D3E8012ED6C-Refrigerant R134a Servicing

Service
Repair Manual
Beetle 2012 ➤ , CC 2010 ➤ ,
CC 2012 ➤ , Eos 2006 ➤ , Golf 1992 ➤ ,
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Refrigerant R134a Servicing

Edition 08.2015
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E8012ED6C

Beetle 2012 ➤ , CC 2010 ➤ , CC 2012 ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
Refrigerant R134a Servicing - Edition 08.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 A/C System, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Additional Information Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 A/C Technology Basic Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Refrigerant R134a Vapor Pressure Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Refrigerant R134a Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 A/C System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 A/C System and Refrigerant R134a Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.12 Refrigerant Circuit, General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Refrigerant Circuit General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Refrigerant Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Refrigerant Circuit Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Refrigerant Circuit Extraction and Filling Valves for Service Station Couplings . . . . . . . . . . 32
2.4 Switches and Sensors on Refrigerant Circuit and Connections . . . . . . . . . . . . . . . . . . . . . . 35
2.5 Electrical Components Not on Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6 Refrigerant Circuit Pressures and Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.7 Refrigerant Circuit with Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.8 Refrigerant Circuit with Restrictor and Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.9 Pressure Gauge, Tests and Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.10 A/C Service and Recycling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.11 Refrigerant Circuit Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Laws and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Laws and Regulations . . . . . . . . . . . . . . . . .V.ol.ks. w. a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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3.2 Recycling and Disposal Regulations lksw . . . . . . . . . . . . . . . . . .es. n.o.t . . . . . . . . . . . . . . . . . . . . . 52
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3.3 Refrigerant Circuit, Converting d bR12 to R134a and Servicing . . . .ua. r.a . . . . . . . . . . . . . . . . . . 53
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3.4 Refrigerant, Keeping Records tho
r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . . . . . . . . . . . . . . 53
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4 Refrigerant Circuit . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . 54
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4.1 A/C System Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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4.2 Refrigerant Circuit, Converting R12 to R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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5 A/C Service Station, Working with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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5.1 Important Information when Working with the A/C Service Station . . . . . . . . . . . . . . . . . . 55
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5.2 A/C Service Station, Connecting for Measuring and Testing . . . . . . . . . . . . . . . . . . . . . . . . 57

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5.3 Discharge Refrigerant Circuit with A/C Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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5.4 Refrigerant Circuit with A/C Service Station, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.5 Refrigerant Circuit with A/C Service Station, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6 A/C System, Operating after Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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5.7 Refrigerant in A/C Service station Container, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.8 A/C Service Station, Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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6 Refrigerant Circuit, Detecting Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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6.1 Searching for Refrigerant Circuit Leaks with Compressed Air or Nitrogen . . . . . . . . . . . . 69
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6.2 Refrigerant Circuit, Tracing Leaks, with Electronic Leak Detector VAG1796 . . . . . . . . . . 72
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6.3 Refrigerant Circuit, Tracing Leaks, with Leak Detection System VAS6196 or Leak Detection
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Kit VAS6201A or Succeeding Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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7 Refrigerant Circuit, Removing Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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7.1 Refrigerant Circuit, Flushing with Compressed Air and Nitrogen . . . . . . . . . . . . . . . . . . . . 81

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7.2 Refrigerant Circuit, Flushing (Cleaning) with Refrigerant R134a . . . . . . . . . . . . . . . . . . . . 83
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8 Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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Contents
8.1 Possible Refrigerant Circuit Concerns . . . . . n. A. G. ..V.o.lk.sw. a.g.en. A. G ....................... 147

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8.2 Odor from the Heater and A/C Unit . V. o.lk.sw . a. . . . . . . . . . . . . . . . o. e.s.no. t .g . . . . . . . . . . . . . . . . 148
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9 Connecting Service Station . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . 151
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9.1 Refrigerant Circuit, Connection au on Low and High Pressure Side . . . . . . . . . .r a.c . . . . . . . . .
th 151
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10 Pressures, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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10.1 Refrigerant Circuit Pressures (with A/C Service Station), Checking . . . . . . . . . . . . . . . . . . 152
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10.2 Checking with Restrictor and Reservoir, with Internally Regulated A/C Compressor . . . . 156
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10.3 Checking with Expansion Valve and Receiver/Dryer, with Internally Regulated A/C ot p
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Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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10.4 Checking with Expansion Valve and Receiver/Dryer, without Regulated A/C Compressor
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........................................................................ 168
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10.5 Checking with Restrictor, Reservoir and A/C Compressor Regulator Valve N280 , Externally
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Regulated A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.6 Checking with Expansion Valve, Receiver/Dryer and A/C Compressor Regulator Valve
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N280 , Externally Regulated A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.7 With Expansion Valve, Receiver/Dryer and Electrically-Driven A/C Compressor . . . . . . . . 186
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11 Components, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

11.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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11.2 Leaking or Damaged Components except A/C Compressor, Reservoir or Receiver/Dryer

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........................................................................ 188
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11.3 A/C Compressor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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11.4 Receiver/Dryer or Reservoir and Restrictor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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12 Tools and Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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12.1 Testing Equipment, Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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13 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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ii Contents
00 – General, Technical Data

1 A/C System, General Information
(Edition 08.2015)
⇒ “1.1 Introduction”, page 1
⇒ “1.2 Additional Information Sources”, page 1
⇒ “1.3 A/C Technology Basic Principles”, page 2
⇒ “1.4 Refrigerant R134a Vapor Pressure Table”, page 3
⇒ “1.5 Refrigerant R134a”, page 4
⇒ “1.6 Refrigerant R134a Characteristics”, page 6
⇒ “1.7 Refrigerant Oil”, page 8
⇒ “1.8 Comfort”, page 9
⇒ “1.9 A/C System Operation”, page 10
⇒ “1.10 Safety Precautions”, page 10
⇒ “1.11 A/C System and Refrigerant R134a Safety Precautions”,
page 14
⇒ “1.12 Refrigerant Circuit, General Precautions”, page 15 agen
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1.1 Introduction yV
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The purpose of this Repair Manual is to provide foremen
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♦ Expert knowledge is achieved by one who has taken part suc‐
ole,
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cessfully in instructional training e.g. AB160 or ST160, includ‐
ing trained experts.
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♦ This Repair Manual also serves as instructional material.
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It should also be available for presentation to the responsible su‐
pervisory agency on request.
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Caution
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Non-approved tools or materials such as leak sealing additives

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Only use tools and materials approved by the manufacturer.

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The warranty is voided if non-approved tools or materials are

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1.2 Additional Information Sources
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♦ Technical Service Handbook outlining action to be taken to

rectify current problems.
♦ For the repair manual for model-specific repair work. Refer to
⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 .
♦ ⇒ Wiring diagrams, Troubleshooting & Component locations
1. A/C System, General Information 1

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♦ Sections of Self StudyhoProgram
ris number 208 are no longer up- ntee
to-date. An example auof this is the statement “The receiver/
t or
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dryer is replaced each time the refrigerant circuit is opened”.
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The following prerequisites apply. Refer to ⇒ page 187 un
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♦ Video programs for in-dealership training.
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♦ Special Tools and Workshop Equipment Catalog.
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♦ Service Organization Volume 1 Additional Equipment.
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♦ Repair manual Air Conditioning with Refrigerant R12. Only
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hardcopies of this manual are available for vehicles through
MY 1993.
1.3 A/C Technology Basic Principles
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⇒ “1.3.1 Physical Principles”, page 2

⇒ “1.3.2 Heat Transfer”, page 2
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⇒ “1.3.3 Pressure and Boiling Point”, page 3

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1.3.1 Physical Principles
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The four known states of water also apply to air conditioning sys‐
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4- solid
When water is heated in a vessel (heat absorption), water vapor

can be seen to rise. If the vapor is further heated through heat
absorption, the visible vapor turns into invisible gas. The process
is reversible. The warmth is extracted from gaseous water, vapor
forms first, then water and then ice.
A - Heat absorption
B - Heat emission
1.3.2 Heat Transfer

Every substance consists of a mass of moving molecules. The
fast moving molecules of a warmer substance give off some of
their energy to the cooler and thus slower molecules. As a result,
the molecular motion of the warmer substance slows down and
that of the colder substance is accelerated. This process contin‐
ues until the molecules of both substances are moving at the
2 Rep. Gr.00 - General, Technical Data

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The boiling point given in tables for a liquid is always referenced
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For example, water boils at a lower temperature the lower the
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pressure.
The vapor pressure curves for water and refrigerant R134a show
rrectness of i
that, at constant pressure, reducing the temperature changes va‐
por to liquid (in the condenser) or that reducing the pressure
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causes the refrigerant to change from liquid to vapor (evaporator).
Vapor pressure curve of water
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C - Vapor pressure curve of water

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Vapor pressure curve of refrigerant R134a

A - Fluid
B - Gaseous
D - Vapor pressure curve of refrigerant R134a
1 - Pressure acting on liquid in bar
2 - Temperature in °C
1.4 Refrigerant R134a Vapor Pressure Ta‐

ble
The vapor pressure table for every refrigerant is published in lit‐
erature for refrigeration system engineers. This table makes it
possible to determine the vapor pressure acting on the column of
liquid in a vessel if the temperature of the vessel is known.
Because each refrigerant has its own characteristic vapor pres‐
sure table, refrigerant can be identified by measuring the pressure
and temperature.
Note
At absolute pressure, 0 bar/psi corresponds to absolute vacuum.

Normal ambient pressure (positive pressure) corresponds to 1
bar (14.5 psi) absolute pressure. 0 pressure corresponds to an
absolute pressure of 1 bar (14.5 psi) on most pressure gauges
(indicated by -1 bar (-14.5 psi) below 0 bar/psi).

Temperature in °C (°F) Pressure in bar (psi) of R134a

-45 (-49) -0.61 (-8.84)
-40 (-40) -0.49 (-7.10)
-35 (-31) -0.34 (-4.93)
-30 (-22) -0.16 (-2.32)
-25 (-13) 0.06 (0.87)
-20 (-4) 0.32 (4.64)
-15 (5) 0.63 (9.13)
-10 (14) 1.00 (14.5)
-5 (23) 1.43 (20.74)
0 (32) 1.92 (27.84)
5 (41) 2.49 (36.11)
10 (50) 3.13 (45.39)
15 (59) 3.90 (56.56)
20 (68) 4.70 (68.16)
25 (77) 5.63 (81.65)
30 (86) 6.70 (97.17)
35 (95) 7.83 (113.56)
40 (104) 9.10 (131.98)
45 (113) 10.54 (152.86)
50 (122) 12.11 (175.64)
55 (131) 13.83 (200.58)
60 (140) 15.72 (227.99)
65 (149) 17.79 (258.02)
70 (158) 20.05 (290.80) agen
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85 (185) 28.14 (408.13)ss c
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90 (194) 31.34 (454.54)

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1.5 Refrigerant R134a ab

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⇒ “1.5.1 Refrigerant R134a Physical Data”, page 4 h re

hole
⇒ “1.5.2 Critical Point”, page 5

spec
es, in part or in w
t to the co
⇒ “1.5.3 Refrigerant R134a Environmental Information”,

page 5
1.5.1 Refrigerant R134a Physical Data

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Vehicle air conditioning systems make use of the vaporization and

condensation process. In this case, one works with a substance
which boils easily, designated as refrigerant.
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The refrigerant employed is tetrafluoroethane R134a, which boils

m
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at -26.5 °C (-15.7 °F) at a vapor pressure of 1 bar (14.5 psi).

