerant
extracted from the refrigerant circuit.
In such cases it is always necessary to empty the service station.
If necessary, clean system and replace filter and dryer as well as
refrigeration oil.
The contaminated refrigerant can be stored in so-called recycling
bottles for processing or correct disposal and sent back the re‐
frigerant supplier (see the country specific legal guidelines, dif‐
ferent or extended standards are possible).
Commercially available service stations can be classified into two
groups:
♦ A. Service stations which purify the extracted refrigerant for
reuse (the so-called suction and recycling
Protected by stations), e.g.forthe
copyright. Copying private or commercial purposes, in part or in whole, is not
air-conditioner service station - SAT 4006D-
permitted .
♦ B. Service stations which extract the extracted refrigerant and
deposit it into recycling bottles (to be treated at large scale at
specialized plants). These installations are known as suction
systems.
5.3 Connecting the air conditioning service

station for carrying out measurements
and tests
• Depending on the type of tools chosen, there may be differ‐
ences in the work process. The specific handling instructions
for each tool must be taken into account.
Note
Basically, the work process must be carried out exactly as de‐

scribed in the instructions manual of the air-conditioner service
station - SAT 4006D- .
In order to prevent air or humidity from entering the refrigerant

circuit through the charging hoses, they must be connected as
follows:

– Switch off ignition.

– Connect the service station to the electrical power source.
– Remove the caps from the service connections or valve con‐
nections (on the specific refrigerant circuit of the vehicle).
⇒ Rep. gr. 87
– Remove the filling hoses.
Note
Connect the charging hoses with quick couplings to the service

connections on the refrigerant circuit.
Caution
Never open valves on the low pressure and high pressure

sides when the engine is running. Otherwise
permittedthe airauthorised
unless conditioner
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
compressor or the air conditioning service respect
station may
to the be af‐
fected by a “short circuit” between the low pressure and high
pressure sides in the refrigerant circuit as long as the air con‐
ditioner is being operated.
– Only turn the handwheel in the quick connector adapter far

enough until the valve has been opened safely in the service
coupling (observe the pressure gauge, do not apply excessive
pressure to the valve).
– Start the engine and perform the planned measurements or
checks.
– Compare the values obtained with the required measurement
values ⇒ page 106
– Before removing the quick connector, close the connection by
turning the handwheel outwards.
5.4 Extract the refrigerant circuit using the

air conditioning service station.
WARNING
High-voltage on high-voltage system. Danger of electric shock

on air conditioner compressor!
Now, ensure there is no voltage in high-voltage system on the
vehicle ⇒ Electric drive,; Rep. gr. 93 ; Ensuring there is no
voltage in high-voltage system .

ences in the work process (the specific handling instructions
for each tool must be taken into account).
• The refrigerant circuit must be emptied if any parts of the re‐
frigerant circuit are to be disassembled, if there is any doubt
about the amount of refrigerant in the circuit or if required by
the safety measures.
• All fundamental instructions for working with the air-condition‐
ing service station can be obtained from the respective oper‐
ating instructions of the air-conditioning service station.

Emptying:
– Connect the air-conditioning service station to the service con‐
nections of the vehicle when observing the respective operat‐
ing instructions ⇒ Rep. gr. 87 and put into operation.
Note
♦ Take into account that, besides the refrigerant, some refriger‐

ant oil may also be sucked out of the refrigerant circuit. In order
to ensure that the compressor is correctly lubricated, new re‐
frigerant oil must be added to the circuit ⇒ Rep. gr. 87 .
♦ In vehicles without electromagnetic coupling on the compres‐
sor (with air conditioning system compressor regulating valve
- N280- ), the engine should run for < 10 minutes with an empty
and closed refrigerant circuit (The air conditioner compressor
always runs simultaneously). The engine speed must not ex‐
ceed 2000 rpm.
♦ The engine can be started in vehicles with electromagnetic
coupling on the compressor, because the air conditioner pres‐
sure switch - F129- or the high-pressure sender - G65- (checks
if refrigerant is in the refrigerant circuit) separates the electro‐
magnetic coupling when no refrigerant is located in the refrig‐
erant circuit.
5.5 Emptying the refrigerant circuit with the

service station
• Basically, the work process must be carried out exactly as de‐
scribed in the instructions manual of the service station.
• The operation with the service station - SAT 4006D - is de‐
scribed here.
Before filling the refrigerant circuit with refrigerant, the circuit must
be extracted 45 minutes long when using one evaporator and 60
minutes long (without air) using two evaporators. Any humidity is
also extracted from the circuit.
Leaks can be detected when extracting the refrigerant.
Draining:
Caution
♦ The engine must not be started during the extraction proc‐

ess and as long as the refrigerant circuitProtected
is empty.
♦ If the refrigerant circuit is empty and the engine

respectis started,
damage can be caused to the air conditioner compressor.
♦ Only start the engine after the refrigerant circuit has been
filled.

– If necessary, correct the amount of refrigerant oil inside the
refrigerant circuit, see the corresponding Repair Manual for
the vehicle ⇒ Rep. gr. 87 .
– Check the amount of refrigerant present in the service station.

– Connect the charging hoses of the service station to the re‐

frigerant circuit on the vehicle by means of quick coupling
adaptors (see the specific refrigerant circuit of the vehicle).
⇒ Rep. gr. 87
– Turn the wheel on the quick coupling adaptors until the service
coupling valves are completely open (do not force the valve).
Note
If the pressure needs to be measured after charging the installa‐

tion in vehicles which only have a service connection on one side
of the refrigerant circuit, a valve adaptor and hose with a valve
opener must be used.
– Start the emptying process on the service station. The refrig‐

erant is extracted automatically (if necessary, observe the time
setting for the extraction).
When the emptying process has completed, the leak inspection
of the refrigerant circuit is started. The vacuum in bar per second
is monitored.
If the vacuum is not maintained, proceed as follows:
– Re-initiate the vacuum phase on the air conditioning service
station. The refrigerant is extracted automatically (if necessa‐
ry, observe the time setting for the extraction). Observe the
vacuum indicator for a while. Charging may be done only when
vacuum is maintained.
♦ When a larger leak is at hand that results in a large quantity of
air entering when extracting that the air conditioning service
station cannot generate sufficient vacuum or when the vac‐
uum indicator displays that air enters immediately after turning
off the service station and the vacuum is reduced,
– the leak on the refrigerant circuit must be detected as follows:
⇒ page 53
5.6 Charging the refrigerant circuit with the

service station
WARNING
High-voltage on high-voltage system. Danger of electric shock

on air conditioner compressor!
Now, ensure there is no voltage in high-voltage system on the
vehicle ⇒ Electric drive,; Rep. gr. 93 ; Ensuring there is no
voltage in high-voltage system .
• Basically, the work process must be carried out exactly as de‐

scribed in the instructions manual of the service station.
• Before charging the refrigerant, correct the amount of refrig‐
erant oil inside the refrigerant circuit ⇒ Rep. gr. 87 .
• The total amount of refrigerant can be charged at either the
low or high pressure side.
Charging the refrigerant circuit.
– Vacuum the refrigerant circuit with the service station
⇒ page 48 .

– Turn the wheel on the quick coupling adaptor (close).

– Allow the charging hose to fill with refrigerant.
– Turn the wheel on the quick coupling adaptor (do not force the
valve), and charge the circuit with the specified amount of re‐
frigerant.
– Disconnect service station for air conditioning system.
Note
If the air conditioner compressor is removed, the poly V-belt / free

pulley must be turned about 10 turns by hand before starting for
the first time. This prevents damage being caused when the air
conditioner is turned on for the first time by a sudden increase of
the fluid quantity in the air conditioner compressor (when oil is
located in the cylinder of the air conditioner compressor, this will
be pressed out by the rotation).
– Start the engine with the compressor disconnected (version

with electromagnetic coupling).
– Set the compressor to its lowest power setting, "Econ" mode
or A/C disconnected (version with regulating valve without
electromagnetic coupling).
– Wait for the engine to start idling at a stable speed.
– Switch on the compressor and allow the system to run in idle
for at least 2 minutes.
– If necessary, check the pressures in the refrigerant circuit with
the service station.
– Switch off the engine.
– Turn the wheel
Protected on Copying
by copyright. the quick coupling
for private adaptor.
– Remove thetohoses
respect fromofthe
the correctness refrigerant
information circuit.
in this document. Copyright by SEAT S.A.
– Replace the protective caps.
5.6.1 Turn on the air conditioner after filling.
Note
If the air conditioner compressor is removed, the poly V-belt / free

pulley must be turned about 10 turns by hand before starting for
the first time. This prevents damage being caused when the air
conditioner is commissioned for the first time by a sudden in‐
crease of the fluid quantity in the air conditioner compressor
When oil is located in the cylinder of the air conditioner compres‐
sor, this will be pressed out by the rotation.

– Start the engine with the compressor disconnected (version

with electromagnetic coupling).
– Set the compressor to its lowest power setting, "Econ" mode
or A/C disconnected (version with regulating valve without
electromagnetic coupling).
– Wait for the engine to start idling at a stable speed.
– Switch on the compressor and allow the system to run in idle
for at least 2 minutes.
– If necessary, check required pressures in refrigerant circuit
with service station for air conditioners.
– Switch off the engine.
– Turn the wheel on the quick coupling adaptor.
– Remove the hose of the refrigerant.
– Replace the protective caps.
5.7 Fill the container of the air conditioning

service station with refrigerant
• Basically, the procedure must be carried out as described in
the instruction manual of the air-conditioning service station.
• A description of how to charge each air-conditioner system
with a determined amount of refrigerant is given. To make sure
that neither insufficient nor too much refrigerant has been filled
(both would influence the cooling output) the refrigerant has
been mounted an a scale.
5.8 Emptying the service station
Note
♦ If the service station needs to be emptied (e.g. after vacuuming

refrigerant with impurities), all filters and desiccants must al‐
ways be replaced (remove the filters and desiccants form their
airtight packaging only immediately before they are to be
mounted, in order to minimize the amount of humidity absor‐
bed).
♦ The bottles in which the used refrigerant (with impurities) is to
be stored are called “recycling bottles”.
♦ Before filling them with refrigerant for the first time, the recy‐
cling bottles must always be vacuumed (refrigerant bottles
which contain air must never be filled with refrigerant).
♦ Do permitted
not mix different
unless authorisedtypes ofS.A.
by SEAT refrigerants (mixed
SEAT S.A does not refrigerants
cannot be treated,
respect and must
to the correctness be disposed
of information of as Copyright
in this document. waste).byIfSEAT
there
S.A.
is any doubt regarding the composition of the contents of a
bottle, the company in charge of recycling the refrigerant must
be informed.

WARNING
♦ When filing recycling bottles (pressurized gas containers),

all applicable regulations, technical regulations and cur‐
rent laws must be observed.
♦ The recycling bottles must under no circumstances be
overfilled (the gas cushion in overfilled recycling bottles
may be insufficient to compensate for expansion of the
liquid caused by heat). This may result in the bottle burst‐
ing.
♦ For your own safety, use only recycling bottles with built-
in safety release valves.
♦ The recycling bottles must be weighed on a calibrated
scale during the filling process. The maximum admissible
filling amount is 75% (filling factor 0.75) of the filling weight
specified on the recycling bottle (the possibility of refrig‐
erant oil from entering the recycling bottled while it is filled
with refrigerant must not be ruled out).

6 Check for possible leaks in the refrig‐

erant circuit
Note
♦ This workshop manual describes how the leak detection is

carried out in the refrigerant circuit using two different proce‐
dures. These procedures have been tested and lead to reliable
results under the different operating conditions as long as they
are carried out correctly and relate directly to the phenomenon
of complaint.
♦ Smaller leaks can be detected using an electronic leak detec‐
tor or a UV leak detection lamp.
♦ Numerous procedures are offered on the open market for de‐
tecting leaks in the refrigerant circuit. These procedures do not
always provide clear results. If the instructions of such proce‐
dures are not followed in detail, leaks may be indicated on
components of the refrigerant circuit although they do not have
a leak. Moreover, components of the refrigerant circuit may be
damaged or influenced with certain procedures.
♦ Components where a leak is detected must not be repaired,
they must be replaced using genuine spare parts.
♦ A leaking refrigerant circuit must not be filled with refrigerant.
This is why the refrigerant circuit must be extracted before fill‐
ing and checked for leaks in the process ⇒ page 48 .
Caution

filled into the refrigerant circuit of the vehicleinfor the pur‐Copyright by SEAT S.A.
respect to the correctness of information this document.
♦ SEAT disapproves of the use of chemical substances
(leak stop additives) for sealing leakage in AC circuits.
(and the service station).
6. Check for possible leaks in the refrigerant circuit 53

Note
♦ SEAT refuses the use of chemical substances for sealing the

leaks in refrigerant systems.
♦ The chemical substances used to seal leaks in refrigerant cir‐
cuits usually react with the ambient air or the humidity con‐
tained in the ambient air. Solid deposits of chemical substan‐
ces build up in refrigerant circuits (and in your air conditioning
service station) and cause malfunctions at valves and other
components if they come into contact with them. These de‐
posits cannot be completely removed from the components
affected (even by flushing).
♦ In most cases, you are not able to see if chemical substances
are used for sealing the leaks in refrigerant systems. In most
cases, the necessary sticker that should be applied for the
purpose of informing about this substance is usually not at
hand. Therefore great care is required on vehicles where the
past records are unknown.
♦ Containers are available at accessory dealers that should sep‐ Copyright by SEAT S.A.
respect to the correctness of information in this document.
arate the chemical substances (for sealing leaks). As SEAT
refuses the use of such substances, they cannot provide any
information to the use of such filters and their efficiency at this
point.
6.1 Locating leaks in the refrigerant circuit

with the leak detector - SAT 4012-
Note
Small leaks may be detected for example using an electronic leak

detector.
To ensure that as little refrigerant as possible does not escape to

the environment when searching for leaks as possible, proceed
in the following way to perform a complete extraction of the re‐
frigerant circuit:
– Extract the refrigerant circuit using the air conditioning service
station ⇒ page 45 .
Note
♦ If a larger leak is detected when extracting, the leak position

must be determined and remedied as described.
♦ If no leak or a very small leak is detected when extracting that
the leak position cannot be determined, proceed as follows:
♦ Refrigerant gas is quickly dispersed by air motion. Therefore
drafts must be avoided during a search for leaks.
♦ When the refrigerant circuit is completely empty, charge it with
approx. 100 g refrigerant.
Leak detection:
– Use the leak detector according to the corresponding instruc‐
tions manual.
– Keep the detection point below the area of the suspected leak.

Depending on model, if the number of clicks increases or a siren

type sound is given out then this means a leak has been detected
(see the relevant instructions).
6.2 Locating leaks in the refrigerant circuit

with the leak detector - SAT 4007B-
Note
Small leaks may be visually located, for example, with a fluores‐

cent medium, such as the leak detection additive - SAT 4007B- .
Leak detection:
– When the refrigerant circuit is completely empty, fill with 100

grammes of refrigerant, with the a/c load station replaced by
SAT 4006D - SAT 4006C- .
– Add leak detection additive - SAT 4007/2- to the refrigerant
circuit, and inspect the refrigerant circuit with an UV lamp UV
lamp - replaced by SAT 4007B/3 - SAT 4007/3- .
Note
The leak detection additive may remain inside the refrigerant cir‐
cuit.

6.3 Tracing leaks in refrigerant circuit
6.3.1 Searching for leaks on the refrigerant

circuit using the leak detection system
VAS 6201A
Note
♦ Certain leaks are difficult or even impossible to find using an

electronic leak detector. Such leaks can be detected using the
VAS 6201A leak detector.
♦ Refrigerant circuit leaks result in a loss of refrigerant oil to‐
gether with the refrigerant. The oil usually remains in the
vicinity of the leak. Adding a small quantity of fluorescent fluid
to the refrigerant circuit makes this oil visible under UV light.
The fluid (PAG oil containing an additive which shows up un‐
der UV light) is poured into the refrigerant circuit and becomes
distributed with the refrigerant oil when the air conditioner is
switched on.
♦ It is necessary to operate the air-conditioning system for at
least 60 minutes (AC compressor running) to ensure that the
additive is distributed uniformly in the entire AC circuit.
♦ The refrigerant oil containing the additive, which shows up un‐
der UV light, can either be filled directly into the open circuit or
pumped in with the circuit charged using the hand pump VAS
6201/1 (from the leak detection system VAS 6201A) via the
service connection on the vacuum side.
♦ If the leak detection additive is applied via the service con‐
nection on the low-pressure end with the refrigerant circuit
charged, a small quantity of additive remains in the service
connection. Carefully remove the remains as this will help to
prevent these remains being falsely identified as a leak when
leak detection is carried out in the future.
♦ If a component forming
Protectedpart of a circuit
by copyright. into
Copying for which
private the leak
detection additive is poured
permitted has to bybeSEAT
unless authorised renewed, thoroughly
S.A. SEAT S.A does not guarantee or accept any liability with
clean joints with otherrespect
components after assembling refriger‐
ant circuit. These leak detector additive residues at the con‐

nection points could be evaluated erroneously as leakage
when searching for leaks later.
♦ On discharging the refrigerant circuit, refrigerant oil and thus
also leak detection additive ingresses into the air conditioner
service station. The refrigerant oil is removed from the refrig‐
erant in the oil separator of the air conditioner service station
and discharged from the air conditioner service station via the
drain. Do not pour the refrigerant oil drained off back in. It is to
be replaced with fresh refrigerant oil.
♦ Observe the following if leak detection fluid has already been
poured into a refrigerant circuit in the course of previous repair
work: Only add new leak detection fluid if refrigerant oil is re‐
placed. If only some of the refrigerant oil has been renewed,
just add the corresponding quantity of leak detection fluid. If,
for example, 100 ml of refrigerant oil has been replaced on a
vehicle containing 250 ml, only add 1 ml (cm3) of leak detection
additive.
♦ Certain materials and their compounds (e.g. oxidation prod‐
ucts on aluminium components, anti-corrosion waxes) also
show up under UV light.

Necessary tools and means: VAS 6201A

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 solvent - VAS 6201/3-
4- UV leakage detector lamp - VAS 6201/4-
5- UV protective goggles - VAS 6201/6-
6- Sticker - VAS 6201/7-
7- Pipe
VAS 6201/8
8- Protective gloves - VAS 6201/9-
Pouring in leak detection additive with refrigerant circuit empty

The cartridge -A- contains 15.4 ml of leak detecting additive (one
unit -B- equates to 2.5 ml).
– Mount the hand pump - VAS 6201- item -1- with the cartridge
-2- -VAS 6201/2- .
– Mount the filling tube - VAS 6201/8- ( ⇒ by
Protected page 57 Copying
copyright. Pos. -7-) to or commercial purposes, in part or in whole, is not
for private
the hand pump. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Open the service valve of the hand pump.

The leak detection additive can be filled into the empty refrigerant
circuit through an open connection.
– Separate a connection position on the refrigeration circuit that
is easy to access.
– Cover the area around the connecting position with film or ab‐
sorbent paper.
– Hold the pipes upwards.
– Screw in the screw knob of the hand pump in until leak detec‐
tion additive exits from pipe.
– 2.5 ± 0.5 ml (millilitre = cm3) Fill leak detection additive in the
refrigerant circuit.
Note
Observe the following if leak detection fluid has already been

work: Only add new leak detection additive if the refrigerant oil is
replaced. If only some of the refrigerant oil has been renewed,
just add the corresponding quantity of leak detection additives. If,
for example, in a vehicle with 250 ml refrigerant oil, 100 ml is re‐
placed, only 1 ml (cm3) of leak detection additive can be filled.
– Replace the O-ring fortothe
respect separated
the correctness connecting
of information position.
in this document. Copyright by SEAT S.A.
– Reassemble the refrigerant circuit.

– Apply a sticker near to the service connection that provides
information that leak detection additive has been filled into this
– Extract and charge the refrigerant circuit as described.
– Switch the air conditioner on:
Note
♦ To enable the leak detection additive to be distributed through‐

out the entire refrigerant circuit, the air conditioner must re‐
main switched on for at least 60 minutes (the air conditioner
compressor must run). Depending on the size of the leak, the
leak can already be detected during this period.
♦ Depending on the size and location of the leak, it may take
several days before the refrigerant oil with leak detection ad‐
ditive escapes.
– Find leaks on the refrigerant circuit using the UV leak detection

lamp VAS 6196/4.