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Chemical formula CH2F–CF3 or CF3–CH2F

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Chemical designation Tetrafluoroethane

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Boiling point at 1 bar (14.5 psi) -26.5 °C (-15.7 °F)

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Solidification point -101.6 °C (-150.88 °F) C py
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Critical temperature 100.6 °C (213 °F) p by
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Critical pressure 40.56 bar absolute (588 psi)

equals 39.5 bar pressure (573
psi)
1.5.2 Critical Point

The critical point (critical temperature and critical pressure) is that
above which there is no longer a boundary between liquid and
gas.
A substance above its critical point is always in the gaseous state.
At temperatures below the critical point, all types of refrigerant in
pressure vessels exhibit both a liquid and a gas phase, i.e. there
is a layer of gas above the liquid.
olkswagen AG
As long as there is still gas present in the container nextsto agthe
en AG. V does
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fluid, pressure is dependent on ambient temperature. by
VRefer
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⇒ “1.4 Refrigerant R134a Vapor Pressure Table”, ris page 3 .
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Different types of refrigerant are never to be mixed. Only the re‐
erm
ab
frigerant designated for the corresponding A/C system may be
ility
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used.
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1.5.3 Refrigerant R134a Environmental Infor‐
t to the co
mation
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ss
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f
inform
mer
♦ R134a is a fluorocarbon and contains no chlorine. atio

m
♦ R134a has a shorter atmospheric life span than refrigerant

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R12.
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♦ R134a does not damage the ozone layer. The ozone depletion
i
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potential is zero.
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♦ The greenhouse potential of R134a (Global Warming Potential t. Cop py
= GWP) is approximately 1430 (the GWP of carbon dioxide is
rig
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♦ The global warming effect of R134a is ten times less than that
AG.
of refrigerant R12.

1.6 Refrigerant R134a Characteristics

⇒ “1.6.1 Commercial Names and Designations”, page 6
⇒ “1.6.2 Color”, page 6
⇒ “1.6.3 Vapor Pressure”, page 6
⇒ “1.6.4 R134a Physical Characteristics”, page 6
⇒ “1.6.5 Affect on Metal”, page 7
⇒ “1.6.6 Critical Temperature/Pressure”, page 7
⇒ “1.6.7 Water Content”, page 7
⇒ “1.6.8 Combustibility”, page 7 AG. Volkswagen AG d
agen oes
lksw not
⇒ “1.6.9 Charge Factor”, page by V7
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⇒ “1.6.10 Evidence ofuLeaks”,
thor
page 7 eo
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1.6.1 Commercial Names and Designations
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Refrigerant R134a is currently available under the following trade
itte
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names:
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♦ H-FKW 134a
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♦ SUVA 134a
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spec
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♦ KLEA 134a
t to the co
Note
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♦ Different trade names may be used in other countries.

♦ Of the wide range of refrigerants available, this is the only one
nform
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which may be used for vehicles. The designations Frigen and

Freon are trade names. They also apply to refrigerants which
m
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may not be used in automotive vehicles.

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1.6.2 Color
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Like water, refrigerants are colorless in both vapor and liquid form.
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Gas is invisible. Only the boundary layer between gas and liquid
yi Co
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is visible. (Liquid level in tube of charging cylinder or bubbles in
C py
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sight glass). Refrigerant R134a fluid may appear colored (milky)
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pyri by
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in a sight glass. This cloudiness is caused by partially dissolved
c by lksw
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refrigerant oil and does not indicate a malfunction. Prote AG.
1.6.3 Vapor Pressure

In a partially filled, closed vessel, the quantity of refrigerant evap‐
orating from the surface equals the quantity returning to the liquid
state as vapor particles condense. This state of equilibrium occurs
under the influence of pressure and is often called vapor pres‐
sure. Vapor pressure is dependent on temperature. Refer to
⇒ “1.4 Refrigerant R134a Vapor Pressure Table”, page 3 .
1.6.4 R134a Physical Characteristics

The vapor pressure curves of R134a and other refrigerants are
sometimes very similar, therefore it is not possible to make a cer‐
tain distinction solely by pressure.
With R134a, the A/C compressor is lubricated with special syn‐
thetic refrigerant oils, for example. PAG oils (polyalkylene glycol
oils).

Refrigerant
en AG. V
olkswR134a
agen AG Servicing - Edition 08.2015
ag does
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1.6.5 Affect on Metal
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In its pure state, refrigerant R134a is au
chemically stable and does
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not corrode iron or aluminum.
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Refrigerant impurities such as chlorine compounds however
itte
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cause corrosion of certain metals and plastics. This can lead to
rm
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blockage, leaks or deposits on the A/C compressor piston.
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1.6.6 Critical Temperature/Pressure
h re
hole
spec
The refrigerant R134a remains chemically stable up to a gas
es, in part or in w
t to the co
pressure of 39.5 bar (572.9 psi) (corresponding to a temperature
of 101 °C (213 °F). Above this temperature, the refrigerant de‐
composes. Refer to ⇒ “1.6.8 Combustibility”, page 7 .
rrectness of i
1.6.7 Water Content
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Only very small amounts of water are soluble in liquid refrigerant.

On the other hand, refrigerant vapor and water vapor mix in any
nform
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ratio.
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Only a small drop of water may get into the refrigerant circuit. The
ion in
dryer, dryer bag or dryer cartridge contained in the reservoir can
r
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absorb approximately 7 grams of water. They are then saturated
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and cannot absorb any more water. If water is still present in the
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refrigerant circuit, it flows up to the expansion valve nozzle or re‐
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strictor and becomes ice.

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The air conditioning system stops cooling.
t. rig
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Water destroys the air conditioner as it combines with other im‐
c by lksw
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purities at high pressures and temperatures to form acids. Prote AG.
1.6.8 Combustibility
Refrigerant is non-flammable. It actually has a fire resistant or fire
extinguishing effect. Refrigerant decomposes when exposed to
flames or red-hot surfaces. UV light (occurring for example during
electric welding) also causes refrigerant decomposition. The re‐
sultant decomposition products are toxic and are not to be in‐
haled. However, irritation of the mucous membranes provides an
adequate and timely warning.
1.6.9 Charge Factor

A vessel must have space for vapor as well as liquid. As the tem‐
perature rises, the liquid expands. The space filled with vapor
decreases. At a certain point, there will only be liquid in the vessel.
Beyond this, even a slight increase in temperature causes high
pressure to build up in the vessel as the liquid tries to continue
expanding even though there is not enough space for it. The
forces that result are strong enough to rupture the vessel. To pre‐
vent a vessel from being overfilled, the regulations regarding
compressed gasses specify how many kilograms of refrigerant
that may be added to a vessel per liter of interior volume. The
product of multiplying this charge factor by the internal volume of
the vessel is the permissible capacity. The figure for refrigerant
used in vehicles is 1.15 kg/liter.
1.6.10 Evidence of Leaks

External damage, for example, can cause a leak in the refrigerant
circuit. The small quantity of refrigerant escaping from minor leaks
can be detected for example using an electronic leak detector or
by introducing a leak detection additive into the refrigerant circuit.
Electronic leak detectors are capable of registering leaks with re‐
frigerant losses of less than 5 g per year. Use leak detectors
designed for the type of refrigerant. For example, a leak detector
for R12 refrigerant will not work with R134a because R134a re‐

frigerant has no chlorine atoms so the leak detector will not

respond to it.
1.7 Refrigerant Oil

Refrigerant oil mixes with the refrigerant (about 20 - 40%, de‐
pending on compressor type and amount of refrigerant) and
circulates constantly in the system, lubricating the moving parts.
Special synthetic refrigerant oils, for example, polyalkylene glycol
(PAG) oil, are used in conjunction with R134a air conditioning
systems. This is necessary as mineral oil, for example, does not
mix with R134a. In addition, the materials of the R134a air con‐
ditioning system could be corroded as a result of mixture flowing
through the refrigerant circuit under pressure at high tempera‐
tures or breakdown of the lubricating film in the compressor. Using
non-approved oils can cause the HVAC system to malfunction.
Only use approved oils.
Refer to the Parts Catalog.
Type of oil for R134a in motor vehicles:
wage
nPAG
AG. Volkswagen AG d
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Note utho eo
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♦ Do not store open containers of refrigerant oil because it at‐
ce
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un
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tracts moisture.
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♦ Always keep oil containers sealed.
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♦ Do not use old refrigerant oil over again.

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♦ Used oil disposal: Volkswagen InfoNet; Operations; Hand‐ spec

books & Dealer Literature; Service Handbook; 15. Environ‐

t to the co
ment Protection. Follow the link “Environment Protection in

Market- and Service Operations” under general information;
4. Waste Management; 6. Methods of Disposals; g. Disposing
of Used Refrigerant Oil
rrectne
♦ Used refrigerant oils from systems employing halogenated hy‐

s
drocarbons (at least one hydrogen atom is replaced, for ex‐

s o
ample, with the halogen elements fluorine, chlorine, bromine

cial p
f in
or iodine) are to be disposed of as waste subject to special

form
mer
supervision. They are not to be mixed with other oils or sub‐

atio
stances. Proper storage and disposal must be ensured in line

om
with local regulations. Refer to the chemical-climate protection

c
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provision and the recycling and disposal regulations in Ger‐

te
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many. Different specifications and rules may apply in other

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countries.
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♦ Addresses in other countries can be obtained from the rele‐
co Vo
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vant authorities. Prote AG.
♦ Ester-based oils are only intended for use in large systems,

not in passenger vehicle A/C systems.
Refrigerant Oil Characteristics

The most important properties are a high degree of solubility with
refrigerant, good lubricity, absence of acid and minimal water
content. For these reasons, only certain oils are used. A list of
approved refrigerant oils and capacities can be found in the ve‐
hicle-specific repair manual. Refer to ⇒ Rep. Gr. 00 or ⇒ Rep.
Gr. 87 .
PAG oils, which are appropriate for refrigerant R134a, are highly
hygroscopic and do not mix with other oils. Opened containers
should therefore be closed again immediately to prevent ingress
of moisture. Moisture and acids promote aging of refrigerant oil,

causing it to become dark and viscous as well as corrosive to‐

wards metals.
Note
olkswagen AG
en AG. V
♦ Only use oils approved
olks
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does
no in refrigerant
circuits withd brefrigerant R134a. Refer to the vehicle-specific
yV t gu
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repair manual.
ho
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ee 87 .
t or
au
♦ Used
ss oil disposal: Volkswagen InfoNet; Operations; Hand‐
c a
books & Dealer Literature; Service Handbook; 15. Environ‐
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ment Protection. Follow the link “Environment Protection in
an
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4. Waste Management; 6. Methods of Disposals; g. Disposing
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1.8 Comfort
spec
es, in part or in w
t to the co
Being comfortable while driving leads to better concentration and
safe driving. Air conditioning makes drivers and passengers more
comfortable when temperatures or humidity are high. While open‐
rrectness of i
ing the windows or sunroof or increasing the air flow can make
vehicle occupants more comfortable, it also exposes them to
l purpos
more noise, draughts, exhaust, pollen and dust.