Pouring in leak detection additive with refrigerant circuit charged
Note
♦ Observe the following if leak detection fluid has already been

work: Only add new leak detection additive if the refrigerant oil
is replaced. If only some of the refrigerant oil has been re‐
newed, just add the corresponding quantity of leak detection
additives. If, for example, in a vehicle with 250 ml refrigerant
oil, 100 ml is replaced, only 1 ml (cm3) of leak detection addi‐
tive can be filled.
♦ A small quantity of the leak detection additive remains in the
service connection. Carefully remove these residues so that
these residues are not mistakenly perceived as a leak with
future leak detections.
The cartridge -A- contains 15.4 ml of leak detecting additive (one

unit -B- equates to 2.5 ml).

– Remove the sealing cap of the service connection of the vac‐
uum side of the refrigerant circuit.
– Mount the hand pump - VAS 6201- Pos. -1- with the cartridge
-2- -VAS 6201/2- .
Note
Ensure that hose on hand pump is completely filled with leak de‐
tection additive.
– Place the quick connector on the service connection on the

low-pressure and open the service connector by turning on the
handwheel. Hold hose pointing upward and screw knob on
hand pump in until leak detection additive exits from the hose.
– Cover the area around the service connection with film or ab‐
sorbent paper.
– By screwing in the screw knob on hand pump 2.5 ± 0.5 ml
(Millilitre = cm3) Fill leak detection additive in the refrigeration
circuit.

– Slacken the quick connector and remove from the service

connection.
– Remove the residues of the leak detection additive from the
service connection with, e.g. absorbent paper.
– Connect the service connection with the sealing cap.
– If required, clean the surroundings of the service connection
using a suitable cleaning solvent.
– Apply a sticker near to the service connection that provides
information that leak detection additive has been filled into this
Note
♦ To enable the leak detection additive to be distributed through‐

out the entire refrigerant circuit, the air conditioner must re‐
main switched on for at least 60 minutes (the air conditioner
compressor must run). Depending on the size of the leak, the
leak can already be detected during this period.
♦ Depending on the size and location of the leak, it may take
several days before the refrigerant oil with leak detection ad‐
ditive escapes.
– Find leaks on the refrigerant circuit using the UV leak detection

lamp VAS 6196/4.
Find leaks on the refrigerant circuit using the UV leak detection
lamp VAS 6196/4
WARNING
Do not look into the UV lamp.

Do not point the UV lamp at another person.
Note
♦ It is necessary to operate the air-conditioning system for at

least 60 minutes after filling (AC compressor running) to en‐
sure that the additive is distributed uniformly in the entire AC
circuit.
♦ Depending on the magnitude and location, it may take several
days for sufficient refrigerant oil and additive to emerge to
clearly identify the leak.
♦ For leaks on the evaporator, the additive can wash off with the
condensed water and leak out from the condensed water
drain-off. As on most vehicles the evaporator is not accessible
without considerable effort, checking the condensate drainauthorised
permitted unless for by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
example can provide an indication of evaporator leakage. This
does however require the additive to have been in the refrig‐

erant circuit for a lengthy period (several days).
♦ The safety goggles are not only designed to provide eye pro‐
tection. They also make the additive more readily visible under
UV light.
♦ Depending on the accessibility of various parts of the refriger‐
ant circuit, it may be necessary to remove certain vehicle
components (e.g. bumper or air cleaner).

– Move the vehicle to a dark area in the workshop (the effect of

the UV lamp is reduced at daylight or with intensive lighting).
– Check accessibility of various parts of the refrigerant circuit
and remove components in area of refrigerant circuit which
would block view of refrigerant circuit components (e.g. noise
insulation and bumper).
– Use eye protection.
– Connect UV lamp to a 12V battery (vehicle battery). Ensure
that it is connected to the correct terminals.
– Switch on UV lamp and illuminate components of refrigerant
circuit. Locations at which leakage has resulted in the emer‐
gence of refrigerant, refrigerant oil and thus also leak detection
additive show up under UV light (fluorescent).

7 Cleaning the inner side of the refrig‐

erant circuit
7.1 Cleaning the refrigerant circuit using the

cleaning station - SAT 4011-
It is necessary to work as cleanly as possible to prevent moisture
and other contamination such as old refrigeration oil from getting
into the circuit. This saves refrigerant and unnecessary installa‐
tion time and avoids unnecessary environmental pollution. For
this purpose it is necessary to flush the circuit with R134a refrig‐
erant or blow it out with nitrogen and a special solvent approved
by the equipment manufacturer and SEAT.

Note
Additional information:⇒ Service Manual for the cleaning station
Note
♦ The unit should be supplied for its consumption during wash‐

ing operations with a pressure circulation of at least 6 bar and
max. 8 bar, which also has a system for limiting moisture.
♦ The sweeping of the refrigerant circuit using nitrogen usually
requires considerably more skilled labour than rinsing with
R134a refrigerant. When rinsing with R134a refrigerant, clean‐
ing of components is usually more thorough and for this reason
a rinse should be done for each complaint (sweeping with ni‐
trogen is done for specific complaints and components)
♦ When blowing through with nitrogen and solvent, the working
pressure may not exceed 12 bar (this corresponds to a pres‐
sure in a loaded coolant circulation at an ambient temperature
of approx. 60 °C; if necessary, pressure reducing valves must
be inserted).
WARNING
♦ Only work with pressure reducing valves for nitrogen gas

cylinders (working pressure at least 8 bar and max. 12
bar).
♦ The solvent solution which comes out of the filtered com‐
ponents should be collected in the container in which it
was transported.
♦ The safety regulations must be closely observed for the
correct use of the unit.
Note
Do not blow nitrogen through the hose clip, the expansion valve,
the compressor or liquid tanks and collectors. ⇒ page 71
– If the condensers have been fitted with a dehydration cartridge

integrated in the liquid tank, remove this bycartridge
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
– First blow out the old refrigerant oil and any dirt with com‐
pressed air, and then eliminate any humidity in the compo‐

nents with nitrogen.
– Adapters for connecting the pressure hose to the refrigerant
circuit and ⇒ Heating, air-conditioning or ⇒ air-conditioning
⇒ page 82
So that oil or humidity from the compressed air system does not
enter into the refrigerant circuit, note the following points.
⇒ page 152
– If the refrigerant pipes are fitted with a connection thread or
bolt use the adaptors from the refrigerant circuit adapter kit -
V.A.G 1785- ( Adapter - V.A.G 1785/1- to Adapter - V.A.G
1785/8- ) to connect the filling hoses 5/8" -18 UNF (some of
these adapters are also included in the adapter kit, set for
SEAT vehicles - SAT 4009- . ⇒ page 82
7. Cleaning the inner side of the refrigerant circuit 63

– For refrigerant pipes lacking the threads or connection (for the

connection of adapters) use the adaptors from the adapter kit,
set for SEAT vehicles - SAT 4009- or an air pistol with a com‐
mercial type rubber tip..
Note
The refrigerant circuit should only be swept using nitrogen if it may

not be rinsed or if the rinsing operation is too complicated for the
specific components (sweeping may also be used to quickly elim‐
inate for example small impurities and dirt in the refrigerant pipes).
The refrigerant circuit (or specific components) must be swept (if

rinsing is not possible or inconvenient):
– If there is dirt or any other impurities in the circuit.
– If, after vacuuming an airtight refrigerant circuit, the vacuum is
not maintained (there is humidity in the refrigerant circuit which
builds up pressure).
– If the refrigerant circuit has remained open longer than nec‐
essary for assembly (e.g. after an accident).
– If, based on pressure and temperature measurements in the
refrigerant circuit, there may be humidity in the circuit.
– There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit,
– if the compressor has to be changed due to internal damage
(for example noise or lack of power),
– if required by the Repair Manual following replacement of cer‐
tain components.
7.1.1 General procedure for cleaning the cool‐

ing circuit
Note
♦ For those vehicles where the refrigerant pipes do not have a

thread for connection of the adapter V.A.G - 1785- . To sweep
specific components the use of the Adapter kit, SEAT pas‐
senger vehicles - SAT 4009- is recommended.
♦ The evaporator must be blown out through the low-pressure
piping connection (large diameter), ensuring that the expan‐
sion valve or choke has been disassembled.
♦ The components must always be rinsed or blown out in the
opposite direction to that of the refrigerant flow.
♦ Inspect the expansion valve. Replace if any dirt or corrosion
is found.
♦ If there are dark or sticky sediments that cannot be removed
using R134a refrigerant, then
Protected sweep
by copyright. these
Copying components
for private or commercialwith
purposes, in part or in whole, is not
nitrogen and solvent or respect

replaceto thethe components.
♦ Thin, light grey sediments inside the piping do not negatively

affect the performance of the components.
♦ After the blowing-out process, always replace the liquid tank
or the collecting tank and the choke. If the condensers have
been fitted with a dehydration cartridge integrated in the liquid
tank, replace this cartridge

After sweeping the refrigerant circuit:

– Replace, depending on the vehicle, these components (hose
clip and collector tank, expansion tank and liquid tank or even
dehydration cartridge) ⇒ Heating, air-conditioning or ⇒ Air-
conditioning and ⇒ Electronic parts catalogue
– Depending on the complaint the compressor must be replaced
⇒ Heating, air conditioning system or ⇒ Air conditioning sys‐
tem and ⇒ Electronic parts catalogue or drain the residual
refrigerator oil from the dismantled compressor (Renew com‐
ponents of the refrigerant circuit) and fill with the specified
amount of refrigerator oil (Approved oil and filling quantities for
refrigerators).
Note
♦ Replacement compressors come with the specific amount of

oil for refrigerant machines. For machines with two evapora‐
tors, if necessary, add the required amount of refrigerant
machine oil to the circuit ⇒ Heating, air-conditioning or ⇒ Air-
conditioning and (special oils and oil quantities for refrigerant
machines).
♦ If the compressor is not to be replaced then the amount of
refrigerant machine oil must be corrected (empty to move the
refrigerant machine oil then put the correct quantity into the
compressor or the refrigerant circuit) (replace components of
the refrigerant circuit) and (approved refrigerant machine oils
and filling quantities).
– Reassemble the refrigerant circuit ⇒ Heating, Air Condition‐

ing .
– Start up the air conditioning according to the specifications ⇒
Heating, air conditioning .
7.2 Description and operation of the clean‐

ing station - SAT 4011-
Additional information:⇒ Service Manual for the cleaning station .
Remove the refrigerant from the circuit using the a/c loading sta‐
tion - SAT 4006D- .
The cleaning station - SAT 4011- has a control panel with two
areas:
WARNING
♦ Only work with pressure reducing valves for nitrogen gas

cylinders (working pressure at least 8 bar and max. 12
bar).
♦ The safety regulations of the manufacturer must be close‐
ly observed for the correct use of the unit.

Zone -A- of the panel for cleaning with nitrogen:

1- Nitrogen input tap to component to be cleaned
Check that the tap on the external nitrogen tank is open, and there
is a maximum output pressure of 12 bar.
Open the tap -IN- until the manometer shows a pressure reading
of 12 bar, then close the tap. Once pressurised, if the pressure
has not changed after 10 minutes, then there are no leaks.
2- Nitrogen output tap from component to be cleaned
Depressurise the circuit by opening the output tap -OUT-.
3- Manometer for nitrogen pressure in the circuit
-Min - Max- operating pressure for washing and flushing circuit:
-8÷12 bars-
If the manometer reading changes, the circuit is not leak proof.
Zone -A- of the panel for cleaning with solvent:
1- Solvent viewing window
It is possible to see through the window whether the solvent is
clean or carrying particles.
If it is very dirty it should be dismounted and clean
2- Tap for circuit flush or purge -Flush- o -Purge-
The purge tap is closed when no more particles are observed in
the solution.
In position -B- or -C- the vacuum pump will start to operate to fill
the machine with solvent.
The numerical field is the operating range for the flushing opera‐
tion; Position -2- leave in this position for ten minutes, then
continue with Position -5-, again for at least 10 minutes, then con‐
tinue with Position -0-. The flushing procedure is then concluded
properly.
3- Manometer for the circuit wash or purge pressure
-Min - Max- operating pressure for washing and flushing circuit:
-6÷8 bar-
Connection area for solvent inlet/outlet: rear

1- Air/solvent separator
Solvent should be treated as hazardous waste, and the regula‐
tions applicable in your region or country must be observed.
2- Solvent input to component or circuit to be cleaned
Solvent input with a fluid impulse system.
3- Solvent output from the component or circuit which is being
cleaned
Circuit closed, in operating position
4- Return to tank tap
On completion of the operation the solvent must be drained from
the machine to the recipient.

Connection area for nitrogen inlet/outlet: rear

1- Nitrogen input to circuit or component
Execution of nitrogen sweep at pressure between -6÷12 bar- in
order to drag away any possible traces of solvent and humidity
that may remain in the component or circuit after the purge phase.
2- Nitrogen output from circuit or component
Circuit closed, in operating position
Connection area for inlet/outlet for filling: side of unit

1- Level of solvent
Do not fill with more than 20 litres, this could cause malfunctions.
2- Solvent filling and drainage connection
Recommended minimum operating level -10 litres-.
Solvent should be treated as hazardous waste, and the regula‐
tions applicable in your region or country must be observed.
On completion of the operation the solvent must be drained from
the machine to the recipient.
3- Compressed air connection Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Set the inlet pressure to a working pressure between
-at least 5 bar- and -max. 8 bar-
4- Input connection from nitrogen tank to equipment
Check that the tap on the external nitrogen tank is open, and there
is a maximum output pressure reading on the pressure control of
-12 bar-.
5- Operating zone selector switch
The selection switch has three possible positions: -CHARGE-
Switch on intake pump to fill unit with solvent.
-STOP- when it is not to be used, disconnected from the com‐
pressed air circuit.
-WORK- operating or wash position.
6- External filter
Replace filter regularly, at least every 10 times a not very dirty
circuit is cleaned, and every 3 washes if the circuits are very dirty.
It should be treated as hazardous waste, and the regulations ap‐
plicable in your region or country must be observed.
When replacing, check that it is not pressurised, that is, it is not
under pressure and the machine is disconnected from the com‐
pressed air installation.
7- Nitrogen discharge connection
The sweep stage is not finished until nitrogen also comes out
through the nitrogen discharge connection.

Input and output hose connections:

1- Red hose connection with the tool
connect to rear of equipment -OUT NITRO- and to the service
connection of the corresponding system to be cleaned, low pres‐
sure end.
Ensure that cone is connected properly, leakage is possible if in‐
stalled incorrectly. Replace rubber cone when worn.
2- Black hose connection with the tool
connect to rear of equipment -IN NITRO- and to the service con‐
nection of the corresponding system to be cleaned, high pressure
end.
Ensure that cone is connected properly, leakage is possible if in‐
stalled incorrectly. Replace rubber cone when worn.
7.3 Blow through refrigerant circuit with

compressed air and nitrogen.
• Compressed air must be used to remove humidity and other
impurities from the refrigerant circuit. Nitrogen must be used
to eliminate the humidity from the refrigerant circuit.
• The blowing of the refrigerant circuit using compressed air and
nitrogen usually requires considerably more labour than rins‐
ing with R134a refrigerant. When rinsing with R134a refriger‐
ant, cleaning of components is usually more thorough and for
this reason a rinse should be done for each complaint (sweep‐
ing with compressed air is carried out for specific complaints
and components)
Blowing through the components is only applied in the following
cases.
♦ If there is no possibility of rinsing the refrigerant circuit
Protected using Copying for private or commercial purposes, in part or in whole, is not
by copyright.
the refrigerant R134a. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ When dirt and other impurities are located in the different com‐
ponents of the refrigerant circuit.
♦ If during the evacuation of a leak-tight refrigerant circuit the
vacuum is not maintained at the gauge (there is moisture in
the refrigerant circuit and this generates vapour pressure).
♦ If the refrigerant circuit has remained open longer than nec‐
♦ If, based on pressure and temperature measurements in the
♦ When this requests for the replacement of certain components
of the vehicle in the specific Repair Manual ⇒ Heating, air
conditioning .
Note
♦ When blowing through the refrigerant circuit using com‐

pressed air and nitrogen, the degree of purity is not reached
than when rinsing with R134a refrigerant. When rinsing using
the refrigerant R134a, the refrigerant oil is released and clean‐
ing the component is more effective.
♦ When blowing the maximum operating pressure of 15 bar
must not be exceeded (when necessary, also use a pressure
reducer for the compressed air).

WARNING
♦ Nitrogen may escape from the bottle in an uncontrolled

manner.
♦ Use only pressure reducers for nitrogen gas cylinders
(maximum working pressure 15 bar).
♦ The mixture of gas blown out of the components must be
sucked up with the appropriate extraction installations.
– The components must always be blown out in the opposite

direction to that of the refrigerant flow.
Do not blow compressed air or nitrogen through the choke, ex‐
pansion valve, compressor, or the liquid and collecting tanks.
– With condensers where a cartridge is mounted in the integra‐
ted container, the cartridge must be removed.
– First blow out the impurities from the container using com‐
pressed air and then the humidity using nitrogen.
– Fit the adapter for connecting the pressure hose to the refrig‐
erant circuit ⇒ Heating, air conditioning .
So that no oil nor humidity from the compressed air system does
not enter into the refrigerant circuit, note the following points:
♦ The compressed air must be cleaned and dehydrated by
means of a compressed air cleaning device. Insert the filter
and dehumidifier (part of the scope of promotion of the tools
for painting work) ⇒ Workshop equipment and special tools
catalogue .
♦ For refrigerant lines with thread connection or union nut, use
the adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- ) for
connecting the filling hose 5/8" -18 UNF. These adapters are
part of the Adapter set for refrigeration - VAS 6338/1- and the
Adapter sets for refrigerant circuits for commercial vehicles -
VAS 6338/50- .
♦ For refrigeration lines without thread or union nut, use the
Adapter set for refrigeration - VAS 6338/1- or the Adapter sets
for refrigerant circuits for commercial vehicles - VAS 6338/50-
or a commercially available compressed air pistol with rubber
nozzles.
Note
♦ The compressed air and nitrogen flowing out of the component

must be captured using a suitable device (e.g. workshop ex‐
traction unit).
♦ Certain impurities
permitted and the
unless authorised old refrigerant
by SEAT do not
S.A. SEAT S.A does notguarantee
alloworthem‐
accept any liability with
selves to berespect
removed at all oroftoinformation
to the correctness be removed from certain
in this document. parts
Copyright by SEAT S.A.
of the refrigerant circuit. Such impurities can only be elimina‐

ted by rinsing then with refrigerant R134a.

7.3.1 Blowing through the refrigerant circuit
Note
♦ On vehicles where no adapter can be connected to the refrig‐

erant pipes, a compressed air gun can be used, for example,
with rubber nozzle for blowing through the different compo‐
nents. When doing so, take special care not to damage any
connections (crushing or scratching).
♦ The evaporator must be blown out through the low-pressure
piping connection (large diameter), ensuring that the expan‐
sion valve or choke has been disassembled.
♦ The components must always be blown out in the opposite
direction to that of the refrigerant flow.
♦ Inspect the expansion valve. Replace if any dirt or corrosion
is found.
♦ If there are dark and sticky sediments which cannot be re‐
moved with compressed air in any components, they must be
replaced.
♦ Minimum residues of grey paint on the inside of the refrigerant
lines do not influence the function of the component.
♦ After the blowing-out process, always replace the liquid tank
or the collecting tank and the choke. In condensers with inte‐
grated driers, the drier cartridge or drier must be replaced.