A well-designed heating and air conditioning system can increase
nf
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comfort by controlling the temperature, humidity and air flow in‐
rm
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atio
m
when it is stationary.
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Air conditioning also offers these advantages:

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♦ It cleans the air that enters the vehicle interior. The damp fins
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on the evaporator collect dust and pollen, which is then re‐

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moved by condensation.
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♦ Temperatures in a mid-size vehicle (for example: after a short
ht
pyri by
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drive, outside temperature 30 °C (86 °F) in the shade and the
by c lksw
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vehicle exposed to sunlight). Prote AG.
Area Temperature with A/ Temperature with‐

C System in Celsius out A/C System in
(Fahrenheit) Celsius (Fahren‐
heit)
Head area 23 °C (73 °F) 42 °C (107 °F)
Upper body area 24 °C (75 °F) 40 °C (104 °F)
Foot area 30 °C (86 °F) 35 °C (95 °F)
Environmental Information
Vehicles manufactured after 1992 have air conditioning systems
that use refrigerant R134a. This refrigerant does not contain
chlorine and does not deplete the ozone layer.
Refrigerant R12 was used through 1992. Due to its chlorine
atoms, this CFC has a high potential for depleting the ozone layer
as well as a tendency to increase the greenhouse effect.
Conversions are offered for existing systems filled with the ozone-
depleting substance R12.
Refer to Repair Manual for A/C systems with refrigerant R12. This
repair manual is only available in hard copy.
For environmental protection reasons, refrigerants must not be
released into the atmosphere. For laws and regulations. Refer to
⇒ “3 Laws and Regulations”, page 48 .

1.9 A/C System Operation

The temperature in the passenger compartment depends on the
amount of heat radiated through the windows and conducted agen
AG. Vby
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the metal parts of the body. In hot weather it is possible
Volksw to achieve not
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a more comfortable temperature for the passengersd b by pumping ara
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off some of the heat. thor eo
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As heat spreads into cooler areas, thess passenger compartment
ce
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is equipped with a unit for generating low temperatures. In the
un
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unit, refrigerant is constantly evaporated. The heat required for itte
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this is extracted from the air flowing through the evaporator.
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After absorbing heat, the refrigerant is pumped off through the
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compressor. The action of the A/C compressor increases the heat
h re
content and temperature of the refrigerant. Its temperature is then
hole
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substantially higher than that of the surrounding air.
es, in part or in w
t to the co
The warm refrigerant flows to the condenser. There, the refriger‐
ant dissipates its heat through the condenser to the surrounding
air due to the temperature difference between the refrigerant and
rrectness of i
air.
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The refrigerant thus acts as a heat transfer medium. As it is to be

reused, the refrigerant is returned to the evaporator.
nform
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For this reason all air conditioning systems are based on the re‐
frigerant circulation principle. There are however differences in
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1.10 Safety Precautions
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⇒ “1.10.1 General Safety Precautions”, page 10
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⇒ “1.10.2 Product Characteristics”, page 11
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⇒ “1.10.3 Handling Refrigerant”, page 11
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⇒ “1.10.4 Protective Eyewear”, page 11
agen
Prote AG.
⇒ “1.10.5 Protective Gloves and Clothing”, page 11

⇒ “1.10.6 Fluid Refrigerant and Skin Precaution”, page 11
⇒ “1.10.7 Do Not Breath In Refrigerant Vapor”, page 11
⇒ “1.10.8 Smoking Hazard”, page 11
⇒ “1.10.9 Welding and Soldering on Refrigeration Systems”, page
12
⇒ “1.10.10 Pungent Odor”, page 12
⇒ “1.10.11 First Aid”, page 12
⇒ “1.10.12 Handling Pressure Vessels”, page 12
⇒ “1.10.13 Not Warming Above 50 °C (122 °F)”, page 12
⇒ “1.10.14 Heating Warning”, page 12
⇒ “1.10.15 Empty Containers”, page 13
⇒ “1.10.16 Extraction and Charging System Safety Regulations”,
page 13
1.10.1 General Safety Precautions

♦ As per VBG 20, German industrial liability insurance associa‐
tion.
♦ Follow the instructions for the workplace. They should be dis‐
played in the workplace.

1.10.2 Product Characteristics

Refrigerants used in motor vehicle air conditioning systems be‐
long to the new generation of refrigerants based on chlorine-free,
partially fluorinated hydrocarbons (H-FKW, R134a).
With regard to their physical properties, these are refrigerants
which have been liquefied under pressure. They are subject to
the regulations governing pressure vessels and use is only to be
made of approved and appropriately marked containers.
. Volkswagen AG
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Compliance with specific conditions is required
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1.10.3 Handling Refrigerant
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WARNING
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There is a danger of ice-up.
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The refrigerant can then escape as a fluid or vapor.
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Do not open containers which store refrigerant.
es, in part or in w
t to the co
If refrigerant vessels are opened, the contents may escape in liq‐
uid or vapor form. This process is intensified the higher the
rrectness of i
pressure in the vessel.
l purpos
The pressure level is governed by two factors:

• The type of refrigerant in the vessel. “The lower the boiling
nform
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point, the higher the pressure.”

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• The temperature level. “The higher the temperature, the high‐
on in
er the pressure.”
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1.10.4 Protective Eyewear
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Put on protective goggles. They prevent refrigerant getting into

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the eyes, as this could cause severe injury from exposure to cold. C py
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1.10.5 Protective Gloves and Clothing co Vo
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Prote AG.
Greases and oils dissolve readily in refrigerants. They would
therefore destroy the protective layer of grease if allowed to come
into contact with the skin. Degreased skin is however sensitive to
the cold and germs.
1.10.6 Fluid Refrigerant and Skin Precaution

The refrigerant draws heat for evaporation from the surrounding
area. Even if this is the skin. This may cause extremely low tem‐
peratures. Local frost bite may result (boiling point of R134a: -26.5
°C (-15.7 °F) at ambient pressure).
1.10.7 Do Not Breath In Refrigerant Vapor
Note
If highly concentrated refrigerant vapor escapes, it mixes with the

surrounding air and displaces the oxygen necessary for breath‐
ing.
1.10.8 Smoking Hazard

A burning cigarette can cause refrigerant to decompose. The re‐
sultant substances are toxic and must not be inhaled.

lkswage es n
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1.10.9 Welding and Soldering on Refrigeration
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Before performing welding or soldering work on vehicles near the
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air conditioning system components, extract the refrigerant and
, is n
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remove the residue by flushing with compressed air and nitrogen.
hole
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The products of refrigerant decomposition due to the effect of heat
es, in part or in w
t to the co
are not only toxic, but may also have a highly corrosive effect on
pipes and system components. They mainly take the form of hy‐
drogen fluoride.
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1.10.10 Pungent Odor
l purpos
A pungent odor indicates that the products of decomposition

mentioned above have already formed. Avoid inhaling these sub‐
nform
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stances under all circumstances, as otherwise the respiratory

system, lungs and other organs could be damaged.
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1.10.11 First Aid
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• Following contact with eyes or mucous membranes, immedi‐
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ately rinse with copious amounts of running water and consult
fo
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an eye specialist.
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• Following contact with the skin, immediately remove affected
t. rig
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clothing and rinse skin with copious amounts of water.
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• Following inhalation of highly concentrated refrigerant vapors,
Prote AG.
immediately take the affected person into the open air. Call a
doctor. Administer oxygen in the event of breathing difficulties.
If the affected person has difficulty breathing or cannot
breathe, tip head back and perform mouth to mouth respira‐
tion.
1.10.12 Handling Pressure Vessels

• Secure vessels to prevent them falling over!
Secure upright cylinders to stop them falling over and cylinders
lying flat to stop them rolling away.
• Do not throw vessels!
If dropped, the vessels could be so severely deformed that they
rupture. The refrigerant evaporates immediately, liberating con‐
siderable force. Flying fragments of cylinders can cause severe
injuries.
Valves may break off if cylinders are not properly transported. To
protect the valves, cylinders are only to be transported with pro‐
tective cap screwed on.
• Never store in the vicinity of radiators.
High temperatures may occur next to radiators. High tempera‐
tures are also accompanied by high pressures and the maximum
permissible vessel pressure may be exceeded.
1.10.13 Not Warming Above 50 °C (122 °F)

To avoid possible risk, pressure vessel regulations specify that
vessels are not to be heated to in excess of 50 °C (122 °F).
1.10.14 Heating Warning

Do not heat with a naked flame under any circumstances. Local‐
ized overheating can cause structural changes in the vessel
material, which then reduce its ability to withstand pressure.
There is also a danger of refrigerant decomposition due to local‐
ized overheating.

1.10.15 Empty Containers

Empty refrigerant vessels must always be sealed to prevent the
ingress of moisture. Moisture causes steel vessels to corrode.
This weakens the vessel walls. In addition, rust particles entering
into refrigeration systems from vessels will cause malfunctioning.
1.10.16 Extraction and Charging System Safety

Regulations
• Make sure the shut-off valves are closed before connecting
the charging system to the air conditioning system.
• Make sure the process is finished before disconnecting the
charging system from the A/C system. This prevents any re‐
frigerant from escaping into the atmosphere.
• Once the purified refrigerant from the charging system has
been transferred to an external compressed-gas cylinder,
close the hand shut-off valves at the cylinder and charging
system.
• Do not expose charging system to moisture or use it in a wet
environment.
n AG. Volkswagen A
• Disconnect from
olks
wapower
ge supply before performing
G do
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service work
on the charging
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• Never tho use an extension cable on account of the fire
e o hazard. If
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s use of an extension cable is unavoidable, the minimum
s c
cross-section should be 2.5 mm2.
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• In case of fire, remove the external cylinder.

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• Entrained oil from the air conditioning system drawn by the

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suction unit into the measurement vessel supplied is subse‐

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, is n
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quently to be transferred to a sealed container as it contains

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a small quantity of refrigerant. It must not be released into the

spec
environment.
es, in part or in w
t to the co
• Following shutdown, A/C service station is to be secured to

stop it rolling away.
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rig ht
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by lksw
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Prote AG.

1.11 A/C System and Refrigerant R134a

Safety Precautions
A/C Service Station - VAS6007A- (and further or current A/C
Service Station)
Refer to the Workshop Equipment Catalog.
WARNING
♦ It is recommended to have an eye-flushing bottle availa‐

ble.
♦ If liquid refrigerant has come in contact with your skin and
eyes, immediately flush withlkscool n AG. Volkswagen AG do
wage water for 15 minutes.es n
Afterwards instill eye drops by V and consult a doctor immedi‐t gua
o o
ately, even when the or
is eyes are not hurting.
e d ran
te
h eo
ut
♦ The doctor must ss be informed that the injury was caused
a ra
c
by refrigerant R134a. Should refrigerant come into contact
ce
e
nl
with other parts of the body despite compliance with safety
pt
du
an
itte
regulations, these must likewise be rinsed immediately for
y li
erm
ab
at least 15 minutes with cold water.
ility
ot p
♦ Work on refrigerant system should only be performed in
wit
, is n
h re
ventilated areas (workshops). Turn on the exhaust gas
hole
ventilation system
spec
es, in part or in w
♦ Refrigerant must not be stored in low-lying areas such as
t to the co
cellars or in their entry ways or windowsills.
rrectness of i
• Do not attempt repair on filled air conditioning systems by sol‐
l purpos
dering, brazing or welding. This applies also for welding and

soldering work on the vehicle, in the event that parts of the A/
C system may heat up. When performing paintwork repairs,
nf
ercia
the temperature in the drying booth or preheating zone must

rm
m
not exceed 80 °C (176 °F).

atio
om
n in
c
Reason:
or
thi
te
sd
a
Exposure to heat increases the pressure in the system, which

iv
o
r
rp
cu
could cause the pressure relief valve to open.

o
m
f
en
ng
t.
Corrective measure:
yi Co
Cop py
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– Discharge refrigerant circuit with A/C service station. rig ht
py by
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Prote AG.
Note
Always replace damaged or leaking A/C system components. Do

not attempt to repair them by soldering, brazing or welding.
Refrigerant containers (for example, charging cylinders of A/C

service station) must never be subjected to excessive heat or ex‐
posed to direct sunlight.
Corrective measure:
– Vessels must never be completely filled with liquid refrigerant.
Without sufficient room for expansion (gas cushion), vessels
will rupture with devastating effect in the event of an increase
in temperature. Refer to
⇒ “1.6 Refrigerant R134a Characteristics”, page 6 .
Refrigerant is never to be transferred to systems or vessels in
which air is present.

Corrective measure:
– Evacuate systems and vessels before charging with refriger‐
ant.
1.12 Refrigerant Circuit, General Precautions

• Follow the instructions for the workplace. They should be dis‐
played in the workplace.
• Ensure absolute cleanliness when working.
• Wear work clothing, safety goggles and gloves when working
with refrigerant and nitrogen.
• Turn on the exhaust gas ventilation system
• Use service station to discharge refrigerant circuit, only then
open screw connections and replace malfunctioning compo‐
nents.
• Use caps to seal off opened assemblies and hoses to prevent
ingress of moisture and dirt.
• Make exclusive use of tools and materials intended for refrig‐
erant R134a.
• Be sure to close the container to prevent the refrigerant from
absorbing moisture from the air.
– Refrigerant Circuit, Flushing with Compressed Air and Nitro‐
gen. Refer to
⇒ “7.1 Refrigerant Circuit, Flushing with Compressed Air and
Nitrogen”, page 81 . en AG. V
olkswagen AG
ag does
ol ksw not
– Flush the refrigerant circuit with R134a
yV refrigerant. Refer to gu
db ara
⇒ “7.2 Refrigerant Circuit, Flushing
rise (Cleaning) with Refrigerant nte
R134a”, page 83 autho eo
ra
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On vehicles with A/C compressor without magnetic clutch:
ce
le
un
pt
an
d
itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
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t.
yi Co
Cop py
t. rig
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by
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au ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
th or
ac
Refrigerant R134a Servicing - Edition 08.2015 ss
ce
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un
pt
an
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ab
Note
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♦ The engine should only be started after assembling the refrig‐
h re
ole,
erant circuit.
spec
♦ If possible start engine only with a filled refrigerant circuit.
t to the co
♦ The A/C compressor is always driven by the ribbed belt pulley/
torsion elastic clutch. It does not have a magnetic clutch.
rrectne
♦ If an A/C compressor locks-up the overload protection for the
A/C compressor shaft is triggered. If no bumps are visible on
ss
the ribbed belt pulley/overload protection, the A/C compressor
o
cial p
f
may be blocked. Another indicator is abraded rubber material
inform
in the area of the ribbed belt pulley/overload protection.
mer
atio
m
♦ The A/C compressor is equipped with a protected oil supply,

o
n
c
this prevents A/C compressor damage in the event that the
i
or
n thi
system is empty. This means that approximately 40 to 50
te
sd
va
cm3 of refrigerant oil remains in the A/C compressor.

i
o
pr
cum
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♦ The engine may only be started when the refrigerant circuit is
en
ng
t.
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installed correctly. For example; if the refrigerant pipes are not Cop py
connected to A/C compressor, when the engine is running the
t. rig
gh ht
yri
A/C compressor may heat up (via internal heat generation) so
p by
co Vo
by lksw
much that the A/C compressor will be damaged. cted agen
Prote AG.
♦ A/C Compressor Regulator Valve - N280- is not activated

when the refrigerant circuit is empty and the A/C compressor
idles with the engine.
♦ If it is necessary to start the engine with a discharged refrig‐
erant circuit:
♦ Refrigerant circuit must be fully assembled.
♦ At least a quarter of the prescribed refrigerant oil must be in
the A/C compressor.
♦ Do not let the engine RPM go above 2,000.
♦ The engine should run less than 10 minutes.
O-ring
♦ Only O-rings that are resistant to refrigerant R134a and re‐
frigerant oil must be installed. Color coding of O-rings is no
longer employed. Colored and black O-rings are used.
♦ Ensure inner diameter on seals used is correct.
Refer to ⇒ Rep. Gr. 87 .
♦ O-rings may only be used once.
♦ Before installing, coat the O-rings lightly with refrigerant oil
(PAG oil).
Note
♦ When flushing components with compressed air and nitrogen,

always extract the gas mixture escaping from the components
with suitable extraction units (workshop extraction system).
♦ After engine all service work, screw sealing caps (with seals)
onto all connections with valve and service connections.
Before starting up A/C system. Pay attention to the vehicle-spe‐

cific filling capacities. Refer to ⇒ Rep. Gr. 87 .

Do not fill refrigerant, extract the refrigerant present and refill the
system.
After Charging A/C System
– After installing a new A/C compressor or fresh refrigerant oil
has been filled into compressor (e.g. after blowing through the
A/C system), turn ribbed belt pulley of A/C compressor 10 ro‐
tations by hand before starting the engine. This prevents
damage to the A/C compressor.
– For 5-cylinder and 10-cylinder diesel engines, rotate A/C com‐
pressor 10 rotations by hand at overload protection. Then
install A/C compressor. This prevents damage to the A/C com‐
pressor.
– Start the engine with the A/C turned off ( A/C Clutch - N25-
and A/C Compressor Regulator Valve - N280- are not actu‐
ated).
– Following engine idling speed stabilization, switch on A/C AG. Volkswagen AG d
compressor and run it for at least 10 minutes at idlingagen
ksw speed
oes
ol not
with maximum cooling output. db
yV gu
ar
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ris tee
tho or
au ac
ss
ce
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un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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fo
en
ng
t.
yi Co
Cop py
t. rig
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Prote AG.

Refrigerant R134a Servicing - Edition
wage 08.2015
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
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itte
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rm
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pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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en
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by
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Prote AG.

2 Refrigerant Circuit General Informa‐

tion
⇒ “2.1 Refrigerant Circuit Components”, page 19
⇒ “2.2 Refrigerant Circuit Design”, page 31
⇒ “2.3 Refrigerant Circuit Extraction and Filling Valves for Service
Station Couplings”, page 32
⇒ “2.4 Switches and Sensors on Refrigerant Circuit and Connec‐
tions”, page 35
⇒ “2.5 Electrical Components Not on Refrigerant Circuit”,
page 39
⇒ “2.6 Refrigerant Circuit Pressures and Temperatures”,
page 41
⇒ “2.7 Refrigerant Circuit with Expansion Valve”, page 41
AG. Volkswagen
⇒ “2.8 Refrigerant Circuit with Restrictor
ksw
agen and Reservoir”,
AG do
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page 43 y Vol ot g
ua
db e ran
ris tee
⇒ “2.9 Pressure Gauge,
ut
ho Tests and Measurements”, page 45 or
sa ac
⇒ “2.10 A/C Service
s
and Recycling Units”, page 46
ce
le
un
pt
⇒ “2.11 Refrigerant Circuit Repair Information”, page 47
an
d
itte
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rm
ab
2.1 Refrigerant Circuit Components
pe
ility
ot
wit
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⇒ “2.1.1 Refrigerant Circuit Component Arrangement”,
h re
hole
page 19
spec
es, in part or in w
⇒ “2.1.2 A/C Compressor with A/C clutch:”, page 20

t to the co
⇒ “2.1.3 A/C Compressor without Magnetic Clutch”, page 21
⇒ “2.1.4 A/C without Magnetic Clutch with Torsion-Elastic Clutch”,
rrectness of i
page 22
l purpos
⇒ “2.1.5 Electrically-Driven A/C Compressor for High Voltage

System”, page 23
nform
ercia
⇒ “2.1.6 Condenser”, page 25

m
a
com
ti
⇒ “2.1.7 Evaporator”, page 25

on in
r
te o
thi
⇒ “2.1.8 Reservoir”, page 26

s
iva
do
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rp
⇒ “2.1.9 Restrictor”, page 27

um
fo
en
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t.
⇒ “2.1.10 Receiver/Dryer”, page 27
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⇒ “2.1.11 Expansion Valve”, page 28
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pyri by
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⇒ “2.1.12 O-Ring”, page 29 Prote
cted AG.
agen
⇒ “2.1.13 Refrigerant Circuit Pipes and Hoses”, page 30

⇒ “2.1.14 Pressure Relief Valve”, page 30
2.1.1 Refrigerant Circuit Component Arrange‐

ment
Caution

2. Refrigerant Circuit General Information 19


used.
• All components of the refrigerant circuit submitted for quality

AG. Volkswagen AG d
observation are always to be sealed
lksw
agen(use original sealing
oescaps
not
of original part). d byV
o gu
a
e ran
ris tee
• Replace damaged or thleaking
o components of refrigerant circuit. or
s au
Refer to ⇒ “11 Components, Replacing”, page 187 . ac
s
ce
e
nl
• To date, the original parts (compressor, reservoir, receiver/
pt
du
an
dryer, evaporator and condenser) have been filled with nitro‐
itte
y li
erm
gen gas. This charge is being gradually discontinued. There
ab
ility
is little or no pressure equalization when removing the sealing
ot p
wit
plugs from the original part.
, is n
h re
hole
High pressure side are the condenser, receiver/dryer and restric‐
spec
tor or expansion valve to separate the high and low pressure liquid
es, in part or in w
t to the co
ends.
High pressure results from the restrictor or expansion valve form‐
ing a constriction and causing the refrigerant to accumulate, thus
rrectness of i
leading to an increase in pressure and temperature.
l purpos
Excess pressure results if too much refrigerant or refrigerant oil

is used, the condenser is contaminated, the coolant fan is mal‐
nform
functioning, the system is blocked or if there is moisture in the
ercia
refrigerant circuit (the restrictor or expansion valve freezes).

m
at
om
io
Low pressure side are the evaporator, reservoir, evaporator tem‐
n
c
in t
perature sensor and compressor to separate high and low pres‐
or
his
e
sure gas ends.

at
do
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cum
A drop in system pressure can occur due to loss of refrigerant,

for
en
g
restrictor or expansion valve (restriction not given), A/C compres‐

n
t.
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sor malfunction or iced evaporator. Cop py
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rig ht
2.1.2 A/C Compressor with A/C clutch:
py by
co Vo
by lksw
cted agen
Prote AG.
Caution

used.

observation are always to be sealed (use original sealing caps
of original part).
• Replace damaged or leaking components of refrigerant circuit.
Refer to ⇒ “11 Components, Replacing”, page 187 .