8 Cleaning refrigerant circuit of impuri‐

ties using R134a refrigerant
8.1 Rinsing (cleaning) the refrigerant circuit

using the refrigerant R134a
WARNING

filled into the refrigerant circuit of the vehicle for the pur‐
(and your air conditioning service station).
• Work as cleanly as possible to prevent moisture and other

contamination (such as abrasion particles from wear or de‐
fective compressor) as well as old refrigeration oil from getting
into the circuit. This saves refrigerant and unnecessary instal‐
lation time and avoids unnecessary environmental pollution.
For this purpose flush the circuit with R134a refrigerant.
The refrigerant circuit must be rinsed with refrigerant R134a:
– If there is dirt or any other impurities
respect in the
to the correctness circuit. in this document. Copyright by SEAT S.A.
of information
– If, after vacuuming an airtight refrigerant circuit, the vacuum is

not maintained (there is humidity in the refrigerant circuit which
builds up pressure).
– If the refrigerant circuit has remained open longer than nec‐
– If, based on pressure and temperature measurements in the
– There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit,
– if the compressor has to be changed due to internal damage
(for example noise or lack of power),
– if required by the Repair Manual following replacement of cer‐
tain components.
– a different air conditioner compressor with other refrigerant oil
is to be fitted.
Necessary tools
♦ Air-conditioning service station with rinsing mechanism - SAT
4006D- (these service stations for air-conditioning have an
additional function called“Rinse refrigerant circuit” and rinsing
equipment necessary for refrigerant circuits) ⇒ Catalogue of
workshop equipment and special tools
♦ Adaptors kit, set for SEAT vehicles - SAT 4009- ⇒ page 150
and ⇒ Catalogue of workshop equipment and special tools
8. Cleaning refrigerant circuit of impurities using R134a refrigerant 71

♦ Adapter set for refrigerant circuits - VAS 6338/1- ⇒ Workshop

equipment and special tools catalogue .
Preparation work
– drain the refrigerant circuit
– Remove the compressor ⇒ Heating, air-conditioning or ⇒ Air-
conditioning
For vehicles with hose clip and collector tank
– Remove the hose clip (for certain vehicles) and reconnect the
pipes⇒ Heating, air-conditioning or ⇒ Air-conditioning
– Remove the collector tank (for certain vehicles) and reconnect
the pipes (using the adapters and the filling hose belonging to
the Adapter kit, set for SEAT vehicles - SAT 4009- ),
⇒ page 150 ⇒ Heating, air-conditioning or ⇒ Air-conditioning
Note
Actually the catch reservoir should also be flushed, however due

to its large internal volume, it contains a great deal of liquid re‐
frigerant. Draining this refrigerant would cause the catch reservoir
to ice up highly, the refrigerant would evaporate very slowly and
significantly slow down evacuation.
For vehicles with expansion valve and liquid tank

– Remove the liquid tank (for certain vehicles, not necessary for
all vehicles) and reconnect the pipes (using the adapters and
the filling hose belonging to the Adapter kit, set for SEAT ve‐
hicles - SAT 4009- ), ⇒ page 150 ⇒ Heating, air-conditioning
or ⇒ air-conditioning
Note
The liquid tank may be rinsed depending on the version (the de‐
hydration cartridge within must be removed), ⇒ Heating, air-
conditioning or ⇒ Air-conditioning
– For vehicles fitted with the dehydration cartridge in the con‐

denser liquid tank (for certain vehicles) remove the dehydra‐
tion cartridge and reseal the hole in the liquid tank ⇒ Heating,
air-conditioning or ⇒ Air-conditioning
– Remove the expansion valve for certain vehicles and fit the
corresponding adapter from the Adapter kit, set for SEAT ve‐
hicles - SAT 4009- , ⇒ Heating, air-conditioning or ⇒ Air-
conditioning .
Caution
♦ When opening by drilling, take care that the sealing sur‐

face of the expansion valve is not damaged.
♦ Otherwise refrigerant will drain out.

Note
♦ If the Adapter kit, set for SEAT vehicles - SAT 4009- or adapter
set for refrigerant circuits - VAS 6338/1- does not include a
suitable adapter for the expansion valve, then the expansion
valve may be widened (the used expansion valve must often
be replaced and is no longer required).
♦ Before widening remove the regulation elements and then drill
the expansion valve using a suitable drill bit (diameter 6 mm
for example).
♦ Expansion valves exist with different versions and with differ‐
ent structures. In case of the version -A- remove for example
the parts -B-, -C- and -D-. For the component -D- the part
-E- (regulation element) must be removed. The expansion
valve must then be drilled in the area -F- using a suitable drill
bit
♦ For the version -G- remove the parts -H-, -I- and -K- then drill
the zone -L- using a suitable drill bit.
♦ Clean the widened expansion valve and remove the remains
(shavings)
♦ Now fit the parts -B-, -C- and -D- for the version-A- or the part
-H- for the version -G-
Note
For vehicles equipped with two evaporators, the second evapo‐

rator circuit must be separated from the first evaporator and they
must be rinsed separately ⇒ Heating, air-conditioning or ⇒ Air-
conditioning .
Rinsing
– Check the quantity of refrigerant in the air-conditioning service
station, this should contain a minimum of 7 kgs of R134a re‐
frigerant
Note respect to the correctness of information in this document. Copyright by SEAT S.A.
Switch on the heater connected to the refrigerant bottle 30 mi‐

nutes before carrying out the first rinsing procedure. This increa‐
ses the pressure in the refrigerant tank and accelerates the filling
of the rinsing circuit.
– Empty the used oil tank on the air-conditioning service station

– Connect the feed hose (high-pressure side) of the air-condi‐
tioning service station using the adapter to the low pressure
pipe going to compressor (this is the widest pipe).
– Connect the return hose (low pressure side or vacuum side)
of the air-conditioning service station to the output of the re‐
frigerant circuit rinsing equipment.
– Connect the input of the refrigerant circuit rinsing equipment
using the adapter to the high-pressure pipe going to the com‐
pressor (this is the thinnest pipe).

Note
♦ Components should always be rinsed in the opposite direction

of flow of refrigerant in the air-conditioning system during nor‐
mal operation. ⇒ page 76
♦ When flushing, impurities from the refrigerant circuit ingress
into the refrigerant circuit flushing attachment and the air con‐
ditioner service station, where they are retained in the built-in
filters and dryer. Depending on the nature of the impurities,
these components are to be replaced more frequently in line
with the operating instructions for the air conditioner service
station or the refrigerant circuit flushing attachment (refrigerant
circuit flushing attachment filter after approx. 5 to 10 flushing
cycles depending on the level of contamination of the refrig‐
erant circuits flushed).
♦ Depending on the nature of the dirt (oil used by refrigerant
machines and particles created by wear and abrasion of the
compressor) deposits are made on the spy hole of the refrig‐
erant circuit rinsing equipment. If necessary, clean the spy
hole after rinsing and, for monitoring purposes, rinse the re‐
frigerant circuit one more time (one rinsing cycle is sufficient
this time).
♦ The liquid refrigerant cannot be driven at the necessary speed
through the expansion valve, hose clip and dehydration bags
in certain liquid tanks; for this reason these components must
be removed from circuit and replaced with adapters if neces‐
sary ⇒ Heating, air-conditioning or ⇒ Air-conditioning
♦ Adaptors for the air-conditioning service station and bridging
of certain components in the refrigerant circuit.
– Activate the air-conditioning service station and rinse the re‐

frigerant circuit (for about 1 or 1.5 hours for each of three
cycles)
Note
♦ The rinsing must be carried out exactly as described in the

instructions manual of the air-conditioning service station.
♦ Depending on the version of the service station for air-condi‐
tioning systems, the container for used cooling machine oil has
a capacity of approx. 125 cm3 If a system with a higher portion
of cooling machine oil is to be rinsed, the container for used
cooling machine oil may be emptied after the first flushing op‐
eration.
♦ Observe refrigerant flowing back into AC service station. The
circuit can be considered to be clean only when the refrigerant
flowing back into the AC service station is transparent and fully
colourless in the observation window in the flushing device for
AC circuits.
♦ For rinsing,
Protectedall
by of the refrigerant
copyright. machine
Copying for private oil in
or commercial the circuit
purposes, in part oris
in whole, is not
washed outunless
permitted (except for by
authorised minimum residues
SEAT S.A. SEAT S.A does for example
not guarantee in the
or accept any liability with
evaporatorrespect
f that may be disregarded).
♦ For particularly intense soiling of the refrigerant circuit, rinsing

maybe required twice (with three rinsing operations each cy‐
cle).

Sequence of rinsing operations (the sequences automatic follow‐

ing a program of the air-conditioning service station).
♦ After switching on, the rinsing cycle (refrigerant circuit with
connection hoses and rinsing device for refrigerant circuits) is
first evacuated and the refrigerant circuit thereby checked for
leaks. (depending on the version of the air conditioner service
station, manual switching to next step may be necessary).
♦ The emptied refrigerant circuit is loaded from the high-pres‐
sure side of the air-conditioning service station (in the opposite
direction to normal flow of the air-conditioning through the low
pressure side of the refrigerant circuit of the vehicle) with a
specific quantity of refrigerant (for example 5 kgs) or until the
refrigerant circuit and the spy holes of the refrigerant circuit
rinsing equipment are filled to a maximum with liquid refriger‐
ant (according to the air-conditioning service station version
refrigerant may not flow for a short time).
♦ Once specified quantity of refrigerant has been loaded into the
system, depending on the version of the air-conditioning serv‐
ice station and the refrigerant circuit rinsing equipment, the
heating for the printing equipment is activated (only if the re‐
frigerant is expelled from the refrigerant circuit rinsing equip‐
ment in a gaseous form).
♦ After evacuating the refrigerant, switch off the heater for the
flushing device for AC circuits (if present). Depending on the
version the AC circuit may be evacuated again, and after
evacuation the AC service station separates the refrigeration
oil evacuated from the circuit.
♦ The refrigerant filling process, vacuuming (and evacuation) is
repeated 2 times (that is, it is completed three times in all).
♦ After the third vacuuming, the rinsing circuit is evacuated de‐
pending on the version of the air-conditioning service station.
– After completion of the flushing cycle, check the observation
window in the flushing device for AC circuits. If contamination
is present it may be necessary to clean the flushing device for
AC circuits or the AC service station in conformance with the
operating instructions and flush again for purposes of check‐
ing (one flushing operation of approx. 30 minutes is sufficient).
– Check pressure in AC circuit. Pressure should not be present
in the circuit (if necessary relieve again momentarily).
– Remove
Protected by copyright. the connections
Copying from the
for private or commercial vehicle
purposes, in partto
orthe air-condition‐
in whole, is not
ing authorised
permitted unless servicebystation
SEAT S.A.on SEATtheS.Arefrigeration circuit
does not guarantee or accept(there should
any liability with be
no positive pressure in the refrigeration circuit)
– Replace, depending on the vehicle, these components (hose

clip and collector tank, expansion tank and liquid tank or liquid
tank dehydration cartridge) ⇒ Heating, air-conditioning or ⇒
Air-conditioning and ⇒ Electronic parts catalogue
– Depending on the complaint the compressor may need to be
replaced ⇒ Heating, air-conditioning or ⇒ Air-conditioning and
⇒ Spare parts catalogue or the refrigerant machine oil must
be emptied from the removed compressor (replace compo‐
nents of the refrigerant circuit) then refill with the quantity of
refrigerant machine oil specified (special oils and oil quantities
for refrigerant machines)

Note
♦ Replacement compressors come with the specific amount of

oil for refrigerant machines. For machines with two evapora‐
tors, if necessary, add the required amount of refrigerant
machine oil to the circuit ⇒ Heating, air-conditioning or ⇒ Air-
conditioning and (special oils and oil quantities for refrigerant
machines).
♦ If the compressor is not to be replaced then the amount of
refrigerant machine oil must be corrected (empty to move the
refrigerant machine oil then put the correct quantity into the
compressor or the refrigerant circuit) (replace components of
the refrigerant circuit) and (approved refrigerant machine oils
and filling quantities).
– Reassemble the refrigeration circuit ⇒ Heating, air-condition‐

ing or ⇒ Air-conditioning .
– Empty and fill the refrigerant circuit as specified and
– Start the air-conditioning according to the specifications ⇒
Heating, air-conditioning or ⇒ Air-conditioning and
8.1.1 Connecting diagram of different rinsing

circuits
Note
♦ The arrows in the illustrations indicate the flow of refrigerant

during rinsing (during rinsing, the refrigerant flows in the op‐
posite direction to normal air-conditioning operation and for
this reason the high-pressure side of the air-conditioning serv‐
ice station is connected to the low pressure side of the refrig‐
erant circuit going to the compressor)
♦ These basic circuit diagrams show a refrigerant circuit with a
hose clip and collector tank and a refrigerant circuit with an
expansion valve, liquid tank and second evaporator (optional
additional equipment for certain vehicles)
♦ Depending on the architecture of the air-conditioning service
station, there may be retention valves between the refrigerant
circuit and the air-conditioning service station (in order to es‐
tablish the correct direction of refrigerant flow for rinsing)
Refrigerant circuit with restrictor and reservoir
Note
For vehicles with a hose clip and collector

Protected tank,Copying
by copyright. remove the hose
clip and the collector tank and reconnect

respect tothe pipes that were dis‐
the correctness of information in this document. Copyright by SEAT S.A.
connected in order to remove the hose clip. The pipe connections
from the removed collector tank are interconnected using two
adapters and the filling tube (from the Adapter kit, for SEAT ve‐
hicles - SAT 4009- )

1 - Air conditioner service sta‐

tion
❑ With electronic module
and rinsing program, for
example Air-condition‐
ing service station with
rinsing equipment - SAT
4006D- or Air-condition‐
ing service station with‐
out rinsing equipment -
SAT 4006C- with kit
SAT 4009
❑ If an AC service station
without flushing pro‐
gramme is used, this
procedure must be per‐
formed manually (evac‐
uate, flush 3 times with
at least 4 kg coolant and
then re-vacuum the
coolant).
2 - Air-conditioning service sta‐
tion refrigerant hose
❑ from the high-pressure
side of the air-condition‐
ing service station (red
in most cases) to the
connection on the vac‐
uum side of the com‐
pressor on the refriger‐
ant circuit (largest pipe)
3 - Connection adapters for the
low pressure side of the refrig‐
erant circuit
vehicle.
❑ Belong to the Adapter
kit, set for SEAT vehicles - SAT 4009-
4 - Connection for the low pressure side of the refrigerant circuit
❑ The versions are different depending on the vehicle.
❑ On the refrigerant pipe from the compressor to the collector tank
5 - Connection to reservoir
❑ On the refrigerant pipe from the compressor to the collector tank
6 - Adapter to bridge removed reservoir
❑ Belong to the Adapter kit, set for SEAT vehicles - SAT 4009- ⇒ page 82
7 - Refrigerant filling hose
❑ Belong to the Adapter kit, set for SEAT vehicles - SAT 4009-
8 - Adapter to bridge removed reservoir

9 - Connection to reservoir

10 - Evaporator
11 - Location of restrictor
❑ Hose clip removed
❑ Remove the hose clip ⇒ Heating, air-conditioning or ⇒ Air-conditioning
12 - Bolted joint on the refrigerant pipe
❑ After the hose clip is removed tighten ⇒ Heating, air-conditioning or ⇒ Air-conditioning
13 - Condenser
14 - Connection for the high pressure side of the refrigerant circuit
15 - Connection adapters for the high pressure side of the refrigerant circuit
16 - Filling tube for refrigerant circuit rinsing equipment
❑ From the connection to the high-pressure side from the compressor on the refrigerant circuit (thinnest
diameter) to the input of the refrigerant circuit rinsing equipment.
17 - Rinsing device for refrigerant circuits
❑ Structures may differ depending on the machine evolution, for example refrigerant circuit rinsing equip‐
ment - Kit SAT 4009- for machines preceding the -SAT 4006D-
❑ With filter, observation window, safety valve, refrigerant reservoir, etc. (depending on version).
❑ Depending on the air-conditioning service station and architecture and the refrigerant circuit rinsing
equipment, there may be a retention valve fitted to the output of the refrigerant circuit rinsing equipment
(used to establish the correct direction of refrigerant flow when rinsing).
18 - Air-conditioning service station refrigerant hose
❑ From the low pressure side of the air-conditioning service station (usually painted blue) to the output of
the refrigerant circuit rinsing equipment.
Refrigerant circuit with expansion valve, liquid tank and second

evaporator
Note
♦ This diagram of basic circuits shows the refrigerant circuit with

an expansion valve, liquid tank and second evaporator (addi‐
tional optional equipment for certain vehicles).
♦ On vehicles with expansion valve and receiver, the expansion
valve is removed and an adapter installed in its place. De‐
pending on the vehicle, the receiver is also removed and the
pipe connections to the receiver are connected using two
adapters and a filler hose.
♦ For vehicles fitted with only one evaporator, the components
from item “16”are not fitted or not needed.


tion
❑ With electronic module
and rinsing program, for
example Air-condition‐
ing service station with
rinsing equipment - SAT
4006D- or Air-condition‐
ing service station with‐
out rinsing equipment -
SAT 4006C- with kit
SAT 4009
❑ If an AC service station
without flushing pro‐
gramme is used, this
procedure must be per‐
formed manually (evac‐
uate, flush 3 times with
at least 4 kg coolant and
then re-vacuum the
coolant).
2 - Air-conditioning service sta‐
tion refrigerant hose
❑ from the high-pressure
side of thebyair-condition‐
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
ing service
permitted unlessstation
authorised(red
in most cases) to the

connection on the vac‐

uum side of the com‐
pressor on the refriger‐
ant circuit (largest pipe)
3 - Connection adapters for the
low pressure side of the refrig‐
erant circuit
vehicle.
❑ Belong to the Adapter
kit, set for SEAT vehicles - SAT 4009- ⇒ page 82
4 - Connection for the low pressure side of the refrigerant circuit
5 - Adapter for removed expansion valve
6 - Evaporator
7 - Connection to receiver
❑ There are no vehicles with a dehydrator cartridge in the condensation liquid tank or with a liquid tank
included in the condenser ⇒ Heating, air-conditioning or ⇒ Air-conditioning .
8 - Adapter to bridge removed receiver
❑ Not fitted to all vehicles
9 - Refrigerant filling hose
❑ For example filling tube (belonging to Adapter kit, for SEAT vehicles - SAT 4009- )

10 - Condenser
❑ If the condenser is fitted with a liquid tank including a dehydrator cartridge then this cartridge must be
removed (reseal the liquid tank close to the condenser following removal) ⇒ Heating, air-conditioning or
⇒ Air-conditioning
❑ If the liquid tank is directly fitted to the condenser, then it can be removed and the liquid tank replaced
after rinsing ⇒ Heating, air-conditioning or ⇒ Air-conditioning
11 - Connection for the high pressure side of the refrigerant circuit
12 - Connection adapters for the high pressure side of the refrigerant circuit
❑ From the connection to the high-pressure side from the compressor on the refrigerant circuit (thinnest
diameter) to the input of the refrigerant circuit rinsing equipment.
❑ These are different versions and different structures, for example refrigerant circuit rinsing equipment
equipment, there may be a retention valve fitted to the output of the refrigerant circuit rinsing equipment
(used to establish the correct direction of refrigerant flow when rinsing).
15 - Air-conditioning service station refrigerant hose
❑ From the low pressure side of the air-conditioning service station (usually painted blue) to the output of
the refrigerant circuit rinsing equipment.
16 - Adapter for sealing the output of the second evaporator
❑ Only necessary for vehicles with the optional “second evaporator”
17 - Adapter for sealing the output of the second evaporator
18 - Connection on the low pressure side of the refrigerant circuit to the second evaporator
19 - Connection on the high pressure side of the refrigerant circuit to the second evaporator
20 - Adapter for removed
Protectedexpansion valveforon
by copyright. Copying second
private evaporator
❑ The versionspermitted
are respect
different depending
unless authorised on
by SEAT S.A. the
SEAT vehicle.
21 - Second evaporator
Rinsing circuit with electric compressor

When replacing the electric compressor without mechanical error
(e.g. defective board), you have to determine the amount of re‐
frigerant oil of the electric compressor.
Amount determined, e.g. 50 cm³
A new compressor will be filled with 150 cm³ refrigerant oil.
– Pour off 90 cm³ with a new electric compressor. 10 cm³ are
extra.