The engine drives the A/C compressor via a ribbed belt.

An electromagnetic clutch installed on the A/C compressor cre‐
ates a frictional connection between the ribbed belt pulley and A/
C compressor crankshaft when the air conditioning system is
switched on.
If the A/C compressor sticks, a fuse installed in the compressor
ribbed belt pulley releases the electromagnetic clutch and pro‐
tects the ribbed belt pulley from overload.
The A/C compressor extracts the refrigerant gas from the evap‐
orator, compresses it and relays it to the condenser.
Note
♦ The A/C compressor contains refrigerant oil, which can be

mixed with refrigerant R134a under any temperature.
♦ The type plate lists the type of refrigerant required for the A/C
compressor. A regulator valve regulates pressure within the
specified range (control characteristics) on the low pressure
side.
♦ So that the A/C compressor does not get damaged when the
refrigerant circuit is empty, the A/C clutch is turned off and the
A/C Compressor Regulator Valve - N280- is no longer activa‐
ted (A/C compressor runs at idle with engine).
2.1.3 A/C Compressor without Magnetic

Clutch
Caution
Non-approved tools or materials such as leak sealing

swagadditives
en AG. V
olkswagen AG
does
by
Volk not
gu
d ara
se nte
Only use tools and materials approvedthby
or the manufacturer.
i
e or
au ac
The warranty is voided if non-approved
ss tools or materials are
ce
le
used.
un
pt
an
d
itte
y li
erm
ab
ility

ot p

wit
is n
h re
of original part).
ole,
spec

t to the co

rrectne

s

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

The engine drives the A/C compressor via a ribbed belt.

Overload protection (shear) installed in the A/C compressor rib‐
bed belt pulley releases when the compressor stops and protects
the ribbed belt pulley from being overloaded.
Note

side.
♦ On this A/C compressor, the control valve is activated from
outside.
♦ The engine should only be started if the refrigerant circuit is
completely assembled. Refer to
⇒ “1.12 Refrigerant Circuit, General Precautions”, page 15 .
2.1.4 A/C without Magnetic Clutch with Tor‐

sion-Elastic Clutch
Caution
. Volkswagen AG
gen AG
Non-approved tools or materialsVol
such
ksw as leak sealing additives
a does
not
can cause damage or malfunctions
ed by in the system. gu
ara
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Only use tools and materials
au
th approved by the manufacturer. eo
ra
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pt
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du
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wit
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of original part).
hole
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es, in part or in w

t to the co

rrectness of i

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nf
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m
atio
om
n in
or c
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te
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22
AG.
Rep. Gr.00 - General, Technical Data
The A/C compressor is driven directly by the power steering vane

pump.
On the A/C compressor driveshaft, there is an overload protection
that shears off when the compressor is blocked so that the power
steering vane pump remains functional.
Note

side.
♦ On this A/C compressor, the control valve is activated from
outside.
♦ The A/C compressor is equipped with a protected oil supply, G. Volkswagen AG d
this prevents A/C compressor damage in the event that the lkswagen A oes
not
system is empty. This means that approximately 40 to 50 by
Vo gu
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cm of refrigerant oil remains in the A/C compressor.
ho
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2.1.5 Electrically-Driven A/C Compressor for

un
pt
an
d
itte
High Voltage System
y li
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Caution
h re
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spec
es, in part or in w
t to the co
rrectness of i
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of original part).
tion in
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te o

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en
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t.
dryer, evaporator and condenser) have been filled with nitro‐ op
yi Co
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Refrigerant R134awServicing
agen
AG. Vo-lkEdition 08.2015
swagen AG
doe
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Vol t gu
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WARNING
autho eo
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♦ Hybrid vehicles have a high voltage system. Health risks

un
pt
to persons with life assist systems.
an
d
itte
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rm
ab
♦ It will also be necessary to work on the high voltage sys‐
pe
ility
tem when performing the following procedures. Any work
ot
wit
, is n
to be performed on a vehicle with a high voltage electrical
h re
system may only be performed by technician specifically
hole
spec
trained to work on this system. The work must be per‐
es, in part or in w
formed by a certified high voltage technician.
t to the co
♦ Follow the General Warnings for working on the high volt‐
age electrical system ⇒ Electric Drive; Repair Group 93;
rrectness of i
General Warnings for Working on High Voltage Electrical
Systems.
l purpos
♦ De-energize the high voltage system. Refer to Electric

Drive; Repair Group 93; High Voltage System, De-Ener‐
nform
ercia
gizing.
m
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WARNING
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The electrically-driven A/C compressor has a different refrig‐

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erant oil! t. Cop py
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See vehicle-specific repair manual. yri
p by
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Prote AG.
Electrically-driven A/C compressor
WARNING
Danger of short circuit

The A/C compressor works with 288 volts at 800 to 8,600 RPM.
Do not touch the A/C compressor when starting the drive gen‐
erators, danger of short circuit.
Note

compressor. The RPM controls the delivery.
♦ The A/C compressor has a relief valve.

2.1.6 Condenser
Caution

used.

of original part).
The condenser conducts heat from compressed refrigerant gas
to the ambient air.
This condenses the refrigerant gas to fluid.
AG. Volkswagen AG d
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aut ra
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2.1.7 Evaporator
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Caution
es, in part or in w
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rrectness of i

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used.
nform
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at
om

on
c
in t

or
his
e
of original part).
at
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um
for
en
g

n
t.
yi Co
Cop py
• To date, the original parts (compressor, reservoir, receiver/ ht. rig
rig ht
dryer, evaporator and condenser) have been filled with nitro‐ py by
co Vo
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AG.

The fluid refrigerant evaporates in the evaporator pipe coils. The

heat required for this is extracted from the air flowing on the evap‐
orator ribbing. The air cools off. Refrigerant evaporates and is
extracted with the absorbed heat by the A/C compressor.
A defined amount of refrigerant is supplied to the evaporator by
a restrictor or expansion valve. In systems with expansion valve,
the throughput is regulated so that only gaseous refrigerant es‐
capes the evaporator outlet. n AG. Volkswagen A age G do
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2.1.8 Reservoir
itte
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ole,
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t to the co
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used.
ss o
cial p
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nform
mer
of original part).
atio
om
n
c

i
or
n thi
e

t
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pr

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en

ng
t.
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gen gas. This charge is being gradually discontinued. There Cop py
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plugs from the original part. op Vo
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The reservoir collects the vaporized and gaseous mixture coming
AG.
from the evaporator to ensure the compressor only receives gas‐

eous refrigerant. Gaseous refrigerant is formed from the vapor.
The refrigerant oil flowing in the circuit is not retained in the res‐
ervoir as it has an oil drilling.
Moisture which has entered the refrigerant circuit during repairs
will be collected by a filter (desiccant bag) in the reservoir.
Gaseous refrigerant is extracted with oil by the A/C compressor.
Note
♦ Replace the reservoir if refrigerant circuit has been open for a

long time (beyond the normal repair time) and moisture has
penetrated inside, or if required due to a specific complaint.
♦ Remove sealing plugs -A- and -B- only immediately prior to
installing.
♦ A desiccant bag in an unsealed reservoir is saturated with
moisture after a short period of time and unusable.
♦ When installing, note arrow for direction of flow if necessary.

2.1.9 Restrictor
Caution AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
Non-approved tools or materials such as leak sealingoradditives
ise nte
eo
can cause damage or malfunctions in the system.aut h
ra
c
ss
ce
le
un
pt
an
d
itte
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erm
used.
ab
ility
ot p
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is n
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ole,
spec
of original part).
t to the co
rrectne
ss
o
cial p
f
inform
mer
atio
m
The restrictor creates a constriction. This restriction reduces the

o
n
c
flow and creates high and low pressure sides in the refrigerant
i
or
n thi
circuit. Before the restrictor the refrigerant which is under a higher
te
sd
a
pressure is warm. After the restrictor the refrigerant which is under

iv
o
pr
c
a low pressure is cold. Before the restriction there is a strainer for
um
r
fo
en
ng
contaminants and after the restriction there is a strainer, to atom‐

t.
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ize the refrigerant before it reaches the evaporator. Cop py
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Note
agen
Prote AG.
♦ Arrow -A- on restrictor points to evaporator.

♦ Replace after each opening of the circuit.
♦ Note different versions.

2.1.10 Receiver/Dryer
Caution

used.

of original part).


The receiver/dryer collects the fluid drops and then directs them
in an uninterrupted stream to the expansion valve. Moisture which
has entered the refrigerant circuit during repairs will be collected
by the dryer bag in the receiver/dryer.
Note
♦ Replace the receiver/dryer if refrigerant circuit has been open

for a long time (beyond the normal repair time) and moisture
has penetrated inside, or if required due to a specific com‐
plaint. Refer to ⇒ “11 Components, Replacing”, page 187 .
♦ Only remove sealing plugs shortly before installation.
♦ A dryer bag in an unsealed receiver/dryer is saturated with
moisture after a short period of time and unusable.
♦ When installing, note arrow for direction of flow if necessary.
The new generation of receivers/dryers are installed directly on

the condenser and contain a dryer cartridge.
Note
♦ Replace the dryer cartridge if refrigerant circuit has been open

for a long time (beyond the normal repair time) and moisture
has penetrated inside, or if required due to a specific com‐
plaint. Refer to ⇒ “11 Components, Replacing”, page 187 .
♦ Remove dryer cartridge from packaging shortly before instal‐
lation. n AG. Volkswagen AG do
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♦ The dryer cartridge becomes saturated byV
o with moisture and un‐ ot g
ua
usable after a short time in ano
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2.1.11 Expansion Valve

un
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Caution
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used.
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of original part).
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tion in

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Prote AG.
The expansion valve atomizes the streaming refrigerant and con‐

trols the flow quantity so that the vapor is gaseous only at the
evaporator outlet, depending on the heat transmission.
2.1.12 O-Ring
Caution

can cause damage or malfunctions in the system. gen AG
. Volkswagen AG
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The warranty is voided if non-approved tools uor
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of original part).
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These o-rings seal off the connection points between individual

components of the refrigerant circuit.
nf
ercia
or
Only O-rings that are resistant to refrigerant r134a and refrigerant
m
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oil must be installed. Make sure they are original replacement atio
om
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parts.
or c
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O-ring:
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• Always use only once. Cop py
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• Make sure diameters -a- and -b- are correct. p by
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• Coat with refrigerant oil before installing Prote AG.
Note
The color coding of refrigerant circuit o-rings with R134a has been
discontinued. Colored and black O-rings are used.


2.1.13 Refrigerant Circuit Pipes and Hoses
Caution

used.

of original part).
The mixture of refrigerant oil and refrigerant r134a corrodes cer‐
tain metals (e.g. copper) and alloys and dissolves some hose
materials. Therefore use original replacement parts only.
Pipes and hoses are joined by threaded connections or special
plug connectors. gen AG
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Observe specified torque for threaded connections, use appro‐
ce
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priate release tools for plug connectors.