Note
♦ In order for the refrigerant oil to drain from the electric com‐
pressor, that latter must be rinsed.
♦ This schematic diagram shows a refrigerant circuit with elec‐
tric compressor.

tion
Note
Rinsing the electric compressor is

carried out manually.
– In event of refrigerant
residues, extract them.
– Empty the oil tank used

by the air conditioning
service station.
Note
With some air conditioning service

stations, the oil is first separated in
the vacuum phase and then stored
in the oil tank.
– Adjust the amount of re‐
frigerant on the air con‐
ditioning service station
to 2 kg and oil quantity to
0.
– Install the flushing kit for

refrigerant circuits - VAS
6336/1- or the flushing
kit for refrigerant circuits
- VAS 6337/1- between
the air conditioning
service station and the
refrigerant return line.
– Allow the refrigerant to

drain for 10 minutes.
Then observe the vac‐
uum indicator. If the vacuum is sustained, fill the circuit with 2 kg refrigerant R134a. Then extract the
refrigerant, drain and repeat the procedure.
2 - Refrigerant line of the air conditioning service station

❑ of the vacuum side of the air-conditioning service station (normally blue) to the outlet of the rinsing
equipment for the refrigerant circuit
❑ Different versions and different design e.g. flushing kit for refrigerant circuits - VAS 6336/1- or flushing
kit for refrigerant circuits - VAS 6337/1- .
equipment, there may be a retention valve fitted to the output of the refrigerant circuit rinsing equipment.


❑ From connecting the high-pressure side of the compressor at refrigerant circuit (smaller diameter) to inlet
of the flushing kit for refrigerant circuits - VAS 6336/1- or flushing kit for refrigerant circuits - VAS 6337/1- .
5 - Adapter for the connection of the high-pressure side of the refrigerant circuit.
❑ Adapter kit for VW / Audi commercial vehicle refrigerant circuits - VAS 6338/1- Adapter no. 6338/3.
6 - High-pressure side of the electric compressor refrigerant line
– Remove the centring pin.
7 - Electric compressor
8 - Low-pressure side of the electric compressor refrigerant line
– Remove the centring pin.
9 - Adapter for the connection of the low-pressure side of the refrigerant circuit.
❑ Adapter kit for VW / Audi commercial vehicle refrigerant circuits - VAS 6338/1- Adapter no. 6338/6.
10 - Refrigerant line of the air conditioning service station
❑ From the high-pressure side of the air-conditioning service station (normally red) to the connection on
the vacuum side via the motor to the electric compressor.
8.2 Application of the flush kit with adapters

-SAT 4009-
ences inbythe
Protected workCopying
copyright. process. The
for private specificpurposes,
or commercial handling instructions
in part or in whole, is not
for each
permitted tool
unless or adapter
authorised by SEAT must
S.A. SEATbeS.Ataken into
does not account.
WARNING
It is recommended that you always have an eye-bath ready for

use in case it is needed.
If the refrigerant comes into contact with the eyes, immediately
begin thorough rinsing of the eyes for 15 minutes.
Then, apply eye drops and seek medical assistance even if the
eyes do not cause any pain.
Always inform the doctor of the type of refrigerant involved.
WARNING
Before installation, the air-conditioning station should be dis‐

connected from the electricity supply.
– Connect the red tube (high-pressure area)-1-, on the side of

the valve rod, to the station coupling-2- after removing the
plastic cap.

– Connect the other end of the red tube to the part of circuit to
be cleaned, using the kit SAT 4009 and the elements required
for the work.
The universal bridge -1- is an example of connection, with the

rubber joint -2- connected to the tube diameter.
On the low pressure side (blue tube) -1- the refrigerant flows
through the air conditioning circuit to be cleaned in liquid form and
follows the connection to the cleaning filter.
At the input -1- the refrigerant flows, by the spy hole -3- where the
level of impurities can be observed.
– This filter removes the particles from the refrigerant which is
then returned to the machine by the rapid connection -2- .
8.3 Adaptation of refrigerant loading ma‐

chines before SAT 4006D to rinse cir‐
cuits with the Kit SAT 4009
R134a refrigerant loading machines supplied by SEAT after the
model SAT 4006D, have the Kit SAT 4006D already included.
Machines prior to the model SAT 4006D supplied by SEAT re‐
quire installation of the Kit SAT 4009 for rinsing of R134a refrig‐
erant circuits.
♦ Additional information ⇒ Operating instructions of the device

itself.
♦ Additional information ⇒ Assembly instructions of the manu‐
facturer rinsing set
♦ Catalogue of tools and utilities.

WARNING
Before installation, the air-conditioning station should be dis‐

connected from the electricity supply.
– Ensure that the content of the cleaning kit is complete.

Special tools and workshop equipment required
♦ Case with support or adapter SAT 4009D ⇒ page 82
♦ Connection pipes
♦ Connection kit with ball valve.
♦ Filter with attachment bracket.
Installation:
– Remove the front and top plate from the refrigerant station
134a.
– Insert the socket -1- into the circuit so that the -T- is as shown,
after the red tap-2- on the refrigerant cylinder. The refrigerant
is liquid in this area.
– Tighten the remaining connections and extract them from the
two holes-1- and -2-
– Fit the handle -B- to the valve with the correct screw.
– Carefully tighten the Schraeder valve-A- with the correspond‐
ing spanner supplied.
Fit the bracket and the filter:
– Carefully tighten the filter attachment bracket to the frame us‐

ing the four bolts.
– Tighten the filter attachment bracket with the two nuts and
bolts.
– Fit the filter to the bracket -1- previously fitted to the machine.

8.4 Adapters to create rinsing circuits -VAS

6338/1-
♦ The following table shows the different adapters necessary for
the connection of the air conditioning service station to the re‐
frigerant circuit for rinsing and to bridge the fluid tank or the
collector tank and the expansion valve (specific to certain ve‐
hicles).
♦ With a filler hose with connections 5/8 -18 UNF (short version
e.g. filler hose - VAS 6338/31- ) join the two adapters mounted
on the collector tank or the dismounted fluid tank (included in
the adapter kit for SEAT passenger vehicles - VAS 6338/1- ).
♦ If a refrigerant circuit is not going to be mounted immediately
after flushing, leave the adapters in the connectors and plug
the connectors in the adapters using the hoods - VAS 6338/30-
(from the adapter case SEAT passenger car kit - VAS
6338/1- ).
♦ Depending on the version of air conditioning compressor and
the manufacturing period, different connection and sealing
techniques are used in the refrigerant circuit⇒ Heating, air
conditioning .
Block or screw connection

Screw connections -A-
Block connections -B-

Block connections with different types of seal

Block connections with radial seal -A- (with plastic or metal guide
-B-)
– Block connections with axial seal -C-

Ibiza 1993; Cordoba 1994; Inca 1995; Arosa 1996

Vehicle Adapters re‐ Adapters required for Others
quired for the re‐ the refrigerant hoses to
frigerant hoses the fluid tank
to the air condi‐
tioning compres‐
sor
Ibiza Adapter - VAS – Dismount the tank – Re‐
1993 ► 6338/14- and bridge the re‐ place
Cordo‐ frigerant hoses. the ex‐
ba 1994 ♦ Adapter - VAS pan‐
► 6338/28- sion
valve
♦ Adapter - VAS with
6338/29- the
– After flushing, fit a adapt‐
new fluid tank. er -
VAS
6338/1
9- (or
an ex‐
pan‐
sion
valve by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless authorised
respect to en‐
the correctness of information in this document. Copyright by SEAT S.A.
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Inca ♦ Adapter - – Dismount the tank – Re‐
1995 ► VAS 6338/4- and bridge the re‐ place
Arosa Low-pres‐ frigerant hoses. the ex‐
1996 ► sure end ♦ Adapter - VAS pan‐
6338/28- sion
♦ Adapter - valve
VAS 6338/2- ♦ Adapter - VAS with
or adapter - 6338/29- the
VAS adapt‐
6338/14- high – After flushing, fit a er -
pressure end new fluid tank.
VAS
6338/1
9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.
Ibiza ♦ Adapter - – Remove the dehy‐ – Re‐
2002 ► VAS drator cartridge and place
Cordo‐ 6338/12- plug the fluid tank. the ex‐
ba 2003 Low-pres‐ pan‐
► sure end – After flushing, fit a sion
new dehydrator valve
♦ Adapter - cartridge. with
VAS 6338/2- the
High pres‐ adapt‐in part or in whole, is not
sure end
Protected by copyright. Copying for private or commercial purposes,
permitted er - or accept any liability with
unless authorised by SEAT S.A. SEAT S.A does not guarantee
VAS
6338/3
4- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.

Toledo 1995; León 1996; Arosa 2000; Inca 2000; Arosa 1997;
Cordoba Vario 1997
to the air condi‐
tioning compres‐
sor
Toledo Adapter - VAS – Dismount the tank – Re‐
1995 ► 6338/14- and bridge the re‐ place
Leon frigerant hoses. the ex‐
1996 ► ♦ Adapter - VAS pan‐
6338/28- sion
valve
♦ Adapter - VAS with the
6338/29- adapter
– After flushing, fit a - VAS
new fluid tank. 6338/1
9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing,
Protected by copyright. Copying for private or commercial purposes, in part or infit a is not
whole,
new any
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept ex‐liability with
respect to the correctness of information in this document. Copyrightpan‐
by SEAT S.A.
sion
valve.
Arosa ♦ Adapter - – Dismount the tank – Re‐
Cordo‐ Low-pres‐ frigerant hoses. the ex‐
ba Vario sure end ♦ Adapter - VAS pan‐
1997 ► 6338/28- sion
♦ Adapter - valve
VAS 6338/2- ♦ Adapter - VAS with the
or adapter - 6338/29- adapter
VAS - VAS
6338/14- high – After flushing, fit a
pressure end 9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Arosa ♦ Adapter - – Dismount the tank – Re‐
2000 ► VAS and bridge the re‐ place
Inca 6338/12- frigerant hoses. the ex‐
2000 ► Low-pres‐ ♦ Adapter - VAS pan‐
sure end 6338/28- sion
valve
♦ Adapter - ♦ Adapter - VAS with the
VAS 6338/2- 6338/29- adapter
High pres‐ - VAS
sure end – After flushing, fit a
9- (or
an ex‐
pan‐
sion
valve
en‐Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
larged
with a of information in this document. Copyright by SEAT S.A.
respect to the correctness
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.

Toledo 1999; Leon 1999; Altea 2004; Toledo 2005; Leon 2006;
Toledo 2013
to the air condi‐
tioning compres‐
sor
Toledo ♦ Adapter - – Dismount the tank – Re‐
Leon Low-pres‐ frigerant hoses. the ex‐
1999 ► sure end pan‐
– 2 adapters - VAS sion
♦ Adapter - 6338/2- and join valve
VAS 6338/2- with hose - VAS with the
High pres‐ 6338/31- . adapter
sure end - VAS
– After flushing, fit a 6338/1
new fluid tank. 9- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill
e.g. 6N
0 820
679 C)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.
Altea ♦ Adapter - Receiver – Re‐
2004 ► VAS – Flush sweeping is place
Altea XL 6338/12- possible. the ex‐
2007 ► Low-pres‐ pan‐
Altea sure end – After flushing, fit a sion
Free‐ new fluid tank. valve
track ► ♦ Adapter - permitted unless authorised by SEAT S.A. SEAT S.A with
doesthe
VAS 6338/3- respect to the correctness of information inadapter not guarantee or accept any liability with
this document. Copyright by SEAT S.A.
High pres‐ - VAS
sure end 6338/1
8- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Toledo ♦ Adapter - Receiver – Re‐
6338/12- possible. the ex‐
Low-pres‐ pan‐
sure end – After flushing, fit a sion
new fluid tank. valve
♦ Adapter - with the
VAS 6338/3- adapter
High pres‐ - VAS
sure end 6338/1
8- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.
Leon ♦ Adapter - Receiver – Re‐
6338/12- possible. the ex‐
Low-pres‐ pan‐
sure end – After flushing, fit a sion
new fluid tank. valve
♦ Adapter - with the
VAS 6338/3- adapter
High pres‐ - VAS
sure end 6338/1
8- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.


to the air condi‐
tioning compres‐
sor
Toledo ♦ Adapter - Reservoir – Restric‐
2013 ► VAS – Screw connection tor re‐
6338/12- at inlet Adapter - moved,
(low-pres‐ VAS 6338/9- pipe
sure side) con‐
– Block connection nec‐
♦ Adapter - with axial seal at tions
VAS 6338/2- outlet Adapter - re-as‐
(high-pres‐ VAS 6338/10- sem‐
sure side) bled
– Remove the dehy‐
drator cartridge and – After
plug the fluid tank. flush‐
ing, fit a
– After flushing, fit a new ex‐
new dehydrator pan‐
cartridge. sion
valve.
Alhambra 1996;
Note
On vehicles with additional evaporator (Alhambra) it is necessary

to flush the front and rear refrigerant circuits separately. The front
refrigerant circuit must be sealed with adapter - V.A.G 1785/1- ,
the adapter - 1785/3- and caps -VAS 6338/30-.


frigerant hoses to the fluid tank and addi‐
the air condition‐ tional evaporator
ing compressor
Alham‐ ♦ Adapter - VAS – As no adapter is – Re‐
bra 6338/7- Low- available for the place
1996 pressure end container, it will re‐ the ex‐
up to main installed and pan‐
May ♦ Adapter - VAS will be rinsed. The sion
2000 ► 6338/2- High flush time will in‐ valve
pressure end crease by approxi‐ (for
♦ or adapter - mately 30 minutes front
VAS 6338/14- due to the addition‐ and
al volume. rear
– If the refrigerant is circuit)
still not clean after with
the third flush, con‐ the
tinue flushing until adapt‐
the refrigerant ap‐ er -
pears clean on VAS
passing the obser‐ 6338/3
vation window. 5- (or
– After flushing, fit a an ex‐
new fluid (dehydra‐ pan‐
tor) tank. sion
♦ Adapter - V.A.G valve
1785/7- low pres‐ en‐
sure hose for addi‐ larged
tional evaporator with a
drill)
♦ Adapter - V.A.G
1785/5- high pres‐ – After
sure hose for addi‐ flush‐
tional evaporator ing, fit
♦ Adapter - V.A.G permittedaunlessnew
1785/3- with hood - expan‐ authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
VAS 6338/30- to sion
plug front refriger‐ valve.
ant circuit.
♦ Adapter - V.A.G
1785/1- with hood -
VAS 6338/30- to
plug front refriger‐
ant circuit.


ing compressor
Alham‐ ♦ Adapter - VAS – Remove the dehy‐ – Re‐
bra 6338/7- Low- drator cartridge and place
1996 pressure end plug the fluid tank. the ex‐
from – After flushing, fit a pan‐
June ♦ Adapter - VAS new dehydrator sion
2000 ► 6338/2- High cartridge. valve
pressure end ♦ Adapter - V.A.G (for
1785/7- low pres‐ front
sure hose for addi‐ and
tional evaporator rear
circuit)
♦ Adapter - V.A.G with
1785/5- high pres‐ the
sure hose for addi‐ adapt‐
tional evaporator er -
♦ Adapter - V.A.G VAS
1785/3- with hood - 6338/3
VAS 6338/30- to 5- (or
plug front refriger‐ an ex‐
ant circuit. pan‐
sion
1785/1- with hood - en‐
VAS 6338/30- to larged
plug front refriger‐ with a
ant circuit. drill)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.


ing compressor
2010 ► pressure end plug the fluid tank. the ex‐
– After flushing, fit a pan‐
♦ Adapter - VAS new dehydrator sion
6338/2- High cartridge. valve
pressure end ♦ Adapter - V.A.G (for
sure hose for addi‐ and
tional evaporator rear
circuit)
♦ Adapter - V.A.G with
1785/5- high pres‐ the
sure hose for addi‐ adapt‐
tional evaporator er - purposes, in part or in whole, is not
Protected by copyright. Copying for private or commercial
permitted unless authorised by SEAT S.A. SEAT S.A VAS
♦ Adapter - V.A.G does not guarantee or accept any liability with
1785/3- with hood - 6338/3

VAS 6338/30- to 5- (or

plug front refriger‐ an ex‐
ant circuit. pan‐
sion
1785/1- with hood - en‐
VAS 6338/30- to larged
plug front refriger‐ with a
ant circuit. drill)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.


ing compressor
2011 ► pressure end plug the fluid tank. the ex‐
– After flushing, fit a pan‐
♦ Adapter - VAS new dehydrator sion
6338/3- High cartridge. valve
pressure end ♦ Adapter - VAS (for
sure hose for addi‐ circuit)
tional evaporator with
the
♦ Adapter - VAS adapt‐
6338/4- high pres‐ er -
sure hose for addi‐ VAS
tional evaporator 6338/1
♦ The refrigerant ho‐ 8- (or
ses that are con‐ an ex‐
nected to the 2nd pan‐
compressor are re‐ sion
leased, until the valve
respect to the correctness of informationadapter can Copyright en‐

be at‐ by SEAT S.A.
larged
in this document.
tached without
bending the refrig‐ with a
erant hoses. drill)
♦ Sealing adapter - – Re‐

VAS 6338/5- for the place
front refrigeration the ex‐
circuit. pan‐
sion
♦ Sealing adapter - valve
VAS 6338/11- for (for
the front refrigera‐ rear
tion circuit. circuit)
with
the
adapt‐
er -
VAS
6338/3
3- (or
an ex‐
pan‐
sion
valve
en‐
larged
with a
drill)
– After
flush‐
ing, fit
a new
expan‐
sion
valve.

Ibiza 2008, Ibiza ST 2010:

Vehicle Adapters re‐ Adapters required for Other re‐
quired for com‐ reservoir/receiver con‐ quire‐
pressor connec‐ nections ments
tions
Ibiza – Compressor Reservoir – Restric‐
2008► manufacturer – Screw connection tor re‐
Ibiza ST “Denso” at inlet Adapter - moved,
2010 ► ♦ Adapter - VAS 6338/9- pipe
VAS con‐
6338/12- – Block connection nec‐
(low-pres‐ with axial seal at tions
sure side) outlet Adapter - re-as‐
VAS 6338/10- sem‐
♦ Adapter - bled
VAS 6338/2- – Remove the dehy‐
(high-pres‐ drator cartridge and – After
sure side) plug the fluid tank. flush‐
ing, fit a
– After flushing, fit a new ex‐
new dehydrator pan‐
cartridge. sion
valve.

Exeo 2009, Exeo ST 2009:

Vehicle Adapters re‐ Adapters required for Other re‐
quired for com‐ reservoir connections quire‐
pressor connec‐ ments
tions
Exeo – Compressor Reservoir with differ‐ – Restric‐
2009 ► manufacturer ent connection ver‐ tor re‐
Exeo ST “Denso” (bloc sions moved,
2009 ► k connections ♦ Version “1” pipe
with radial con‐
and axial – Block connections nec‐
seal) with axial seal at in‐ tions
♦ Adapter - let and outlet re-as‐
VAS ♦ Adapter - VAS sem‐
6338/12- 6338/10- (required bled
(low-pres‐ twice)
sure side) – After
flush‐
♦ Adapter - ing, fit a
VAS 6338/2- new ex‐
(high-pres‐ pan‐
sure side) sion
valve.
– Compressor ♦ Version “2”
manufacturer
“Denso” (bloc – Block connections
k connections with radial seal at
with radial inlet and outlet
and axial ♦ Adapter - VAS
seal)⇒ Air- 6338/8- (required
conditioning; twice)
Rep. gr. 87
♦ Adapter -
VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

Mii 2012
to the air condi‐
tioning compres‐
sor
Mii 2012 ♦ Adapter - Receiver – Re‐
► VAS – Flush sweeping is place
6338/12- possible. expan‐
Low-pres‐ sion
sure end – After flushing, fit a valve
new fluid tank. with
♦ Adapter - adapter
VAS 6338/3- - VAS
High pres‐ 6338/3
sure end 6- or
adapter
Protected by copyright. Copying-for
VASprivate or commercial purposes, in part or in whole, is not
6338/3
respect to the correctness 4- (or
of information in this document. Copyright by SEAT S.A.
drilled-
out ex‐
pan‐
sion
valve
e.g. 1S
0 820
078)
– After
flush‐
ing, fit a
new ex‐
pan‐
sion
valve.
Leon 2013:
to the air condi‐
tioning compres‐
sor
Leon ♦ Compressor Fluid tanks (different – Expan‐
2013 ► manufacturer versions) sion
“Denso” or – No adapter neces‐ valve
“Sanden” sary, the fluid tank re‐
is mounted (or inte‐ moved
♦ grated in the con‐ and
denser). adapter
- VAS
– Depending on the 6338/3
version of the con‐ 8- (or
denser, the dehy‐ drilled-
drator cartridge of out ex‐
the fluid tank in the pan‐
condenser may al‐ sion
so have to be re‐ valve
moved before e.g.
flushing and then 5Q0
opened and closed 820
again (see note) 679 X
fitted)

9 Complaints
9.1 Possible complaints regarding the re‐

frigerant circuit
Note
♦ The air-conditioner operates correctly if air is blown out

through the vents on the instrument panel at a temperature of
7 0C or lower.
♦ Climatronic setting “LO”.
♦ Air-conditioner setting “AC”; “max.”; “cold”.
9.1.1 Check prerequisites

• The self-diagnosis does not detect any fault with the vehicle
information, measurement and diagnosis system - VAS
5051A- through the “Guided fault location”, in the measure‐
ment value block no deactivation condition is observed for the
air-conditioner compressor (only for vehicles with “Air-condi‐
tioning” self-diagnosis). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Rep. gr. 87 respect to the correctness of information in this document. Copyright by SEAT S.A.
9.1.2 Possible complaints
Note
♦ For all complaints marked with a * “Check pressures”.

♦ For vehicles fitted with two evaporators, when the complaint
concerns one evaporator check the pressures in the refriger‐
ant circuit.
♦ Refrigeration has completely failed. *

♦ Refrigeration power insufficient at any vehicle speed and/or all
engine speeds *
♦ Refrigeration non-existent or insufficient after several kilome‐
tres. **
♦ No refrigeration or insufficient refrigeration in one or both
evaporators (for vehicles with two air-conditioning units).** * *
♦ The air-conditioner compressor, the air-conditioner electro‐
magnetic coupling - N25- , or the air-conditioner compressor
regulating valve - N280- is deactivated by the air-conditioner
low-pressure switch - F73- , the electromagnetic coupling
high-pressure switch - F118- , the air-conditioner pressure
switch - F129- , or by the air-conditioner control unit and dis‐
play, Climatronic - E87- or the Climatronic control unit - J255-
due to a too high or too low pressure.*
♦ Non-existent fresh air intake or considerable reduction after
several kilometres (evaporator frozen). *
The following complaints may also occur:
The air conditioner compressor is noisy
– Retighten the bolts securing the compressor and the com‐
pressor support with a torque wrench.
9. Complaints 101
– Check the tension of the refrigerant pipes, they should not be

in contact with any other components and must be free from
tensions or twisting (if necessary, correct alignment).
Noises are heard immediately after turning on the air-conditioner
and/or when turning or braking the vehicle (refrigerant knocking):
– Empty the refrigerant circuit, vacuum it and recharge (exces‐
sive refrigerant in circuit).
Note
♦ Excessive refrigerant oil in the circuit may also give rise to this
complaint (e.g. the amount of refrigerant oil was not compen‐
sated for after replacing the compressor). With such com‐
plaints, rinse the refrigerant circuit using the refrigerant R134a.
⇒ page 71
♦ The refrigerant must be extracted from the air conditioner
compressor (replace the O-ring) via the oil drain plug. To make
this operating procedure easier, the pulley of the Poly-V-belt
or pulley of the electromagnetic coupling disc in the air condi‐
tioner compressor must be turned by hand. Then the complete
quantity of refrigerant oil must be filled into the refrigerant cir‐
cuit according to the ⇒ Repair Manual of the respective vehicle
(50 grams direct in the air conditioning compressor).
An air-conditioner which otherwise operates correctly, spatters

water through the vents (on the instrument panel or in the foot‐
well).
– Check that the condensation drainage tube is correctly laid,
and that it is not squashed or kinked.
– Check the water condensation output valve, it should not be
blocked by wax or underbody protection and must close per‐
fectly.
– Check the cover of the plenum chamber, and ensure that it is
not damaged and is mounted correctly (no water must enter
the evaporator).
– Check the drains of the plenum chamber; ensure that these
are not blocked (for example by dead leaves).
9.2 Odour in the air conditioner
9.2.1 Can the odour be determined on the

evaporator or the heat exchanger?
♦ The smell of fish
– Caused by leakage in the engine cooling system or air condi‐
tioner heat exchanger
Note
If the fish odour depends oncopyright.

Protected by the setCopying
temperature: with “cold”
for private or commercial lessin part or in whole, is not
purposes,
or when “warm” more intensive,
permitted check
unless authorised theS.A.
by SEAT airSEAT
conditioner heat or accept any liability with
S.A does not guarantee
exchanger for leaks. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Smell of burnt coupling

♦ Odour given off by floor coverings, retrofitted loose seat cov‐
ers, etc.
♦ Mould or mustiness odour

– Due to the collection or deposits of leaves or other residues in

the plenum chamber.
Note
Clean the plenum camber.
– Use water so that it cannot flow out of plenum chamber.
Note
Check the drain of the plenum chamber.
♦ Odour in the air conditioner
Note
Odours occurring in the air conditioner unit are usually perceptible

in both fresh air and recirculated-air mode.
– Caused by too much water condensation in the air condition‐

ing unit
Note
Check the drain of the condense water, for this purpose ⇒ Rep.
gr. 87 view the repair manual of the respective vehicle.
– As a result of high soiling in the dust and pollen filter or its

operating life has been exceeded.
Note
Check the dust and pollen filter, for this purpose ⇒ Rep. gr. 80
view the repair manual of the respective vehicle.
– Caused by deposits on evaporator fins.
Note
The evaporator with the ultrasonic air conditioner cleaner unit -

VAS 6189A- ⇒ page 104 of with the pressure cup spray gun -
V.A.G 1538- and the respective blast tube ⇒ page 104 .
9. Complaints 103
9.2.2 Ultrasonic air conditioner cleaning unit -

VAS 6189B-
– The ultrasonic air conditioner cleaning unit - VAS 6189B- is
placed in the footwell on the passenger side and disperses the
agent, Aero-Clean. Aero-Clean neutralises germs and bacte‐
ria in the air conditioning unit.
The operating instructions are supplied with the device, functional
improvement by replacement -B-
the designation.
Current devices ⇒ ServiceNet; Workshop Equipment; Catalogue;
Test equipment; Air conditioning/heating; Service devices
9.2.3 Spray the evaporator with the pressure

cup spray gun - V.A.G 1538- and the
blast tube
The steamer is directly injected with Contra Sept. along with the
steel pipe (around 10 bar). Contra Sept. neutralises germs and
bacteria directly in the steamer.
In order to access the evaporator easier, preliminary work and
different steel tubes are required, e.g. V.A.G 1538/5; V.A.G
1538/6 or V.A.G 1538/7.
The cleaning fluid for the evaporator D 600by 100
Protected A2Copying
copyright. has aforspecial
private or commercial purposes, in part or in whole, is not
operating instruction included for the vehicle VAS 6189/1.
Current devices and blast tubes ⇒ ServiceNet Function “Search”

10 Connect the air conditioning service

station
10.1 To vehicles equipped with a connection

on both the high and low pressure sides
of the refrigerant circuit
10.1.1 Service stations connection to carry out

measurements and inspections
– Attach the quick coupling adaptors to the charging hoses of
the service station (wheels or manual shut-off valves not
open).
– Connect the service station and vacuum the charging hoses
(only necessary if there is air inside the charging hoses).
– Disconnect the service station.
– Unscrew the caps from the service connections (with valve).
– Connect the service station to the service connections of the
refrigerant circuit on the vehicle with the quick coupling adap‐
tors.
– Turn the wheel on the quick coupling adaptors until the refrig‐
erant circuit connection valves are completely open (check the
manometer; do not over-pressurize the valves).
– Carry out the planned inspections and measurements.
10. Connect the air conditioning service station 105

11 Checking the pressures in vehicles
11.1 Check the pressure in the refrigerant cir‐

cuit (using the air conditioning service
station)
Note
♦ Checking the cooling performance. The air-conditioner oper‐

ates correctly if air is blown out through the vents on the
instrument panel at a temperature of 7 0C or lower.
♦ Climatronic setting “LO”.
♦ Air-conditioner setting “AC”; “max.”; “cold”.
♦ Valve connections and service connections to carry out meas‐
urements and inspections.

• Radiator and condenser must be clean (clean them if neces‐
sary).
• The thermal protection insulation of the expansion valve is in
order and correctly mounted. See the repair manual of the ve‐
hicle in question ⇒ Rep. gr. 87 .
• The Poly-V belt is in good condition and properly tensed. The
compressor and alternator belts are in good condition and
properly tensed. See the repair manual of the respective ve‐
hicle ⇒ Rep. gr. 87 .
• All air ducts, covers and seals are OK and properly installed.
• Fault-finding on the electrical systems and vacuum system
has found no faults. See the repair manualProtected
of thebyrespective
vehicle ⇒ Rep. gr. 87 .
copyright. Copying for private or commercial purposes, in part or in whole, is not
• The air-conditioner self-diagnosis does not detect any fault
with the vehicle information, measurement and diagnosis sys‐
tem - VAS 5051A- through the “Guided fault location”, in the
measurement value block no deactivation condition is ob‐
served for the air-conditioner compressor (only for vehicles
with “Air-conditioning” self-diagnosis).
• Air flow through dust and pollen filter not impeded by dirt See
the repair manual of the respective vehicle ⇒ Rep. gr. 87 .
• The heater and the air conditioner do not obtain additional air
at full speed from the fresh air blower. The evaporator and
heating do not draw any uncooled air at highest fresh air blow‐
er speed. See the repair manual of the respective vehicle ⇒
Rep. gr. 87 .
• The air duct flaps of the heater and the air conditioner reach
their end position. See the repair manual of the respective ve‐
hicle ⇒ Rep. gr. 87 .
• The fresh air intake ducts below the bonnet and in the pas‐
senger compartment, as well as the corresponding drain
valves, are in good condition. See the repair manual of the
vehicle in question ⇒ Rep. gr. 87 .
• Engine at operating temperature
• Vehicle not exposed to direct sunlight.

• Ambient temperature above 15°C

• All dash panel air vents are open.
• With engine running and air conditioning set for maximum
cooling output:
⇒ Rep. gr. 87
Set maximum cooling output.
Setting on the air-conditioner control unit and display, Climatronic
- E87- :
– Set the operating mode “Auto” (air-conditioner compressor
activated).
– Select the temperature setting “LO” for the driver and front
passenger side.
Setting on the heater controls:
– A/C button and Rec (air recirculation) button depressed.
– The temperature selector rotating control is at the end position
“cold”.
– The fresh air blower rotating control is set to position “4”.
• The refrigerant fan/s - V7- are running (at least speed 1).*
Note
In some versions, the fan only starts running after the pressure in
the refrigerant circuit has surpassed a preset value.
• The fresh air blower - V2- is running at maximum speed.

• The air recirculation/fresh air flap set to position “Air recircu‐
lation”/ closes the air retention flap and opens the air recircu‐
lation flap (within 1 minute after starting the vehicle).*
• The refrigerant shut-off valve is closed.*
• The valves of the valve unit and pump are closed (and the
refrigerant recirculation pump is not running).*
11.1.2 Checking pressures

– Connect AC service station. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Read off pressure on pressure gauges; two
respect to the results
correctness are possi‐
ble.
♦
Ambient temperature (in °C) Pressure in refrigerant circuit in
bar
+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
11. Checking the pressures in vehicles 107

Note
♦ The temperature of the refrigerant circuit components must be

equal to the ambient temperature.
♦ If any of the refrigerant circuit components are hotter or colder,
the pressure is different to the values in the table.
♦ Absolute pressure means that 0 bar corresponds to an abso‐
lute vacuum. The normal ambient pressure (positive pressure)
corresponds to 1 bar absolute pressure. In general, most man‐
ometer scales represent atmospheric pressure as 0 bar,
meaning an absolute pressure of 1 bar (this can be recognized
if there is a -1 on the scale).
♦ In vehicles equipped with a high-pressure sender - G65- in
which the pressure measured is displayed in the measure‐
ment value block, the measured pressure must coincide with
the values in the table.
⇒ Rep. gr. 87
The pressure in the refrigerant circuit is lower than indicated in
the table.
Insufficient refrigerant in circuit.
– Determine refrigerant circuit leaks .
– Check the high-pressure safety valve.
If the high-pressure safety valve has blown off:
– Check activation of radiator fan.
– Check for constricted refrigerant pipe and hose cross-sections
caused by inadequate bending radii.
– Check for any external damage on the refrigerant piping and
hoses.
– Clean the refrigerant circuit (rinse with refrigerant R134a or
sweep with compressed air or nitrogen).
The pressure in the refrigerant circuit is equal to or greater than
that in the table.
– Start the engine.
– Adjust permitted
air conditioning forbymaximum
unless authorised refrigeration
SEAT S.A. SEAT capacity.
Note
If the low-pressure switch was disassembled when connecting

the air-conditioning service station, bridge the electrical connec‐
tions of the corresponding plug to measure the pressure.
• The air-conditioner compressor is driven with the engine

through the air-conditioner electromagnetic coupling - N25- .
• The air-conditioner regulating valve - N280- is activated by the
Climatronic control unit - J255- .
⇒ Rep. gr. 87
If the compressor is not driven while the engine is running, or if
the regulating valve is not activated:
– Locate and eliminate the cause, e.g. by consulting the air-
conditioner fault memory.

– Observe the test prerequisites.

– Check the power supply of the air-conditioner electromagnetic
coupling - N25- . If correct, repair the electromagnetic cou‐
pling.
– Check the activation of the air-conditioner compressor regu‐
lating valve - N280- .
⇒ Rep. gr. 87 .
11.1.3 Continuation of test:

♦ Checking pressures on vehicles with restrictor and reservoir
(with internally regulated compressor) ⇒ page 109
♦ Checking pressures on vehicles with expansion valve and re‐
ceiver (with internally regulated compressor) ⇒ page 113 .
♦ Checking pressures on vehicles with restrictor, reservoir and
air conditioner compressor regulating valve - N280- (with ex‐
ternally regulated compressor) ⇒ page 118 .
♦ Checking pressures on vehicles with expansion valve, liquid
collection container and air conditioner compressor regulating
valve - N280- (with externally regulated compressor)
⇒ page 123 .
11.2 Checking pressures with restrictor and

reservoir (with internally regulated com‐
pressor)
Note
♦ Connect AC service station. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Observe test requirements ⇒ page 106 .
– Let the engine run at a speed of 2000 rpm.

– Observe pressure reading (e.g. pressure gauge) of air condi‐
tioner service station.
Note
♦ The switching pressures of the refrigerant circuit switches are

specific to the vehicle.
♦ The valve connection for the low-pressure switch or the evap‐
orator must only be used on vehicles with no service connec‐
tion on the low-pressure side and with a non-accessible
connection on the compressor or collecting tank (measure‐
ment precision). Applies only for certain vehicles⇒ heater and
air conditioning; Rep. gr. 87 or ⇒ air conditioning; Rep. gr. .
11.2.1 Specifications:
High-pressure side:
Increasing by a maximum of 20 bar from the initial pressure (when
connecting the manometers).

Low-pressure side:
Decreasing to the value of the diagram from the initial pressure
(when connecting the manometers).
A - High pressure (measured at the service connection) in bar
positive pressure.
B - Low pressure (measured at the valve connection of the com‐
pressor or the collecting tank) in bar.
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.
Possible deviation from specification Possible cause of fault How to rectify fault
• High pressure remains constant Insufficient refrigerant in circuit. – Find leak with leak de‐
or increases only slightly (above tector and eliminate.
the pressure measured when the
engine is stopped), – Recharge refrigerant
circuit.
• The low pressure falls to the dia‐unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
gram value or lower, respect to the correctness of information in this document. Copyright by SEAT S.A.
• and the required cooling output is

not attained.
• High pressure is normal,

• Low pressure matches the dia‐
gram value,
not attained.

• Low pressure too low (see graph)
not attained.
Note
Clean the refrigerant circuit (rinse with refrigerant R134a or sweep

with compressed air or nitrogen).

Possible deviation from specification Possible cause of fault Measures to be taken

• High pressure increases only Compressor defective – Clean refrigerant cir‐
slightly above the pressure cuit (flush with refrig‐
measured when the engine is erant R134a or blow
stopped, out with compressed
air and nitrogen).
• Low pressure falls only slightly,
• and the required cooling output is – Renew compressor.
not attained.
Possible deviation from specification Possible cause of fault How to rectify fault
• High pressure rises above spec‐ Restriction or obstruction in the refrigerant – Feel AC circuit with
ification, circuit. hand to determine
temperature differ‐
• Low pressure falls quickly to the ences.
diagram value or lower,
• and the required cooling output is • If temperature differ‐
not attained. ences are percepti‐
ble on a component:
– Renew hose or pipe
if kinked or constric‐
ted.
– In the event of clog‐

ging of the refriger‐
ant circuit, clean
(flush with refrigerant
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not R134a or blow out
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with with compressed air
and nitrogen ).
• If no fault is found.
– Clean refrigerant cir‐
cuit (flush with refrig‐
erant R134a or blow
out with compressed
air and nitrogen).
• High pressure and low pressure Moisture in the refrigerant circuit. – Blow through refrig‐
normal. After a while, erant circuit with
compressed air and
• High pressure rises above spec‐ nitrogen.
ification,
• The low pressure falls to the dia‐ – Replace the collect‐
gram value or lower, ing tank.
• and the required cooling output is – Repeat the check. If

not attained. operation is not cor‐
rect:
– Flush the refrigerant

circuit (clean)
– Recharge refrigerant
circuit.
– Repeat check.
• High and low pressure normal at The air conditioner compressor is defective. – Flush the refrigerant
first circuit (clean)
• After lengthy operating period, – Renew the air condi‐
low pressure drops excessively tioner compressor.
(evaporator ices up)

Note
♦ In the case of the fault “High pressure normal, low pressure

too low”, the following must be taken into account:
♦ If this fault occurs, the evaporator may be frozen, or the air-
conditioner low-pressure switch - F73- may disconnect the
compressor in spite of the fact there is a correct amount of
refrigerant in the circuit.

• High pressure normal or too high. Too much refrigerant in circuit – Extract some refrig‐
erant from the refrig‐
• Low pressure too low (see graph) erant circuit.
• the air-conditioner compressor is
noisy (especially after connec‐ • The quantity of re‐
tion), frigerant extracted is
about equal to the
• the requested cooling power is prescribed charge
not achieved. quantity.
permitted unless authorised by SEAT S.A. SEAT S.A does – not
Renew
guaranteethe air condi‐
tionerCopyright
respect to the correctness of information in this document. compressor.
by SEAT S.A.
• The quantity of re‐

frigerant extracted is
significantly greater
than the prescribed
charge quantity.
– Recharge refrigerant
circuit.
– Repeat check.

• High and low pressure normal Too much refrigerant oil in the circuit. – Drain refrigerant cir‐
cuit.
not attained. – Clean refrigerant
circuit (flush with re‐
frigerant R134a or
blow out with com‐
pressed air and ni‐
trogen).
• High and low pressure normal
• Compressor noise (particularly
after switch-on)
• Required cooling output is at‐
tained

Note
♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor
was renewed.
♦ If the air conditioner compressor is not replaced, the refriger‐
ant must be extracted from the compressor (replace the O-
ring) via the oil drain plug. Fill the 50 grams in the ⇒ Repair
Manual of the respective vehicle indicated complete refriger‐
ant oil quantity in the air conditioner compressor and the rest
in the refrigerant circuit.
11.3 Checking the pressures with expansion

valve and liquid tank (with internally con‐
trolled compressor)
Note
♦ Connect AC service station.