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2.1.14 Pressure Relief Valve

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Caution
spec
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dryer, evaporator and condenser) have been filled with nitro‐ ht. rig
rig ht
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is little or no pressure equalization when removing the sealing Prote
cted AG.
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Beetle 2012 ➤ , CC 2010 ➤ , CC r a 2012 ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
s c
s Refrigerant R134a Servicing - Edition 08.2015
ce
le
un
pt
an
d
The pressure relief valve is installed on the A/C compressor or
itte
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rm
receiver/dryer.
ab
pe
ility
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At a pressure of approximately 38 bar (551 psi) positive pressure,
wit
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valve opens and closes again once pressure has dissipated (ap‐
h re
hole
proximately 30 bar (435 psi)).
spec
es, in part or in w
Refrigerant does not escape completely.
t to the co
Depending on the version, a transparent plastic disc may be in‐
stalled which breaks off as soon as the valve is activated.
rrectness of i
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nform
ercia
2.2 Refrigerant Circuit Design

m
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⇒ “2.2.1 Refrigerant Circuit with Expansion Valve and Evapora‐
n in
r
te o
tor”, page 31
thi
s
iva
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⇒ “2.2.2 Refrigerant Circuit with Restrictor and Reservoir”,
r
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page 31
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op
2.2.1 Refrigerant Circuit with Expansion Valve
C py
ht. rig
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and Evaporator
py by
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Prote AG.
1- Evaporator
2- Expansion Valve
3- Valve for extracting, filling and measuring
4- Receiver/dryer with dryer bag/dryer cartridge
5- Condenser
6- A/C Compressor
Note
Arrows point in direction of refrigerant flow.
2.2.2 Refrigerant Circuit with Restrictor and

Reservoir
1- A/C Compressor
2- Condenser
3- Restrictor
4- Evaporator
5- Reservoir with dryer bag
Note

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, Golf 1992 ➤ , G ...
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Refrigerant
s R134a Servicing - Edition 08.2015
ce
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2.3 Refrigerant Circuit Extraction and Filling
y li
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Valves for Service Station Couplings
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⇒ “2.3.1 Evacuating and Charging Valve with Schrader Valve”,
hole
page 32
spec
es, in part or in w
⇒ “2.3.2 Evacuating and Charging Valve, High Pressure Side”,
t to the co
page 32
⇒ “2.3.3 Evacuating and Charging Valve, Low Pressure Side”,
rrectness of i
page 33
l purpos
2.3.1 Evacuating and Charging Valve with

Schrader Valve
nf
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orm
Special tools and workshop equipment required
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n in
♦ Torque Wrench 1783 - 2-10Nm - VAG1783- with Torque
or c
thi
Wrench 1783 - 1/4" Drive Ratchet - VAS6234-
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WARNING
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Cop py
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Refrigerant will leak out if refrigerant circuit is not discharged.
by c lksw
cted agen
Prote AG.
Refrigerant must be extracted before opening refrigerant cir‐
cuit. If refrigerant circuit is not opened within 10 minutes of
extraction, pressure may form in refrigerant circuit due to evap‐
oration. Extract the refrigerant once more.
• Only valves and connections that are resistant to refrigerant

R134a and refrigerant oil must be installed.
• Different connections (outer diameter) for high pressure and
low pressure side.
• Always screw on sealing caps.
Allocation in vehicle.
Refer to ⇒ Rep. Gr. 87 for the vehicle-specific repair manual.
Note

♦ Use a suitable Refrigerant Sockets - T10364- to loosen the
Schrader valve insert. Refer to
⇒ Fig. ““ Refrigerant Sockets -T10364- for the high pressure/
low pressure side service connection valves in the refrigerant
circuit”“ , page 201
A - Service connection (soldered in)

B - Schrader valve insert (2.4 ± 0.2 Nm)
C - O-ring (belongs to the valve)
D - Sealing cap with seal
2.3.2 Evacuating and Charging Valve, High

Pressure Side


WARNING

Refrigerant must be extracted before opening refrigerant cir‐

R134a and refrigerant oil must be installed. agen
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• Different connections (outer diameter) for highd bpressure
yV and ua
ran
low pressure side. horise tee
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• Always screw on sealing caps. ss
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Note
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rrectness of i
valve insert. Refer to
l purpos

circuit”“ , page 201
nform
ercia
1- Socket with external and internal threads

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2- O-ring: 10.8 mm; 1.8 mm identification: black or with colors
n in
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3- Valve with M12 x 1.5 mm external threads and groove for
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O-ring (7 ± 1 Nm)
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4- O-ring for the cap: 10.8 mm; 1.8 mm identification: black or

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with colors Cop py
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5- Cap py by
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2.3.3 Evacuating and Charging Valve, Low

Pressure Side

WARNING
There is a danger of ice-up. olkswage es n
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Refrigerant will leak out if refrigerant circuit is not rdischarged.
ise
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or
Refrigerant must be extracted before opening aurefrigerant cir‐ ac
ss
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R134a and refrigerant oil must be installed.
hole
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• Different connections (outer diameter) for high pressure and
es, in part or in w
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low pressure side.
• Always screw on sealing caps.
rrectness of i
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nform
ercia
Note
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valve insert. Refer to
en
ng
t.
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Co
op py
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circuit”“ , page 201 p by
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cted agen
Prote AG.
1- Connection with external thread and groove for O-ring
2- O-ring: 7.6 mm; 1.8 mm identification: black or with colors
3- Valve with M10 x 1.25 mm external threads and groove for
O-ring (7 ± 1 Nm)
4- O-ring for the cap: 7.6 mm; 1.8 mm identification: black or
with colors
5- Cap

2.4 Switches and Sensors on Refrigerant

Circuit and Connections
⇒ “2.4.1 A/C Refrigerant High Pressure Switch F23 ”,
page 35
⇒ “2.4.2 Magnetic Clutch High Pressure Switch F118 ”,
page 35
⇒ “2.4.3 A/C Refrigerant Low Pressure Switch F73 ”, page 36
⇒ “2.4.4 Refrigerant Circuit Connections with Valve for Switches”,
page 36
⇒ “2.4.5 A/C Pressure Switch F129 ”, page 37
⇒ “2.4.6 High Pressure Sensor G65 ”, page 37
⇒ “2.4.7 A/C Pressure/Temperature Sensor G395 ”, page 38
⇒ “2.4.8 A/C Compressor Regulator Valve N280 ”, page 38
2.4.1 A/C Refrigerant High Pressure Switch -

F23- swa
gen AG
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For switching pressures, removing and installing switches and

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switch arrangement and version, see vehicle-specific refrigerant

an
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circuit.
erm
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ility
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Function:
spec
es, in part or in w
Switches the coolant fan to the next higher level when the pres‐
t to the co
sure in the refrigerant circuit increases (approximately 16 bar (232

psi)).
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
2.4.2 Magnetic Clutch High Pressure Switch -

p
cum
for
F118-
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ng
t.
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Cop py
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pyri by
Vo
Note
o
by c lksw
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Prote AG.

circuit.

Function:
Switches off A/C compressor when there is excessive pressure
in the refrigerant circuit (approximately 32 bar (464 psi)).
2.4.3 A/C Refrigerant Low Pressure Switch -

F73-
Note

circuit.

Function:
Switches off A/C compressor when there is excessive pressure
in the refrigerant circuit (approximately 2 bar (29 psi)).
AG. Volkswagen AG d
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2.4.4 Refrigerant Circuit Connections with

e
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Valve for Switches

itte
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Note
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circuit.
rrectness of i

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WARNING
nform
ercia

m
at
om
io

n
c
in t
or
his
e
Refrigerant must be extracted before removing valve -C-. If re‐

at
do
riv
frigerant circuit is not opened within 10 minutes of extraction,

p
cum
or
pressure may form in refrigerant circuit due to evaporation.

f
en
g
Extract the refrigerant once more.

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

• Different threads for switch on high pressure and low pressure

sides.
• Only valves and o-rings that are resistant to refrigerant R134a
and refrigerant oil must be installed.
A - Connection (soldered in)
B - O-Ring
C - Valve (with o-ring)
2.4.5 A/C Pressure Switch - F129-
Note AG. Volkswagen AG d

agen oes
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For switching pressures,iseremoving
db
y
and installing switches anduaran
switch arrangement and ho version, see vehicle-specific refrigerant
r tee
ut or
circuit. ss
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This pressure switch has 3 functions:
ility
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1. Switches the coolant fan to the next higher level when the
wit
, is n
h re
pressure in the refrigerant circuit increases (approximately 16 bar
hole
(232 psi)).
spec
es, in part or in w
2. Switches off A/C system if pressure is excessive (approximate‐

ly 32 bar (464 psi)), for example. because of insufficient engine t to the co
cooling. rrectness of i
3. Switches off A/C system if pressure is insufficient (approxi‐

mately 2 bar (29 psi)), for example. loss of refrigerant.
l purpos
nform
ercia
Note
m
at
om
A/C Pressure Switch - F129- replaces the A/C Refrigerant High

ion
c
Pressure Switch - F23- , A/C Refrigerant Low Pressure Switch -

in t
or
his
e
F73- and the Magnetic Clutch High Pressure Switch - F118- .

at
do
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cum
for
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ng
t.
2.4.6 High Pressure Sensor - G65-
yi Co
Cop py
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pyri by
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by
Note cted agen
Prote AG.

circuit.

This High Pressure Sensor - G65- is installed in place of an A/C

Pressure Switch - F129- .
The high-pressure sensor generates a square-wave signal or a
data telegram when voltage is applied. This signal changes along
with pressure in the system.
The downstream control modules (coolant fan control module,
ECM), Front A/C Display Control Head - E87- or Climatronic Con‐
trol Module - J255- , etc.) use this signal to calculate pressure in
the refrigerant circuit and to activate the coolant fans and motor
and A/C Clutch - N25- or to change the A/C Compressor Regu‐
lator Valve - N280- activation.
2.4.7 A/C Pressure/Temperature Sensor -

G395-
Note

switch arrangement andlksversion,
wage see vehicle-specific
es n refrigerant
circuit. db
yV
o ot g
ua
r e an
ris tee
tho or
Refer to ⇒ sRep.
au Gr. 87 . ac
s
ce
le
un
pt
WARNING
an
d
itte
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erm
ab

ility
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wit
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h re
ole,
spec
The refrigerant must be extracted before the A/C Pressure/

Temperature Sensor - G395- is removed. If refrigerant circuit

t to the co
is not opened within 10 minutes of extraction, pressure may

form in refrigerant circuit due to evaporation. Extract the re‐
frigerant once more.
rrectnes
This A/C Pressure/Temperature Sensor - G395- is installed in‐

s o
cial p
stead of the High Pressure Sensor - G65- or A/C Pressure Switch

inform
- F129- .
mer
atio
The pressure signal is always being checked, where the temper‐

om
ature signal is only checked at temperatures above 0 °C (32 °F).

c
i
or
n thi
te
The Climatronic Control Module - J255- operates with this infor‐

sd
iva
o
r
mation and controls the coolant fans and activation of the A/C
p
cum
r
fo
Compressor Regulator Valve - N280- .

en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
2.4.8 A/C Compressor Regulator Valve -

N280-
Note

circuit.