Note
♦ The switching pressures and version of the refrigerant circuit

switches are specific to the vehicle.
♦ The pressurespermitted
must be measured
authorised by on the
S.A.service connections.
unless SEAT SEAT S.A does not guarantee or accept any liability with
The position of these connections
respect are
to the correctness differentin this
of information according to
document. Copyright by SEAT S.A.
the vehicle ⇒ Heating, Air Conditioning; Rep. gr. 87 .
High-pressure side:
Increasing by a maximum of 20 bars from the initial pressure
Low-pressure side:
A - High pressure in bar positive pressure.
B - Low pressure in bar positive pressure.

Possible deviation from Possible cause of fault Measures to be taken

specification
• High pressure remains Too little refrigerant in circuit or expan‐ – Extract some refrigerant from the
constant or increases sion valve defective. refrigerant circuit.
only slightly (above the
pressure measured • If quantity of refrigerant extracted
when the engine is stop‐ roughly corresponds to actual ca‐
ped), pacity:
• Low pressure falls – Renew the expansion valve.
quickly to the diagram
value or lower, – Recharge refrigerant circuit.
• and the required cooling – Repeat the check.
output is not attained.
• High pressure is normal, • If quantity of refrigerant extracted is

substantially less than specified ca‐
• Low pressure matches pacity:
the diagram value,
– Find leak with leak detector and
• and the required cooling eliminate.
– Recharge refrigerant circuit.
– Repeat the check.
Note
If no fault can be found and air conditioner operation is not OK

when test is repeated, clean refrigerant circuit (flush with refrig‐
erant R134a or blow out with compressed air and nitrogen).
Possible deviation from Possible cause of fault How to rectify fault

specification
• High pressure rises ♦ Restriction or obstruction in the re‐ – Feel AC circuit with hand to deter‐
above specification, frigerant circuit. mine temperature differences.
• Low pressure falls ♦ Expansion valve defective. • If temperature differences are per‐
quickly to the diagram ceptible on a component:
value or lower,
– Renew hose or pipe if kinked or
• and the required cooling constricted.
– In the event of clogging, clean re‐
frigerant circuit (flush with refriger‐
ant R134a or blow out with com‐
pressed air and nitrogen and renew
expansion valve if applicable).
– Clean refrigerant circuit (flush with
refrigerant R134a or blow out with
compressed air and nitrogen and
renew expansion valve if applica‐
ble).

Note
If, after cleaning (flushing with R134a refrigerant or blowing out

with compressed air or nitrogen) the AC circuit still does not op‐
erate properly, replace the expansion valve.
Possible deviation from Possible cause of fault Measures to be taken

specification
• High and low pressure ♦ Expansion valve defective. – Inspect the expansion valve. Re‐
normal at first place if any dirt or corrosion is
♦ Moisture in the refrigerant circuit. found.
• after a time the high-
pressure increases be‐ – Blow through refrigerant circuit
yond the specified val‐ with compressed air and nitrogen.
ue, the low-pressure
falls to the diagram val‐ – Replace the collecting tank.
ue or lower,
• and the required cooling – Repeat the check. If operation is
output is not attained. not correct:
– Flush the refrigerant circuit (clean)
– Repeat check.
• High and low pressure
normal at first
• After lengthy operating
period, low
Protected pressure
drops
permittedexcessively
(evaporator ices up)

Note
Always replace the liquid tank when this fault occurs.
Possible deviation from specifica‐ Possible cause of fault How to rectify fault
tion
• High pressure normal or too ♦ Too much refrigerant in cir‐ – Extract some refrigerant from the
high, cuit. refrigerant circuit.
• Low pressure too high (see di‐ ♦ Expansion valve or compres‐ • If quantity of refrigerant extracted
agram), sor faulty. roughly corresponds to actual ca‐
• Required cooling output is not pacity:
attained – Renew the expansion valve.
after switch-on) – Recharge refrigerant circuit.

• The quantity of refrigerant extrac‐
ted is significantly greater than the
prescribed charge quantity:

Note
If operation of the air conditioning system is not OK when the test

is repeated, re-fit old expansion valve and clean refrigerant circuit
(flush with refrigerant R134a or blow out with compressed air and
nitrogen). Replace the compressor and liquid tank.
Possible deviation from specifica‐ Possible cause of fault Measures to be taken

tion
• High pressure increases only Compressor defective – Clean refrigerant circuit (flush with
slightly above the pressure refrigerant R134a or blow out with
measured when the engine is compressed air and nitrogen).
stopped,
– Replace the compressor and liq‐
• Low pressure falls only slightly, uid tank.
• and the required cooling output
is not attained.

tion
• High pressure is normal, Expansion valve or compressor – Renew the expansion valve.
faulty.
• Low pressure too low (see – Recharge refrigerant circuit.
graph)
• Required cooling output is at‐ – Repeat the check.
tained
Note
♦ If operation of the air conditioning system is not OK when the

test is repeated, re-fit old expansion valve and clean refriger‐
ant circuit (flush with refrigerant R134a or blow out with com‐
pressed air and nitrogen). Replace the compressor and liquid
tank.
♦ When respect
this fault
to the occurs,
correctness it
of is possiblein thisfor the evaporator to S.A.
ice
information document. Copyright by SEAT
up even when the proper quantity of refrigerant is present in
the circuit.

tion
• High and low pressure normal Too much refrigerant oil in the cir‐ – Drain refrigerant circuit.
cuit.
• and the required cooling output – Clean refrigerant circuit (flush with
is not attained. refrigerant R134a or blow out with
compressed air and nitrogen).
• High and low pressure normal
after switch-on)
• Required cooling output is at‐
tained

Note

was renewed.
♦ If there is too much refrigerant oil in the circuit, discharge com‐
pressor and renew receiver. After cleaning the refrigerant
circuit (flush with refrigerant R134a or blow out with com‐
pressed air and nitrogen), add the correct amount of refriger‐
ant oil to the circuit ⇒ page 141 .
11.4 Checking with expansion valve and liq‐

uid tank (without regulating compressor)

• Radiator and condenser must be clean (clean them if neces‐
sary).
• The compressor and alternator Poly-V belt is in good condition
and properly tensed.
• All air ducts, covers and seals OK and properly fitted
• Protected
The flaps reach
by copyright. their
Copying for end
privatepositions.
• Engine
respect toat
theoperating
correctness of temperature
information in this document. Copyright by SEAT S.A.
• The evaporator and heating do not draw any uncooled air at

highest fresh air blower speed.
While the engine is running and the air-conditioner is set to its
maximum cooling power, observe the following points:
• The fresh air blower is working
• The radiator fan is ready for operation and starts.
• The air recirculation/fresh air flap is in the position “Air recir‐
culation”.
• Ambient temperature of over 15° 0 C.
• The temperature switch for evaporator - E33- is correctly fitted
and its switching temperatures are correct.
11.4.2 Checking
– Connect manometer battery (AC service station.)
– Read the manometers. Two results A and B may be displayed.
Ambient temperature in °C Pressure in refrigerant circuit in
bar (overpressure)
+ 15 °C 3.9
+ 20 °C 4.7
+ 30 °C 6.7
+ 40 °C 9.1
♦ A - The pressure in the refrigerant circuit is lower than that
indicated in the table (insufficient refrigerant in the circuit).

- Check for leaks using leak detector.

- Pressure relief valve open, check that the refrigerant fan acti‐
vates according to the electrical circuit diagram.
Check that refrigerant piping and hoses and not bent too much or
kinked (narrowing cross-section), and ensure that they are not
damaged. If no faults are found, purge the refrigerant circuit.
♦ B - The pressure in the refrigerant circuit is equal to or higher
than that indicated in the table.
– Start the engine.
– Set air conditioning system for maximum cooling output.
– Open the doors.
– Open the dash panel vents.
The compressor is driven by the engine by means of a Poly-V belt
and an electromagnetic coupling.
Note
♦ If the air-conditioner compressor is not activated, check the

power supply to the air-conditioner electromagnetic coupling
- N25- with the electrical circuit diagram.
♦ If the power supply is correct, repair the electromagnetic cou‐
pling. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the compressor is driven, check the refrigerant circuit:
– Let the engine run at a speed of 2,000 rpm.
– Observe the manifold gauge.
11.4.3 Specified values

High-pressure side:
Increasing from the pressure when the engine is stopped to a
maximum of 20 bar positive pressure.
Low-pressure side:
Decreasing from the pressure when the engine is stopped to 1.3
bar positive pressure.
11.5 Pressures with restrictor, reservoir and

air conditioner compressor regulating
valve - N280- : Check (with externally
regulated compressor)
Note



Note
♦ Switching pressures for actuation of air conditioner compres‐

sor regulating valve - N280- and radiator fans - V7- are vehicle-
specific.
♦ The pressures must be measured on the service connections.
The position of these connections are different according to
the vehicle ⇒ Heating, Air Conditioning; Rep. gr. 87 .
High-pressure side:
Increasing by 20 bar from the initial pressure (when connecting
the manometers).
Low-pressure side:
A - Low-pressure (measured at the service port) in bar absolute
pressure.
B - Control current for air conditioner compressor regulating valve
- N280- in amps
Note
♦ Under unfavourable conditions (very high ambient tempera‐

tures, highbyaircopyright.
Protected humidity),
Copyingthe pressure
for private in thepurposes,
or commercial high-pressure sideis not
in part or in whole,
may increase
permitted up to abymaximum
unless authorised SEAT S.A. SEAT ofS.A
29does
bar.
not guarantee or accept any liability with
♦ The control current -B- is indicated in the measured values
block.
♦ The high pressure is indicated in the measured values block
⇒ Rep. gr. 87 .
♦ The low pressure is adjusted according to the control current
for the air-conditioner compressor regulating valve - N280-
within the tolerance margin in the compressor power range.
tures, high air humidity), the power may not always be suffi‐
cient to reach the prescribed value.
♦ The set working current for the regulating valve must be great‐
er than 0.3 A to ensure that the regulating valve is reliably
activated.
♦ 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 .
lute vacuum. The normal ambient pressure corresponds to 1
bar absolute pressure. In general, most manometer scales
represent atmospheric pressure as 0 bar, meaning an abso‐
lute pressure of 1 bar (this can be recognized if there is a -1
on the scale).

Possible deviation from Possible cause of fault How to rectify fault

specification
• High pressure remains ♦ The control for the AC compres‐ – Check control for AC compressor
constant or increases on‐ sor regulating valve - N280- is regulating valve - N280- .
ly slightly (above the defective.
pressure measured when – Find leak with leak detector and elim‐
the engine is stopped), ♦ Insufficient refrigerant in circuit. inate.
• The low pressure falls to – Recharge refrigerant circuit.
the diagram value or low‐
er,
• and the required cooling

• Low pressure too low
(see graph)

• Low pressure too low
(see graph)
Note
Clean the refrigerant circuit (rinse with refrigerant
to the correctness ofR134a orinsweep
respect information this document. Copyright by SEAT S.A.
with compressed air or nitrogen).
Possible deviation from spec‐ Possible cause of fault Measures to be taken

ification
• High pressure increases ♦ The control for the AC compres‐ – Check control for AC compressor
only slightly above the sor regulating valve - N280- is regulating valve - N280- .
pressure measured when defective.
the engine is stopped, – Clean refrigerant circuit (flush with
♦ Compressor defective refrigerant R134a or blow out with
• Low pressure falls only compressed air and nitrogen).
slightly,
• and the required cooling – Renew compressor.


ification
• High pressure rises above ♦ Restriction or obstruction in the – Check control for AC compressor
specification, refrigerant circuit. regulating valve - N280- .
• Low pressure falls quickly – Feel AC circuit with hand to deter‐
to the diagram value or mine temperature differences.
lower,
• and the required cooling • If temperature differences are per‐
output is not attained. ceptible on a component:
– Renew hose or pipe if kinked or con‐
stricted.
– If clogged use compressed air and

nitrogen in the AC circuit.
– Clean refrigerant circuit (flush with
refrigerant R134a or blow out with
compressed air and nitrogen).

ification
• High pressure and low ♦ Moisture in the refrigerant circuit. – Blow through refrigerant circuit with
pressure are normal at compressed air and nitrogen.
first, but after a while, the
high pressure increases – Replace the collecting tank.
beyond the specification,
– Repeat the check. If operation is not
• The low pressure falls to correct:
the diagram value or low‐
er, – Flush the refrigerant circuit (clean)
output is not attained. – Recharge refrigerant circuit.
Protected by copyright. Copying for private or commercial purposes, in part or – Repeat

in whole, is not check.
• High and low pressure ♦ Theofcontrol for thedocument.

AC compres‐ – Check the activation
of the air-con‐
respect to the correctness information in this Copyright by SEAT S.A.
normal at first sor regulating valve - N280- is ditioner compressor regulating valve
defective. - N280- .
• After lengthy operating pe‐
riod, low pressure drops ♦ The air conditioner compressor is – Flush the refrigerant circuit (clean)
excessively (evaporator defective.
ices up) – Renew the air conditioner compres‐
sor.

Note
♦ It is not initially necessary to clean the refrigerant circuit (flush

with refrigerant R134a or blow out with compressed air and
nitrogen) when this problem occurs. Normally, there is only a
small quantity of moisture in the system which can be removed
by lengthy evacuation.
♦ If problem involving moisture in refrigerant circuit only occurs
after a lengthy operating period or only infrequently (low pres‐
sure drops below specification and evaporator ices up), it is
sufficient to replace the dryer in the receiver (adjust quantity
of refrigerant oil). Subsequently, evacuate refrigerant circuit
for at least 3 hours.
♦ A problem with evaporator output temperature sender - G263-
can also cause icing-up of refrigerant circuit. In the event of
such complaints it is also necessary to take into consideration
the reading block for the evaporator output temperature sen‐
sor - G263- ⇒ Vehicle diagnostic tester; in the “guided diag‐
nostic mode ” of the air conditioning and ⇒ heater, air
conditioning; Rep. gr. 87 or ⇒ air conditioning; Rep. gr. .
♦ 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 defective, the evaporator may
ice up or the cooling output will not be achieved.

ification
• High pressure is normal, ♦ Too much refrigerant in circuit. – Extract some refrigerant from the
• Low pressure too low (see
graph) • The quantity of refrigerant extracted
• the air-conditioner com‐ is about equal to the prescribed
pressor is noisy (especial‐ charge quantity:
ly after connection), – Renew the air conditioner compres‐
• the requested cooling sor.
power is not achieved.
• The quantity of refrigerant extracted
is significantly greater than the pre‐
scribed charge quantity:
permitted unless authorised by SEAT S.A. – SEATRecharge refrigerant
S.A does not guarantee circuit.
– Repeat check.

ification
• High pressure and low ♦ Too much refrigerant oil in the circuit. – Drain refrigerant circuit.
pressure are normal at
first, – Flush the refrigerant circuit
(clean)
• the requested cooling


ification
• High and low pressure
normal
• the air-conditioner com‐
pressor is noisy (especial‐
ly after connection),
• the requested cooling
Note

was renewed.
pressor and renew reservoir. After cleaning the refrigerant
11.6 Checking pressures with restrictor, res‐

ervoir and air conditioner compressor
regulating valve - N280- (with externally

regulated compressor)
Note

♦ If a problem is only encountered at one evaporator on vehicles
fitted with two evaporators, check the pressures in the refrig‐
erant circuit. If these are OK, check the pipe connection be‐
tween the problematic evaporator and the outlet of the pipe
connection at the refrigerant pipe junction (for cross-sectional
constriction or clogging). If no fault is found, discharge the re‐
frigerant circuit and re-fill it with the specified quantity of re‐
frigerant. Check pressures and performance of air condition‐
ing system again If the subject of the complaint is still present,
replace the expansion valve in front of the evaporator in ques‐
tion ⇒ heater, air conditioning; Rep. gr. 87 or ⇒ air condi‐
tioning; Rep. gr. 87 .


Note
♦ The switching pressures to activate the air-conditioner com‐

pressor regulating valve - N280- and the refrigerant fans - V7-
are specific to the vehicle.
♦ The pressures must be measured on the service connections.
The position of these connections are different according to
the vehicle ⇒ Rep. gr. 87 .
11.6.1 Specified values

High-pressure side:
Increasing by a maximum of 20 bar from the initial pressure (when
connecting the manometers).
Low pressure:
A - Low-pressure (measured at the service port) in bar absolute
pressure.
B - Control current for air conditioner compressor regulating valve
- N280- in amps
C - Permissible tolerance range (valid for compressor operation
percentage between 10 ... 90%)
Note

tures, high air humidity), the pressure in the high-pressure side
may increase up 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 ⇒
Rep. gr. 87 .
♦ The low pressure is adjusted according to the control current
for the air-conditioner compressor regulating valve - N280-
within the tolerance margin in the compressor power range.
tures, high air humidity), the power may not always be suffi‐
cient to reach the prescribed value.
♦ The set working current for the regulating valve must be great‐
er than 0.3 A to ensure that the regulating valve is reliably

activated.
♦ At the “maximum cooling power” setting, the control current is
set to between approximately 0.65 A and 0.8 A (depending on
the vehicle, it is indicated in the measurement value block)⇒
Rep. gr. 87 .
lute vacuum. The normal ambient pressure corresponds to 1
bar absolute pressure. In general, most manometer scales
represent atmospheric pressure as 0 bar, meaning an abso‐
lute pressure of 1 bar (this can be recognized if there is a -1
on the scale).

Possible deviation from speci‐ Possible cause of fault Measures to be taken

fication
• High pressure remains con‐ ♦ The control for the AC compressor reg‐ – Check control for AC com‐
stant or increases only ulating valve - N280- is defective. pressor regulating valve -
slightly (above the pressure N280- .
measured when the engine ♦ Insufficient refrigerant in circuit.
is stopped), ♦ Expansion valve defective. – Extract some refrigerant
from the refrigerant circuit.
• The low pressure falls to the
diagram value or lower, • If quantity of refrigerant ex‐
• and the required cooling tracted is substantially less
output is not attained. than specified capacity:
• High pressure is normal, • Insufficient refrigerant in circuit. – Extract some refrigerant

from the refrigerant circuit.
• Low pressure matches the
diagram value, • The quantity of refrigerant
• and the required cooling extracted is significantly less
output is not attained. than the prescribed charge
quantity.
– Look for leaks using leak de‐
tector and rectify them.
– Repeat check.
• The quantity of refrigerant

extracted is about equal to
the prescribed charge quan‐
tity.
• Expansion valve defective. •

– Renew the expansion valve.

Note
♦ Clean the refrigerant circuit (rinse with refrigerant R134a or

sweep with compressed air or nitrogen).
♦ 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 defective, the evaporator may
ice up or the cooling output will not be achieved.
♦ If, after replacing the expansion valve, operation of the air
conditioning system is not OK when the test is repeated (re-fit
old expansion valve), clean refrigerant circuit (flush with re‐
frigerant R134a or blow out with compressed air and nitrogen).
Replace the compressor and liquid tank.
♦ When this fault occurs, it is possible for the evaporator to ice
up even when the proper quantity of refrigerant is present in
the circuit.
♦ If the expansion valve is faulty (constantly closed or does not
open enough), the air-conditioner compressor regulating valve
- N280- is activated at maximum power, and the low pressure
drops to or below the value of the diagram (the air-conditioner
compressor sucks refrigerant from the low-pressure side). But,
as the refrigerant cannot flow through the expansion valve, the
cooling power cannot be achieved, and the pressure may also
not increase or only increase slightly, seeing as there is no
energy transformation.

fication
• High pressure increases ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
only slightly above the pres‐ ulating valve - N280- is defective. tioner compressor regulating
sure measured when the valve - N280-
engine is stopped,
• Low pressure falls only
slightly,
♦ The air conditioner compressor is de‐ – Extract refrigerant.

fective.
– Flush the refrigerant circuit
(clean)
– Renew the air conditioner

compressor.


fication
• High pressure rises above ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
specification, ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• Low pressure quickly drops ♦ Restriction or obstruction in the refrig‐
to value in graph erant circuit. – Feel AC circuit with hand to
• and the required cooling ♦ Expansion valve defective. determine temperature dif‐
output is not attained. ferences.
• If temperature differences
are perceptible on a compo‐
nent:
– Renew hose or pipe if kinked
or constricted.
– In the event of clogging of the

refrigerant circuit, clean
(flush with refrigerant R134a
or blow out with compressed
air and nitrogen ).
– Clean refrigerant circuit
air and nitrogen).
– If function is not OK, repeat

test:
– Renew the expansion valve

and receiver.
Note
♦ If this fault occurs, the evaporator may freeze in spite of the

fact there is the correct amount of refrigerant in the circuit.
compressor sucksunless
refrigerant from
SEATtheS.A.low-pressure side). But,
permitted authorised by SEAT S.A does not guarantee or accept any liability with
as the refrigerant cannot
respect to the flow through
correctness the expansion
of information valve,
in this document. theby SEAT S.A.
Copyright


fication
• High pressure and low ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
pressure normal. After a ulating valve - N280- is defective. tioner compressor regulating
while, valve - N280-
♦ Moisture in the refrigerant circuit.
• High pressure rises above – Clean refrigerant circuit
specification, (flush with refrigerant R134a
• The low pressure falls to the or blow out with compressed
diagram value or lower, air and nitrogen).