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➤ , G ...
a
ss Refrigerant
c R134a Servicing - Edition 08.2015
ce
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The regulator valve is implemented into the compressor. It is ac‐
ility
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tivated by the A/C Display Control Head - E87- or Climatronic
wit
, is n
Control Module - J255- . Pressure on the low pressure side is
h re
influenced via the regulator valve and thus regulates the temper‐
hole
spec
ature in the evaporator.
es, in part or in w
t to the co
Note
rrectness of i
The A/C Compressor Regulator Valve - N280- is a component of
l purpos
the A/C compressor and cannot be replaced separately.
nform
mercia
at
2.5 Electrical Components Not on Refriger‐
om
ion
c
in t
ant Circuit
or
his
ate
do
riv
⇒ “2.5.1 A/C Programmer J127 ”, page 39

p
cum
for
en
g
⇒ “2.5.2 Coolant Fan Control Module J293 ”, page 39

n
t.
yi Co
Cop py
.
⇒ “2.5.3 Coolant Fan Control Module J293 ”, page 40
ht rig
rig ht
py by
co Vo
⇒ “2.5.4 A/C Evaporator Temperature Switch E33 ”, page 40
by lksw
cted agen
Prote AG.
⇒ “2.5.5 Evaporator Vent Temperature Sensor G263 or Evapo‐
rator Temperature Sensor G308 ”, page 41
2.5.1 A/C Programmer - J127-

This programmer switches the refrigerant flow direction through
the second evaporator if the temperature on the cooling fins on
the second evaporator lowers to the freezing point for water (icing
protection).
2.5.2 Coolant Fan Control Module - J293-
Note
There are different construction styles.

This control module switches on and off the A/C clutch and there‐
fore the A/C compressor. It switches the coolant fan and calcu‐
lates the pressure in the refrigerant circuit on vehicles with a High
Pressure Sensor - G65- or A/C Pressure/Temperature Sensor -
G395- .
2.5.3 Coolant Fan Control Module - J293-
Note
Available in different construction styles, some installed on cool‐

ant fan -arrows-.
This control module switches on and off the A/C clutch and there‐
fore the A/C compressor. It switches the coolant fan and calcu‐
lates the pressure in the refrigerant circuit on vehicles with a High
Pressure Sensor - G65- or A/C Pressure/Temperature Sensor -
G395- .
AG. Volkswagen AG d
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2.5.4 ss
A/C Evaporator Temperature Switch - c
ce
le
E33-
un
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Function:
ility
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The A/C Evaporator Temperature Switch - E33- determines the

wit
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temperature between the evaporator cooling fans. It prevents the

ole,
possibility of ice building up between the evaporator cooling fans

spec
because the current entry to the condenser magnetic clutch is

t to the co
interrupted when the temperature on the cooling fins lowers to the

freezing point for humidity.
The insertion depth of the feeler tube is marked or indicated in the
rrectne
repair manual. Refer to ⇒ Rep. Gr. 87 .

ss o
cial p
Note
inform
mer
Installed on VW vehicles with the A/C compressor drive above the

atio
m
ribbed belt
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5.5 Evaporator Vent Temperature Sensor -

G263- or Evaporator Temperature Sen‐
sor - G308-
Function:
The Evaporator Vent Temperature Sensor - G263- or Evaporator
Temperature Sensor - G308- determines the temperature behind
the evaporator. This value goes to the air conditioning control
module and serves as a reference signal for regulating the A/C
compressor. This prevents the evaporator from icing up. n AG. Volkswagen AG do
wage e ks s no
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2.6 Refrigerant Circuit Pressures and Tem‐
t
au ra
c
ss
peratures
ce
e
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itte
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WARNING
ility
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wit
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When performing work on refrigerant circuit, observe all gen‐
h re
hole
erally applicable safety precautions and pressure vessel reg‐
spec
ulations.
es, in part or in w
t to the co
The pressures and temperatures in the refrigerant circuit depend
rrectness of i
on the current operating conditions (such as engine RPM, coolant
fan level 1, 2 or 3, engine temperature, A/C compressor on or off)
l purpos
as well as on the effects of outside influences (such as outside

temperature, humidity, desired cooling output).
nform
ercia
In vehicles with A/C Compressor Regulator Valve - N280- , the

pressure is modified on the low pressure side by the valve.
m
at
om
ion
For this reason, values indicated in the following table are valid
c
in t
or
only as reference points. They are attained at an engine speed of
his
ate
1,500 to 2,000 RPM and an ambient temperature of 20 °C (68 °
do
priv
c
F) after about 20 minutes.
um
for
en
ng
t.
yi
The connections provided for measuring pressure for the man‐
Co
op py
ometer battery are located in the vehicle-specific refrigerant cir‐ t. C rig
gh ht
cuit. pyri by
Vo
o
by c lksw
cted agen
Refer to ⇒ Rep. Gr. 87 . Prote AG.
At 20 °C (68 °F) with the engine not running, the pressure in the
refrigerant circuit is 4.7 bar (68.17 psi). Refer to
⇒ “1.4 Refrigerant R134a Vapor Pressure Table”, page 3 .
2.7 Refrigerant Circuit with Expansion Valve

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

AG. Volkswagen AG d
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Component Aggregate Pressure bar (psi) Positive Temperature in Degrees

State of Re‐ Pressure Celsius (Fahrenheit)
frigerant
-1- Evaporator, from input to Vapor Approximately 1.2 (17.4) 1) Approximately -7 (20)2)
output
(Approximately 1.8 (26.1))3) Approximately -1 (30)3)
-2- A/C compressor A-side Gas Approximately 1.2 (17.4) 1) Approximately -1 (30)
-3- A/C compressor B-side Gas Approximately 14 (203.1) Approximately 65 (149)
-4- Condenser Gas, vapor, Approximately 14 (203.1) Approximately 55 (131) at
fluid outlet
-5- Receiver Fluid Approximately 14 (203.1) Approximately 55 (131)
-6- Extraction and filling valve, Fluid Approximately 14 (203.1) Approximately 55 (131)
B-side
-7- Expansion valve Fluid, re‐ Approximately 14 (203.1) Approximately 55 (131), re‐
leased as va‐ duced to -7 (20)
por
-8- Extraction and filling valve, Gas Approximately 1.2 (17.4) 1) Approximately -7 (20)2)
A-side

1) Pressure in refrigerant circuits is maintained at approximately 2 bar (29 psi), regulated by A/C compressor, even though heat transfer
changes and engine speeds vary. However, this applies only within the performance range of the A/C compressor; if the performance limits
of the A/C compressor are exceeded, the pressure increases. Refer to ⇒ “10 Pressures, Checking”, page 152 .
2) Within the control range of the A/C compressor, temperature in the refrigerant circuits is maintained, regulated by A/C compressor, even
though heat transfer changes and engine speeds vary. However, this applies only within the performance range of the A/C compressor; if
the performance limits of the A/C compressor are exceeded, the temperature increases. Refer to
⇒ “10 Pressures, Checking”, page 152 .
3) Measured values for A/C systems with two evaporators
Note
♦ A/C compressors which do not regulate their performance are

switched off by the respective control module via the A/C
Compressor Regulator Valve - N280- at an evaporator tem‐
perature below 0 °C (32 °F).
♦ In vehicles with A/C Compressor Regulator Valve - N280- , the
2.8 Refrigerant Circuit with Restrictor and Reservoir

A-Low pressure side of refrigerant circuit.
B-High pressure side of refrigerant circuit.
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Component Aggregate state Pressure bar (psi) positive Temperature in degrees
Co
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of refrigerant pressure Celsius (Fahrenheit)
t. C rig
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-1- A/C compressor B-side Gas up to 20 (290) up to 70 (158)
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-2- Condenser From gas to va‐ up to 20 (290) up to 70 (158)
AG.
por to fluid
-3- Restrictor From fluid to va‐ B-side to 20 (290), A-side B-side up to 60 (140), A-
por greater than 1.5 (21.8) side warmer than -4 (25)
-4- Evaporator From vapor to Greater than 1.5 (21.8) Warmer than -4 (25)
gas
-5- Reservoir Gas
-6- A/C compressor A-side Gas
Pressures on A-side are maintained at approximately 2 bar (29
psi) by “regulating” A/C compressor also at various engine
speeds. However, this applies only within the performance range
of the A/C compressor; if the performance limits of the A/C com‐
pressor are exceeded. Refer to

Note
In vehicles with A/C Compressor Regulator Valve - N280- , the

2.9 Pressure Gauge, Tests and Measure‐

ments
Indicators on pressure gauge
1- Temperature scale for refrigerant R134a CF3–CH2F or
CH2F–CF3.
2- Pressure scale
The pressure gauge may have one or more temperature scales
next to the pressure scale. The R134a scale values are allocated
respectively in the vapor pressure table. Since various refriger‐
ants create different vapor pressures at the same temperature,
each temperature scale is identified for the respective refrigerant.
Pressure Gauge Uses
a – Pressure and temperature measurement at refrigerant circuit
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♦ High pressure gauge measures pressure ksw
agen and temperature,
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which expand uniformly from outlet
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condenser up to constriction
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♦ Low pressure gauge measures pressure and temperature,
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which expand uniformly from constriction (restrictor, or expan‐

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sion valve) via evaporator up to input of A/C compressor with

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A/C system switched on.

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The relationship between pressure and temperature indicated on

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the gauges only exists in a refrigerant circuit that contains liquid

or vapor, but not gas. In a gaseous state, the temperature is ap‐
proximately 10 °C (50 °F) to 30 °C (86 °F) higher than indicated
rrectness of i
on the gauge.
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b – Verification of refrigerant in a closed container

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Refrigerant R134a is present in a closed vessel or in a refrigerant

circuit when the temperature indicator on the gauge matches the
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refrigerant temperature (the temperature of standing fluid is equal

on
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to the outside temperature).

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A closed vessel or a refrigerant circuit that has been switched off

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is empty when the temperature indicated on the gauge is below

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the temperature of the refrigerant.

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The relationship between pressure and temperature indicated on
the gauges no longer applies if no liquid is present and the pres‐
sure is built up solely by gas.

2.10 A/C Service and Recycling Units

⇒ “2.10.1 Extraction System Group Classifications”, page 46
⇒ “2.10.2 Charging Systems not Requiring a Permit”, page 46
2.10.1 Extraction System Group Classifica‐

tions
At this time, A/C service units for extracting, cleaning and filling
refrigerant for motor vehicle A/C systems are available from var‐
ious manufacturers.
Group 3:
Mobile extraction and charging systems for filling compressed-
gas vessels permanently connected to the system.
The refrigerant or refrigerant/oil mixture is transferred to com‐
pressed gas vessels which are permanently connected to the
mobile systems. In accordance with 3 Para. 5 No. 3 of pressure
vessel regulations, compressed-gas vessels are classified as
pressure vessels in this case.
The charging systems require:
♦ no permit agen
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♦ no expert testing as ed the gas is transferred to compressed-gas
by ara
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vessels whichthareoris
classed as being pressure vessels. (Sys‐ eo
tems used for
s au transfer from these pressure vessels to com‐ r ac
pressed-gas vessels for supplying to third parties do require a
s
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permit and are subject to mandatory testing).