• High and low pressure nor‐ – Renew receiver with dryer.

mal at first
– Evacuate refrigerant circuit
• After lengthy driving time, for at least 3 hours.
low pressure drops below
specification (evaporator – Recharge refrigerant circuit.
ices up)
– Flush the refrigerant circuit
(clean)
Note
♦ If this incident occurs only after a prolonged service period or

occasionally (the low pressure drops to below the specification
and the evaporator freezes), only the desiccant needs to be
replaced (located in the liquid tank). The amount of refrigerant
oil must be compensated for. The refrigerant circuit must now
be vacuumed for at least 3 hours.
♦ In principle it is not necessary to blow out the refrigerant circuit
with compressed air and nitrogen in the event of this com‐
plaint, seeing as there is generally only a small amount of
humidity in the system which may be eliminated by vacuuming
the circuit for a prolonged period of time.


fication
• High pressure normal, low ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
pressure too low (see dia‐ ulating valve - N280- is defective. tioner compressor regulating
gram), the required cooling valve - N280-
power is delivered. ♦ Expansion valve or compressor faulty.
♦ Compressor defective – Clean refrigerant circuit
air and nitrogen) (not always
necessary, refer to notes).

and receiver.

test:
– Renew compressor.
– with
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability Recharge refrigerant circuit.
Note
♦ In the case of the fault “High pressure normal, low pressure

too low”, the following must be taken into account: Error, the
evaporator may freeze, or the cooling power is not achieved.
♦ Check the measurement value of the evaporator outlet tem‐
perature sender - G263- or the evaporator temperature sender
- G308- and the controlling of the air conditioning system com‐
pressor regulating valve - N280- . If the value measured by the
high-pressure sender - G65- is incorrect, the evaporator may
freeze or the cooling power is not achieved.
♦ If the air-conditioner compressor regulating valve - N280- is
faulty (the regulating valve is not activated, but the compressor
operates correctly), it is not necessary to blow out the refrig‐
erant circuit. In this case, replacing the air-conditioner com‐
pressor is sufficient (compensate for the amount of refrigerant
oil in the new air-conditioner compressor).
⇒ Rep. gr. 87


fication
• High pressure normal or too ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
high, ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• Low pressure too high (see ♦ Too much refrigerant in circuit.
diagram), – Extract some refrigerant
♦ Expansion valve defective.
• Compressor noise (particu‐ from the refrigerant circuit.
larly after switch-on) ♦ Compressor defective
• If quantity of refrigerant ex‐
• Required cooling output is tracted roughly corresponds
attained to actual capacity:
and receiver.

test: purposes, in part or in whole, is not
Protected by copyright. Copying for private or commercial
– Renew compressor.
• The quantity of refrigerant

extracted is significantly
greater than the prescribed
charge quantity:
Note
♦ If the air-conditioner compressor regulating valve - N280- is

faulty (the regulating valve is not activated, but the compressor
operates correctly), it is not necessary to blow out the refrig‐
erant circuit. In this case, replacing the air-conditioner com‐
pressor is sufficient (compensate for the amount of refrigerant
oil in the new air-conditioner compressor).
♦ The refrigerant circuit may be overcharged with refrigerant oil
if, for example, the compressor has been replaced without
compensating the amount of refrigerant oil.
♦ If the air conditioner compressor is not replaced, the refriger‐
ant must be extracted from the compressor (replace the O-
ring) via the oil drain plug. Fill the 50 grams in the ⇒ Repair
Manual of the respective vehicle indicated complete refriger‐
ant oil quantity in the air conditioner compressor and the rest
in the refrigerant circuit.


fication
• High and low pressure nor‐ ♦ The control for the AC compressor reg‐ – Check actuation of air condi‐
mal ulating valve - N280- is defective. tioner compressor regulating
valve - N280-
• Required cooling output is ♦ Too much refrigerant in circuit.
attained – Drain refrigerant circuit.
♦ Expansion valve defective.
– Clean refrigerant circuit
air and nitrogen).
• High and low pressure nor‐ – Add correct quantity of refrig‐
mal erant oil to circuit (see note).
• Compressor noise (particu‐ – Recharge refrigerant circuit.
larly after switch-on)
• Required cooling output is – If function is not OK, repeat
attained test:
– Renew the expansion valve.
Note
♦ Overfilling with refrigerant oil may occur if, for example, the
compressor has been renewed without adjusting the quantity
of refrigerant oil.
♦ If expansion valve is defective (permanently open), evaporator
temperature is no longer regulated such that only refrigerant
in gas form exits from the evaporator. Under certain usage
conditions, liquid droplets may then be drawn in by the com‐
pressor and cause noise (liquid cannot be compressed).
pressor and renew receiver. After cleaning the refrigerant
11.7 With expansion tank, liquid tank and

electric compressor for hybrid vehicles
Note
The electric compressor is not fitted with air conditioner compres‐

sor regulating valve
Protected- by
N280- . Regulation
copyright. is orperformed
Copying for private via the
commercial purposes, in part or in whole, is not
speed of the electric compressor.
permitted unless The S.A.
authorised by SEAT operating electrics
SEAT S.A does andorthe
not guarantee accept any liability with
G-charger that runs the refrigerant are located on the electric
compressor.
The pressure can only be tested using ⇒ Vehicle diagnostic tester.

12 Replacing components
12.1 Renewing refrigerant circuit compo‐

nents
• All refrigerant circuit components which are sent for quality
control must always be closed (use the original plugs from the
spare part).
• Compressor parts, collected tank, liquid tank, evaporators and
condenser are, until now, filled with nitrogen gas. This filling
will now gradually be stopped, or else the pressure of the ni‐
trogen will be so low that the gas will not be heard escaping
when the component is first opened.
• In vehicles without an electromagnetic coupling on the com‐
pressor, the engine must only be started if the refrigerant
circuit is completely assembled (the compressor operates
constantly at the same time).
• To prevent damage to the air conditioner compressor
Protected whenfor private or commercial purposes, in part or in whole, is not
by copyright. Copying
the refrigerant circuit is empty, air conditioning
permitted unlesssystem
authorised com‐
pressor regulating valve - N280- (without electromagnetic cou‐
pling), it is equipped with a protected oil supply. This means

that approx. 40 to 50 cm3 of refrigerant oil remains in the air-
conditioner compressor. ⇒ page 15
Note
♦ As spare parts in the spare parts catalogue are stored at dif‐

ferent locations over longer periods, when opening for the first
time (also genuine spare parts of the same series) gas may
escape in some cases and not in other cases. For this pur‐
pose, carefully remove the caps of the connections on the
genuine parts to allow the nitrogen gas to escape slowly.
♦ The refrigerant circuit contains a choke and a collecting tank,
or else an expansion valve and a liquid tank.
♦ Close any open connections and hoses (to prevent humidity
from entering).
♦ Always replace the choke.
The collecting tray / liquid container, the dryer bag or the dryer
cartridge must not be replaced when the following conditions are
fulfilled:
• After an accident, the collecting / liquid tank have not been
damaged.
• The repair is carried out in a brief period of time (no longer than
standard repair time) and no humidity has entered. The vehicle
is no more than 5 years old.
The collecting / liquid tank or the desiccant cartridge must be re‐
placed if the following conditions are met.
• The refrigerant circuit was opened and the vehicle is more than
5 years old.
• The refrigerant circuit has been open for an indefinite period
of time (slow leak).
• The repair time is longer than usual, and humidity has entered.
• After blowing through with compressed air / nitrogen or rinsing
with the refrigerant R134a, the collecting tray / liquid container
or the dryer cartridge must always be replaced. Keep the gen‐

uine spare parts in their original packing as long as possible

to prevent them from getting wet.
• The air-conditioner compressor is blocked.
• The collecting / liquid tank is damaged (accident).
Caution
Handling the refrigerant oil ⇒ SEAT-ServiceNet, Guidelines,

Service Guidelines; Environment Protection .
The used refrigerant oil will be handled in the same way as old
oil with unknown origin.
12.1.1 The refrigerant circuit

Protected was
by copyright. completely
Copying for private or commercial purposes, in part or in whole, is not
empty permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Disassemble the faulty component.

– Remove air conditioner compressor.
– Drain refrigerant oil from air conditioner compressor via block
connections.
Note
♦ To accelerate the draining of the refrigerant oil, turn the com‐

pressor via the pulley of the Poly-V-belt or via the electromag‐
netic coupling disc.
♦ Extract the refrigerant from the air conditioner compressor,
handling the refrigerant oil ⇒ SEAT-ServiceNet, Guidelines,
Service Guidelines; Environment Protection .
♦ Then fill air conditioner compressor with a quantity of fresh
refrigerant oil corresponding to quantity of refrigerant oil in
original compressor ⇒ Rep. gr. 87 .
♦ Use different types and amounts of refrigerant oil for different
air-conditioner compressors ⇒ Rep. gr. 87 .
♦ In order to ensure proper lubrication of the compressor during
commissioning, the compressor must be filled with at least 80
cm 3 cooling machine oil; the remaining oil for instance can be
siphoned off into a separate liquid collection container ⇒ Rep.
gr. 87 .
♦ If any dirt has entered the compressor while the refrigerant
circuit is open (e.g. after an accident), the compressor must
be replaced.
♦ Blow out the refrigerant circuit out with compressed air and
then with nitrogen.
– Replace liquid tank or collecting tank and choke.

– Assemble, vacuum and recharge the refrigerant circuit.
12.1.2 There is still refrigerant in the refrigerant

circuit
– Drain refrigerant circuit.
– Disassemble the faulty component and blow it out with com‐
pressed air, collecting any refrigerant oil which comes out.
– Fill the new component with the same amount of new refrig‐
erant oil as the amount blown out previously (plus 20 cm3 in
12. Replacing components 133

the evaporator, plus 10 cm3 in the condenser and in the re‐

frigerant piping and hoses).
– Replace the choke.
– Assemble, vacuum and charge the refrigerant circuit.
12.2 Replacing the air conditioner compres‐

sor
12.2.1 If it is not necessary to clean (rinse) the

refrigerant circuit, e.g. after external
damage resulting from an accident
Note
If a different air conditioner compressor with other refrigerant oil

is fitted, flush the refrigerant circuit with R134a refrigerant
⇒ page 71 .
– Remove the compressor oil drain plug.
Note
The “Denso” (Nippondenso) compressor has a seal
respect to theinstead
correctnessof an
O-ring on the oil drain plug, which must always be replaced.

– To facilitate draining the refrigerant oil, turn the compressor by
the electromagnetic coupling disc.
– Pour out the used oil of the air conditioner compressor. Han‐
dling the refrigerant oil ⇒ SEAT-ServiceNet, Guidelines, Serv‐
ice Guidelines; Environment Protection .
– Unscrew the oil drain plug on the old air conditioner compres‐
sor (replace the O-ring), turn the compressor around so that
the refrigerant oil can run out and only fill with the same amount
that has run out (of the old compressor).
Note
♦ If, e.g. 70 cm3 has been extracted from the defective com‐
pressor and 220 cm3 from the genuine part compressor (a
small quantity of refrigerant remains in the compressor), in this
case, 70 cm3 of refrigerant oil has been filled into the new
compressor (the refrigerant oil can be used that has been ex‐
tracted from the compressor replaced).
♦ If a larger volume of refrigeration oil was drained from the de‐
fective compressor (more than 80 cm3), the remaining refrig‐
eration oil can also be filled into the evaporator or into the fluid
container ⇒ Rep. gr. 87 .


12.2.2 Leaking or due to internal damage (e.g.

noises or loss of power)
Note
♦ With internal damage (in the air conditioner compressor), rinse

the refrigerant circuit using the refrigerant R134a ⇒ page 71 .
♦ If a different air conditioner compressor with other refrigerant
oil is fitted, flush the refrigerant circuit with R134a refrigerant
⇒ page 71
12.3 Replacing liquid tank or collecting tank

and choke
12.3.1 After cleaning the refrigerant circuit, e.g.

due to moistness (the refrigerant circuit
was left open over a longer period) or dirt
having entered
The collecting / liquid tank or the desiccant bag / cartridge do not
need to be replaced if the following conditions are met.
• After an accident, the collecting / liquid tank have not been
damaged.
• The repair is carried out in a brief period of time (no longer than
standard repair time) and no humidity has entered. The vehicle
is no more than 5 years old.
The collecting / liquid tank or the desiccant cartridge must be re‐
placed if the following conditions are met.
• The refrigerant circuit was opened and the vehicle is more than
5 years old.
• The refrigerant circuit has beenpermitted
open for anauthorised
unless indefinite period
of time (slow leak). respect to the correctness of information in this document. Copyright by SEAT S.A.
• The repair time is longer than usual, and humidity has entered.
• After blowing through with compressed air / nitrogen or rinsing
with the refrigerant R134a, the collecting tray / liquid container
or the dryer cartridge must always be replaced. Keep the gen‐
uine spare parts in their original packing as long as possible
to prevent them from getting wet.
• The air-conditioner compressor is blocked.
• The collecting / liquid tank is damaged (accident).
– Eliminate the cause of the fault.

– Inspect the expansion valve. Replace if any dirt or corrosion

is found.
– Remove the compressor oil drain plug.
Note
The “Denso/Nippondenso” compressor has a seal instead of an

O-ring on the oil drain plug, which must always be replaced ⇒
Electronic parts catalogue .
– To facilitate draining the refrigerant oil, turn the compressor by

the electromagnetic coupling disc.
– Pour out the used oil of the air conditioner compressor. Han‐
dling the refrigerant oil ⇒ SEAT-ServiceNet, Guidelines, Serv‐
ice Guidelines; Environment Protection, Emission protection .
– Then fill air conditioner compressor with a quantity of fresh
refrigerant oil corresponding to quantity of refrigerant oil in
original compressor ⇒ Rep. gr. 87 .
Note

♦ In order to ensure proper lubrication of the compressor during
commissioning, the compressor must be filled with at least 80
cm 3 cooling machine oil; the remaining oil for instance can be
siphoned off into a separate liquid collection container ⇒ Rep.
gr. 87 .
♦ If any dirt has entered the compressor while the refrigerant
circuit is open (e.g. after an accident), the compressor must
be replaced.
– Replace liquid tank or collecting tank and choke.

12.3.2 If the refrigerant does not have to be

cleaned (e.g damaged in an accident),
no refrigerant has escaped and no in‐
gress of moisture and dirt into refrigerant
circuit
– Drain refrigerant circuit. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Disassemble the fluid tank or collecting tank.
– Clean any dirt in the liquid tank or collecting tank.
– Weigh the disassembled liquid tank or collecting tank.
Note
♦ Fill the new liquid tank or collecting tank with as much refrig‐
erant oil as necessary to reach the weight of the disassembled
tank.
♦ Assemble the new fluid tank or collecting tank.


13 Quantity of refrigerant R134a, quan‐

tity of the refrigerant oil: SEAT vehi‐
cles
13.1 Top-up quantities of refrigerant R134a
Note
♦ When filling refrigerant circuits, always fill the high pressure

side to the limit of the upper tolerance (there is refrigerant left
in the filler hoses).
♦ The compressor correspondence (“Zexel”, “Sanden” or “Den‐
so / Nippondenso”) can be found in the ⇒ Electronic parts
catalogue and in ⇒ Heating, air conditioning or ⇒ air condi‐
tioning ⇒
Note
Modified refrigerant circuits (from R12 to R134a) should be filled

to the level shown in the Repair Manual “Air conditioning using
R12 refrigerant”. ⇒ Air conditioning using R12 refrigerant (The
repair manual is only available in printed format).
13.1.1 Filling quantities for Arosa (1H_) 1997►

Refrigerant circuit characteristics:
• Expansion valve
• Receiver
• “Sanden” compressor with magnetic coupling
Vehicle model Production period Load in grams Differences in this refriger‐
ant circuit
Arosa to 09.00 750 + 50 • Condenser with part
number 6N0 820 413.
after 06.00 750 + 50 • Condenser with part

number 6X0 820 413
and index“A”.
Note
To prevent alteration to the refrigeration capacity of the air con‐

ditioner, only chokes with an opening of the same diameter should
be fitted.
13.1.2 Filling quantities for Ibiza 93, Cordoba

(6K_) 1993►, ► 2001
• Expansion valve
• Receiver

• “Sanden” compressor with magnetic coupling⇒ Heating, air

Vehicle Production period Load in grams Differences in this refrigerant circuit
model
Ibiza from 05.93 850 + 30 • Guide, left side
Córdoba from 06.94 900 + 30
• Guide, right side
Note
At the start of production only “Fa Denso” compressors were fit‐

ted. In models made since 1993, compressors manufactured by
“Sanden” have also been fitted ⇒ Heating, air conditioning and
⇒ Electronic parts catalogue .
13.1.3 Filling amounts for Inca (6K_) 1995►

• Expansion valve
• Receiver

Vehicle model Production period Load in grams Differences in this refrigerant circuit
Inca Since 07.95 850 + 30 • Guide, left side
900 + 30
Note
At the start of production, only “SD7- V16” type compressors

manufactured by “Sanden” were fitted.
13.1.4 Filling amounts for Cordoba Vario (6K_) 1997►

• Reservoir
• “Denso” compressor with magnetic coupling⇒ Heating, air
Cordoba Vario Since 05.97 850 + 30 • Guide, left side
900 + 30
13.1.5 Filling amounts for Toledo (1L_) 1994►, ►1999

• Reservoir
13. Quantity of refrigerant R134a, quantity of the refrigerant oil: SEAT vehicles 139

Toledo From 10.94 850 ± 30 • Guide, left side
to 09.98 900 ± 30 • Guide, right side
Note
If the condenser that is fitted is replaced by a condenser with an‐

other part number, the top-up quantity given on the label attached
to the vehicle should be checked, and where necessary correc‐
ted, or another label showing the correct top-up quantity should
be stuck on top ⇒ Heating, air conditioning and ⇒ Electronic parts
catalogue .
13.1.6 Filling amounts for Toledo 99, Leon 2000 (1M_) 1999 ►
• Reservoir
• “Denso” compressor with magnetic coupling.
Vehicle Production period Load in grams Differences in this refrigerant circuit
model
Toledo From 10.98 onwards 750 + /-50 • none
León Since 11.99 750 + /-50 • none
Note
At the start of production, only “7 SEB - 16” type compressors

manufactured by “Denso” were fitted. ⇒ Air conditioning and ⇒
Electronic parts catalogue
13.1.7 Filling amounts for Ibiza, Cordoba, Cordoba Vario (6K_) 1999 ►
• Reservoir
• “Denso” or “Zexel” compressor with magnetic coupling⇒ Heat‐
ing, air conditioning and ⇒ Electronic parts catalogue
Vehicle mod‐ Production period Load in grams Differences in this refrigerant circuit
el
Ibiza Since 05.99 750 + /- 50 • none
Cordoba
Cordoba Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Vario permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

13.2 Refrigerant oils and top-up quantities for

authorised refrigerant oils
Note
♦ PAG (polyalkylene glycol) oil is extremely hygroscopic (water

absorbent), and therefore all open containers should be im‐
mediately resealed.
♦ PAG oil in containers which have been open for any length of
time should not be used.
13.2.1 Authorised refrigerant oils
Note
♦ Oils used for the R12 refrigerant are not suitable for the R134a
refrigerant.
♦ The compressor manufacturer “Nippondenso” has changed its
name to “Denso”.
♦ The special oil, only for use in R134a coolant circuits, can no
longer be obtained on the refrigerant oil market.
♦ Refrigerant oils specially adapted to the respective compres‐
sor are therefore available through the spare parts programme
⇒ Electronic parts catalogue .
♦ The use of other refrigerant oils may cause the installation to
break down, given that they are not always miscible with the
R134a refrigerant and therefore their circulation (to lubricate
the compressor) is not guaranteed.
♦ Different refrigerant oils for “Zexel”-, “Denso”- and “Sanden”
compressors. ⇒ electronic parts catalogue
♦ Refrigerant oils for use with the “Denso” compressor (formerly
known as “Nippondenso”) (G 052 300 A2) are also included in
the Retrofit-Kit repair kit (part number 4A0 298 107 A) ⇒ Elec‐
tronic parts catalogue .
♦ For refrigerant circuits with “Zexel” or “Sanden” compressors,
refrigerant oil with part number G 052 154 A2 ⇒ Electronic
parts catalogue should be used.
♦ For refrigerant circuits with “Zexel” compressors, in addition to
refrigerant oil G 052 154 A2, refrigerant oil G 052 200 A2 in‐
cluded in the Retrofit–Kit (part number 4A0 298 107) may also
be used ⇒ Electronic parts catalogue .
13.2.2 Top-up quantities for refrigerant oils
Note
♦ The compressor correspondence (“Zexel”, “Sanden” or “Den‐

so”) can be found in the relevant vehicle repair manual ⇒
Heating, air conditioning or ⇒ Air conditioning and in the Elec‐
tronic parts catalogue ⇒ Electronic parts catalogue
♦ For “Zexel”, “Denso” and “Sanden” compressors, the quantity
of refrigerant oil given on the spare compressor is equivalent
to the total quantity of oil. If the compressor is replaced, the
quantity of oil in the new compressor should be corrected (an
incorrect quantity of refrigerant oil will cause damage to the
compressor).
♦ When pouring the refrigerant oil from the replacement com‐
pressor (or the faulty compressor), a small amount of oil is
usually left in the compressor (20 to 30 cm3); this quantity of
refrigerant oil does not effect the working of the compressor,
and can therefore be ignored (it remains in all compressors).
♦ After the first connection, the refrigerant oil is distributed
throughout the refrigerant circuit.
♦ Filling quantities for refrigerant oil when replacing defective
components of the refrigerant circuit. ⇒ Heating, air-condi‐
tioning , ⇒ Air conditioner and ⇒ Electronic parts catalogue
13.2.3 Filling quantities for Arosa (1H_) 1997►

• Expansion valve
• Reservoir
• “Sanden” compressor with magnetic coupling for air condi‐
tioning - N25- ⇒ Heating, air conditioning and ⇒ Electronic
parts catalogue
Vehicle model Production period Total quantity of oil in refrig‐ Compressor brand
erant circuit, in cm3
Arosa From 03.97 100 SD7B10
From 06.00 120 Electromagnetic clutch
SD6V12
Electromagnetic clutch
Note
♦ All of the oil required forbythe

Protected refrigerant
copyright. Copying forcircuit
private oriscommercial
locatedpurposes,
in the in part or in whole, is not
replacement compressor. If the compressor is replaced, the
amount of oil in the compressor must be corrected according‐
ly.
♦ As the compressor always operates together with the engine
and the total quantity of refrigerant oil is located in the com‐
pressor, the engine should only be started if the circuit has
been completely fitted. ⇒ Heating and air conditioning
♦ As replacement compressors of this type are supplied with
different oil capacities, the exact part no. must be heeded. ⇒
electronic parts catalogue

13.2.4 Filling quantities for Ibiza 93, Cordoba (6K_) 1993►, ►2001
• Expansion valve
• Receiver
• “Sanden” or “Denso” compressor with magnetic coupling for
air conditioning - N25- ⇒ Heating, air conditioning and ⇒
Vehicle mod‐ Production period Total quantity of oil in refrig‐ Compressor brand
el erant circuit, in cm3
Ibiza Since 05.93 115 DIAVIA
Electromagnetic clutch HARRISON
Cordoba From 06.94 115 DIAVIA
Electromagnetic clutch HARRISON
Note
♦ All of the oil required for the refrigerant circuit is located in the
ly.
♦ At the start of production only “Sanden” compressors were fit‐
ted. ⇒ Heating, air conditioning and ⇒ Electronic parts cata‐
logue .
13.2.5 Filling amounts for Inca (6K_) 1995►

• Expansion valve
• Receiver
• Compressors from a variety of manufacturers with magnetic
coupling for air conditioning - N25- ⇒ Heating, air conditioning
and ⇒ Electronic parts catalogue
Vehicle Production period Total quantity of oil in refrigerant cir‐ Compressor brand
model cuit, in cm3
Inca Since 07.95 115 SD7V16
Note
ly.
♦ Depending on the date of manufacture and the engine, differ‐
ent compressors are fitted.
♦ This compressor is available as a spare part with different
quantities of top-up oil,; therefore the oil quantity in the com‐
pressor and the exact part number should be checked ⇒
Heating, air conditioning and ⇒ Electronic parts catalogue .
♦ It is possible that the manufacturer has attached a plate to the
compressor showing the part number and quantity of oil in the
compressor.
13.2.6 Filling amounts for Cordoba Vario (6K_) 1997 ►

• Expansion valve
• Reservoir
• “Sanden” compressor with magnetic coupling for air condi‐
tioning - N25- ⇒ Heating, air conditioning and ⇒ Electronic
parts catalogue
Cordoba Since 05.97 115 Electromagnetic clutch
Vario
Note
All of the oil required for the refrigerant circuit is located in the
amount of oil in the compressor must be bycorrected accordingly.
permitted unless authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
13.2.7 Filling amounts for Toledo (1L_) 1994►, ►1999

• Expansion valve
• Reservoir
Toledo Since 10.94 115 SD7V16

Note
ly.
♦ Different makes of compressor are fitted in the Toledo, de‐
pending upon the engine and production date. ⇒ Heating, air
13.2.8 Filling amounts for Toledo 99, Leon 2000 (1M_) 1999 ►
• Expansion valve
• Reservoir
Vehicle model Production peri‐ Total quantity of oil in refrigerant cir‐ Compressor brand
od cuit, in cm3
Toledo From 10.98 on‐ 135 + /- 15 SD7V16
wards Electromagnetic clutch
León Since 11.99 135 + /- 15 SD7V16
Note
ly.
♦ Different makes of compressor are fitted in the Toledo 99 and
Leon 2000, depending upon the engine and production date.
This compressor is available as a replacement compressor
with different top-up quantities of oil, therefore
Protected the Copying
by copyright. exact forpartprivate or commercial purposes, in part or in whole, is not
number should be checked.⇒ Airpermitted
conditioning and ⇒by SEAT
unless authorised Elec‐ S.A. SEAT S.A does not guarantee or accept any liability with
tronic parts catalogue respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ It is possible that the manufacturer has attached a plate to the

compressor showing the part number and quantity of oil in the
compressor.
13.2.9 Filling amounts for Ibiza, Cordoba, Cordoba Vario (6K_) 1999 ►
• Expansion valve
• Reservoir
air conditioning - N25- ⇒ Air conditioning and ⇒ Electronic
parts catalogue
Ibiza Since 05.99 135 SD7V16
Cordoba Electromagnetic clutch
Cordoba
Vario
Note
ly.
♦ Different makes of compressor are fitted in the models, de‐
pending upon the engine and production date. This compres‐
sor is available as a replacement compressor with different
top-up quantities of oil, therefore the exact part number should
be checked.⇒ Air conditioning and ⇒ Electronic parts cata‐
logue

14 Verification equipment and tools
14.1 List of testers, tools and materials
Note
This list provides a general overview of the verification equipment,

tools and materials required to correctly repair the refrigerant cir‐
cuit.
Caution

be used.
Warranty claims arebyinvalid
Protected copyright.ifCopying
toolsfororprivate
materials arepurposes,
or commercial used that
in part or in whole, is not
14.1.1 Tools and materials which may be ac‐

quired from the distribution centre or im‐
porter
Overview page
Air-conditioning service station - ⇒ page 149
SAT4006D- , other service stations⇒ SAT
Workshop equipment catalogue with pro‐
gram for rinsing the refrigerant circuit with
refrigerant R134a.
Cleaning station - SAT 4011- for rinsing the ⇒ page 150
circuit with solvent product for the refrigerant
circuit with refrigerant R134a.
Electronic leak detector - SAT 4012- ⇒ page 150
Leak detecting system - VAS 6196- ⇒ page 151
Leak detecting system - VAS 6201- ⇒ page 151
Release tool - VAS 6127- ⇒ page 151
Rinse set - SAT 4009- , adapter set for con‐ ⇒ page 150
necting the air-conditioning service station to
the refrigerant circuit and for bypassing cer‐
tain components when rinsing or blowing
out.
Rinse set - VAS 6338/1- , adapter set for Not illustrated
connecting the air-conditioning service sta‐
tion to the refrigerant circuit and for bypass‐
ing certain components when rinsing or
blowing out.
Counterhold tool - T20017A- ⇒ page 152
Extractor - T20017A- for electromagnetic ⇒ page 152
coupling (Sanden compressor)
Extractor for electromagnetic coupling - ⇒ page 152
T20017A- (Kit)
14. Verification equipment and tools 147

Overview page
Rinse set - SAT 4009- with program for rins‐ ⇒ page 150
ing the refrigerant circuit with refrigerant
R134a.
Adaptor kit for refrigerant - V.A.G 1785 -10- ⇒ page 153
R134a circuit
Combined fine filter unit for compressed air Not illustrated
system, and oil, dirt and water separators
commonly found in painting plants ⇒ Work‐
shop device catalogue
O-rings ⇒ Electronic parts catalogue Not illustrated
Refrigerant oil ⇒ Electronic parts catalogue Not illustrated
14.1.2 Commercially available tools and mate‐

rials
Caution

be used.
Overview page
Fin comb ⇒ page 154
Charging hoses 5/8”-18 UNF with valve opener ⇒ page 154
Connection parts for refrigerant bottles and seal for quick coupling connection ⇒ page 155
or screw connection 5/8” - 18 UNF
Valve caps 5/8”-18 UNF ⇒ page 155
Manometer bank with pressure relief valve for nitrogen ⇒ page 155
Quick coupling adaptor for service connections, 2 units included with the serv‐ ⇒ page 155
ice station
Open end spanner. The spanner widths correspond with the screw connec‐ Not illustrated
tions of the refrigerant hoses.
Valve opener for charging hoses. Not illustrated
Joint nozzle for conical surface seal 5/8” - 18 UNF Not illustrated
Compressed-air gun with rubber nozzle Not illustrated
Valve opener for Schrader valves Not illustrated
Manual shut-off valve 5/8” - 18 UNF Not illustrated
Recycling bottle for refrigerant R134a Not illustrated
Digital thermometer ⇒ page 150
Safety goggles Not illustrated
Refrigerant R134a with pressurized bottle (contents according to demand) Not illustrated
Nitrogen with pressurized bottle Not illustrated
Clamp spanner (oil filter) as retention tool for Poly-V belt pulley Not illustrated

14.1.3 Proprietary tools

Overview page
Charging hose with connection for workshop ⇒ page 156
compressed-air system
14.1.4 Tools and materials which may be ac‐

quired from the distribution centre or im‐
porter
Caution

be used.
Air-conditioning filling station - SAT 4006D- with the rinsing kit -

SAT 4009- (and other service stations that may be presently
supplied)
⇒ Workshop device catalogue
♦ Work processes: The verification, vacuuming (recycling),
emptying and charging operations must be respect
carried out
to the ac‐ of information in this document. Copyright by SEAT S.A.
correctness
cording to the corresponding instructions manuals.
♦ Filters and desiccants must be replaced at the latest once the
service period specified in the instructions manual has ex‐
pired, and whenever the station is emptied (ensure that there
are sufficient spare filters). Available from the manufacturer
(see instructions manual).
♦ Other service stations not mentioned here may also be used.
⇒ Workshop device catalogue
Note
♦ The following individual devices are included in this service

station: Charging cylinder, manometer bank, emptying pump,
shut-off valves and charging hoses.
♦ This service station includes a quick coupling (for service con‐
nections on the high and low pressure sides).
– Adaptors for air-conditioning refrigerant pipes, all models

⇒ page 82

Cleaning station - SAT 4011- with nitrogen + solvent

Work processes: The verification, vacuuming (recycling), empty‐
ing and charging operations must be carried out according to the
corresponding instructions manuals.
Filters and desiccants must be replaced at the latest once the
service period specified in the instructions manual has expired,
and whenever the station is emptied (ensure that there are suffi‐
cient spare filters). Available from the manufacturer (see instruc‐
tions manual).
– For all models:
Rinse set - SAT 4009- or -VAS 6338/1-

– For all models:
Digital thermometer - SAT 4002-

– For all models:
Electronic leak detector - SAT 4012-

Leak detecting system - VAS 6196-
Leak detecting system VAS 6201
Case release tool - VAS 6127- includes the tools release tool -
VAS 6127/1- , release tool - VAS 6127/2- and release tool - VAS
6127/3-
– Application:
Release tool - VAS 6127/1- release tool - VAS 6127/2-

♦ Blue 1/2 inch
♦ Black 5/8 inch
♦ Red 3/8 inch
♦ White 3/4 inch
– Application:

Release tool - VAS 6127/3-

♦ Green DN 8 for high pressure lines
♦ Black DN 13 for vacuum lines
Counterhold for clutch pulley (for “Sanden” air conditioner com‐

pressors)
– For all models including compressor with electromagnetic
clutch:
Extractor (for air-conditioner compressor manufactured by “San‐

den”)
For Sanden compressor (with threaded holes electromagnetic
coupling disc)
Electromagnetic coupling extractor kit - T20017A- (with conical

plugs to prevent dirt or humidity from entering the components)
– Counter hold or dolly for the extraction of the compressor cou‐
pling disk nut.
– Pulley bearing extraction and assembly tool
Composed of cone-shaped plugs of different diameters used to
seal the refrigerant circuit if this needs to be opened for repairs,
for all models.
– Adapters

Magnetic coupling puller V.A.G 1719 (for “Zexel” compressor)
Adapter for performing flush circuits - V.A.G 1785-

♦ Adaptor for blowing out refrigerant circuit with compressed air
and nitrogen
A - Thread 5/8” - 18 UNF for conical surface seal
B - Connection nut (for screw connection with O-ring)
♦ 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
B - Threaded sleeves for O-rings
♦ M 18x1.5 V.A.G 1785/5

♦ M 20x1.5 V.A.G 1785/6
♦ M 24x1.5 V.A.G 1785/7
♦ M 28x1.5 V.A.G 1785/8
Valve adapters
B - Interior thread for valve opener M10 xrespect
1.25toVAG 1785/9of (for
the correctness information in this document. Copyright by SEAT S.A.
valve connections on high-pressure side), M12 x 1.5 VAG
1785/10 (for connections on low-pressure side)
Note
♦ A Schrader valve is screwed onto connection -A-.

♦ A valve opener must be installed in the filler hose connection.

Adapter set for service connection V.A.G 1786

A - Adapter with union nut - V.A.G 1786/1- (only for connections
with small valve core at low-pressure side)
B - Filler hose with union nut 5/8"-18 UNF(short version)
C - Adapter with service connection - V.A.G 1786/2-
Note
For connections with large valve core (standard on “Zexel” com‐

pressors, gradual change to small valve core from 10.94 on‐
wards), adapter V.A.G 1785/10 should be used (remove valve
from adapter V.A.G 1785/10 or install valve opener in filler hose
-B-).
Socket - T10364- for valves of the service connections HD/ND

side (high / low pressure) in the refrigerant circuit.
14.1.5 Commercially available tools and mate‐

rials
Fin comb
– Spare:
Charging hoses
5/8"-18 UNF valve
Note
♦ Use charging hoses of different colours, 1800 mm long.

♦ Maintain a stock of valve openers and spare seals.

Connection parts for refrigerant bottles and seal for quick coupling
connection or screw connection 5/8” - 18 UNF
Valve plug with spare seals (for thread 5/8” - 18 UNF)

The seals may also be used for the charging hoses.
Manometer bank with pressure relief valve for nitrogen (max. re‐
duction pressure: 15 bar)
1- Manifold gauge with pressure reducer
2- Pressure hoses (interior diameter 5 mm, length 2 meters)
with accessories for hoses
3- Nitrogen bottle
4- Hose accessory
Note
To connect to the refrigerantpermitted
circuitunless
adaptor kit by
authorised - V.A.G
SEAT S.A. 1785-
SEAT S.Awith
does not guarantee or accept any liability with
thread 5/8” - 18 UNF respect to the correctness of information in this document. Copyright by SEAT S.A.
Service connection quick coupling adaptor

♦ High-pressure side with nominal diameter 16 mm
♦ Low-pressure side with nominal diameter 13 mm
Note
This quick connector is included in the scope of supply of the air

conditioning service station.

14.1.6 Proprietary tools

Charging hose with connection for workshop compressed-air sys‐
tem
A - Charging hose 5/8”-18 UNF** (large interior diameter version)
B - Connection for workshop compressed-air system** (use only
with filter)
** Commercially available tools and materials

S01DCBXXX20-Air - Conditioner - With - Refrigerant - R134a Seat Leon F5 MK3 2013-2020

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S01DCBXXX20-Air - Conditioner - With - Refrigerant - R134a Seat Leon F5 MK3 2013-2020

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Service

Toledo 2005 ➤ , Toledo 2013 ➤

Service Department. Technical Information

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Copyright © 2016 Seat S.A S01DCBXXX20

8 Cleaning refrigerant circuit of impurities using R134a refrigerant . . . . . . . . . . . . . . . . . . . . 71

After studying this manual, the operator should be qualified inSEAT

This documentation is also intended for use by the persons in

When using tools or materials that have not been approved

1.2 Other means of information

1. General notes on air conditioning systems 1

1.3 Basics of air conditioning

1.3.1 Physical basics:

When water is heated in a container (heat absorption), the rising

1.3.2 Heat always flows from warmer to colder

the cooler, slower moving molecules. By doing so, the movement

1.3.3 Pressure and boiling point

2 Rep. gr.00 - Technical data

refrigerant changes from a liquid state into a vapour state (evap‐

Vapour pressure curve for refrigerant R134a

1.4 Vapour pressure table for refrigerant

Absolute pressure means that 0 bar corresponds to an absolute

Temperature in ° C Pressure in bar (positive pres‐

1. General notes on air conditioning systems 3

Temperature in ° C Pressure in bar (positive pres‐

1.5 Coolant agent R134a

1.5.1 Physical data of refrigerant R134a

1.5.2 Critical point

At temperatures below the critical temperature, all refrigerants are

4 Rep. gr.00 - Technical data

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

1.5.3 Environmental aspects of refrigerant

1.6 Characteristics of refrigerant

1.6.1 Commercial names and designations

♦ Other trade designations may be used in other countries.

1.6.3 Vapour pressure

1. General notes on air conditioning systems 5

1.6.4 Physical properties of R134a

1.6.5 Effects on metal

1.6.6 Critical temperature and critical pres‐

1.6.7 Water content

1.6.9 Charge factor

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

6 Rep. gr.00 - Technical data

1.6.10 Detecting leaks

1.7 Refrigerant machine oil

♦ Do not store refrigerant oil in open containers, as it is very

1.7.1 Properties of refrigerant oil

from moisture. Refrigerant oil ages due to the effect of humidity

1. General notes on air conditioning systems 7

♦ In refrigerant circuits designed for refrigerant R134a, only oil

1.8.1 Environmental aspects

8 Rep. gr.00 - Technical data

1.9 How air conditioning works

1.10 General aspects regarding workplace

1.10.2 Handling refrigerants

There is a freezing hazard.

When opening tanks or containers which contain refrigerant, their

1. General notes on air conditioning systems 9

How high the pressure is depends on two factors:

1.10.3 Use protective goggles

1.10.4 Wear protective gloves and apron

1.10.5 Do not allow liquid refrigerant to come in