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The A/C service and recycling units used in motor vehicle work‐
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shops are extraction and charging systems not requiring a permit

es, in part or in w
(Group “3”) but which are only to be operated by qualified per‐

t to the co
sonnel. Instructions for unit operation and maintenance can be

found in the relevant manufacturer's documentation.
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2.10.2 Charging Systems not Requiring a Per‐

l purpos
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At this time, A/C service units for extracting, cleaning and filling
refrigerant for motor vehicle A/C systems are available from var‐
m
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Charging systems not requiring a permit are ones used for trans‐
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ferring compressed gases to mobile compressed-gas vessels for

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Some A/C service units are charging systems not requiring a per‐ rig ht
py by
mit. When working with such equipment, the refrigerant is not
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transferred to mobile compressed-gas vessels, but rather into a
agen
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permanently installed charging cylinder with visible level gauge
and float switch.
Recommendation:
It is advisable to use a portable cylinder with visible level gauge
and pressure relief valve for surplus refrigerant for internal use.
Observe the different technical regulations for handling and filling
compressed gases in other compressed-gas vessels (for exam‐
ple RGS 400, TRGS 402, TRGS 407, TRGS 510, TRBS 3145 /
TRGS 725).

2.11 Refrigerant Circuit Repair Information
WARNING
When performing work on refrigerant circuit, observe all gen‐

erally applicable safety precautions and pressure vessel reg‐
ulations.
Caution

used.
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Special tools and accessories: agen oes
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The performance of proper workmanlike repairs
oris on an air condi‐
ed
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• Requires the use of special tools and materials as listed in.
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Refer to ⇒ “12 Tools and Testing Equipment”, page 193 .
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• Requires compliance with the basic instructions for use of leak
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detectors. Refer to
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⇒ “6.2 Refrigerant Circuit, Tracing Leaks, with Electronic Leak
wit
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Detector VAG1796 ”, page 72 .
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• Requires expert knowledge.
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Note
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Releasing refrigerant into the environment is not permitted (pun‐
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⇒ “3 Laws and Regulations”, page 48 .
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3 Laws and Regulations

⇒ “3.1 Laws and Regulations”, page 48
⇒ “3.2 Recycling and Disposal Regulations”, page 52
⇒ “3.3 Refrigerant Circuit, Converting R12 to R134a and Servic‐
ing”, page 53
⇒ “3.4 Refrigerant, Keeping Records”, page 53
3.1 Laws and Regulations
Note
♦ The laws and regulations listed below are applicable in Ger‐

many. Different or additional laws and regulations may apply
in other countries.
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agen
♦ Addresses in other countries can be obtained from
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The effects of climate change can be Protecting seen
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the climate is one of the most important responsibilities. However,
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The Kyoto Protocol outlines worldwide goals regarding climate
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protection, among other things. In addition to target reductions of
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carbon dioxide, this protocol also outlines target reductions for
, is n
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fluorinated greenhouse gases such as refrigerant R134a due to
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their high potential of contributing to the greenhouse effect.
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t to the co
Numerous laws have been created for the automotive industry,
for example at the European level. For example, chemical-climate
protection regulations were put into effect on August 1, 2008 in
rrectness of i
Germany in order to define the European legislation in more de‐
tail.
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♦ Provision (EU) number 1005/2009

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♦ Guideline 2006/40/EU
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♦ Chemical Climate Protection Regulations, Recycling and Re‐ C py
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Maintenance and repair work on the A/C system refrigerant circuit cted agen
Prote AG.
All individuals performing maintenance and repair work on vehicle

A/C systems must have completed a training program and be
competent in the work required. Other regulations may apply in
addition to those of the European Union.
The following general points apply:
Operation, repair, decommissioning, take-back obligation
♦ When operating, repairing and decommissioning items that
contain refrigerant, allowing the refrigerant to vent into the air
is prohibited.
♦ It is therefore recommended to keep a record of the quantities
used during operation and maintenance, so they can be pre‐
sented to the authorities upon request. A record sheet no
longer needs to be kept in the EU due to a provision by the

European Parliament in 2005. Other provisions may apply in

countries that are not members of the EU.
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♦ Distributors of the substances and preparations agen discussed AG does
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above are obligated to accept these items
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ensure they are accepted by a third
ris party of their choosing.
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a of items containing refrig‐ ra
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erant that are named in the legislation Substances and prep‐
ce
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arations named in this legislation may only be accepted by
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those with the necessary expertise and technical equipment.
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Criminal offenses and infringements of the law
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♦ Infringement of the law in regard to the laws mentioned above.
h re
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spec
erating, repairing or decommissioning items that contain re‐
es, in part or in w
frigerant constitutes a violation of the laws and legislation
t to the co
described above.
rrectness of i
ple TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725,
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TRBS 3145).
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Note
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The TRGS (technical regulations for compressed gases) are lis‐
r
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ted (concerning vehicle manufacturers and workshops) below.
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♦ TRGS 400 (hazard assessment for activities with hazardous
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substances).
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♦ TRGS 402 (determining and evaluating the danger of activities
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♦ TRGS 407 (activities with gasses - hazard assessment).
♦ TRGS 510 (storage of hazardous substances in transportable
tanks).
♦ TRBS 3145 / TRGS 725 (transportable tanks - filling, keeping
ready, internal transportation, emptying).
Note
♦ The technical regulations for compressed gases (TRG), tech‐

nical regulations for hazardous substances (TRGS) and the
technical regulations for operational safety (TRBS). These
provide the laws and regulations, the safety precautions and
work hygiene as well as the protected industrial science knowl‐
edge for the provision and use of work equipment and the
system use subject to special supervision or for the activities
with hazardous substances.
♦ The provided technical regulations apply to Germany, in other
countries specifications and rules may apply.

ple TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725,
TRBS 3145).
♦ General regulations for charging systems.
♦ Definition of terms and explanatory note.
♦ Build and operation of charging systems.
Charging systems
3. Laws and Regulations 49

♦ Does not apply to vehicle manufacturers or workshops.

♦ Charging systems are systems for filling mobile compressed-
gas vessels. The charging system includes the premises and
facilities concerned.
♦ Charging systems requiring a permit are ones used to transfer
compressed gases to mobile compressed-gas vessels for
supplying to third parties.
♦ Charging systems not requiring a permit are ones used for
transferring compressed gases to mobile compressed-gas
vessels for internal use only.
Employees and employee instruction
Employees are to be given instruction on the following topics be‐
fore beginning work and at regular, appropriate intervals, however
at least once a year:
• Hazards specifically associated with handling compressed
gases
• The safety regulations, especially the applicable TRGS and
TRBS.
• Procedures in the event of malfunction, damage and accidents
• The use of fire-extinguishing and protective equipment
• Operation and maintenance of the charging system according
to the operating instructions.
Charging systems are only to be operated and maintained by
personnel
• who are 18 years of age and older,
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• who possess the necessary technical knowledge ksw
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• who can be relied upon to work diligently. ised b ara
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Supervised work may also be performed by personnel
s aut that do not ra
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meet the requirements stipulated in item 2.1, points
s 1 and 2.
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Filling of pressure vessels (separate technical regulations apply an

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♦ A compressed-gas vessel is only to be filled with the com‐

h re
pressed gas declared on it and the quantity must comply with

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the stipulated pressure, weight or volume data. Refer to pres‐

es, in part or in w
sure vessel regulations.

t to the co
♦ In the case of vessels approved for use with several types of

compressed gas, the compressed gas with which it is to be
rrectness of i
filled and - if the compressed gas has a tc ≥ -10 °C (tc = critical

temperature) - the maximum permissible charging weight in
l purpos
line with TRGS must be marked on the vessel prior to con‐

nection for filling.
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♦ Compressed-gas vessels marked with the maximum permis‐

orm
sible charge pressure in bar (psi) at 15 °C (59 °F) must be filled

m
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manometrically. If, at the time of filling, the temperature is not

o
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c
15 °C (59 °F), the pressure corresponding to the prevailing

or
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temperature must be established; it must be ensured that the

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in the compressed- gas vessel. The charged vessels are to be

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♦ Compressed-gas vessels on which the maximum permissible op Vo
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capacity is indicated by the net weight (filling weight, permis‐ cted agen
Prote AG.
sible weight of fill) in kilograms must be filled gravimetrically.
The vessels are to be weighed during filling and subsequently
subjected to a weight check on special scales to establish

possible overfilling. Scales used for this purpose must be cali‐

brated.
♦ Under certain conditions, gases with a tc greater than or equal
to 70 °C (158 °F) may be transferred volumetrically from com‐
pressed-gas vessels with a maximum volume of 150L to com‐
pressed-gas vessels with a volume of maximum 1000 cm3.
The stipulations of the TRGS apply to the transfer of liquefied
gas to cylinders used by workmen.
♦ Different TRGS applies to vessels in vehicles:
– For gas with tk ≥ 70 °C (158 °F).
– For industrial gas with tk ≥ 70 °C (158 °F).
AG. Volkswagen A gen G do
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– Liquefied extremely low-temperature
yV
olk compressed gasesnomay,
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contrary to item 4, berisefilled ara
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tem and/or the vessels
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uring or limitingssthe volume of the charge and – with the
a ac
exception of motor vehicle vessels as per item 3 – for meas‐
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uring the temperature of the charge. When filling volumetri‐
du
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indicated on the vessel is not exceeded. To determine possi‐
ility
ot p
ble overfilling, the filled containers are to be checked gravi‐
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metrically on a calibrated scale or – provided that the
h re
pressurized gases are not highly toxic – volumetrically. Volu‐
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metric checking requires the use of appropriate equipment
es, in part or in w
with completely separate charging and checking devices.
t to the co
♦ Charging and check measurements are to be performed by
different people. Check measurements must be performed
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immediately upon completion of the filling process.
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♦ Overfilled vessels must be drained immediately and in a safe

manner until the permissible fill is attained. The compressed-
gas fill is then to be determined again. nform
ercia
♦ Specific TRGS 407 components do not or only partially apply

m
at
om
to vessels for liquefied, extremely low-temperature com‐

ion
c
pressed gases which are neither flammable nor toxic; this

in t
or
does not affect the provisions of road traffic legislation.

his
ate
do
riv
♦ When filling compressed gas vessels with liquefied gases at

p
cum
for
charging temperatures less than or equal to -20 °C (-4 °F), the

en
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compressed gas vessel, if the vessel material has not been
Co
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tested for temperatures less than or equal to -20 °C (-4 °F), is
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not to be released from the charging system for transportation py by
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until the vessel wall temperature is greater than or equal to 20
by lksw
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°C (68 °F).
AG.
Refrigerant Circuit, Converting R12 to R134a and Servicing
Note
♦ For environmental reasons and on account of the correspond‐

ing legislation, refrigerant R12 can no longer be manufactured
or supplied. Refrigerant R134a has been developed as a re‐
placement for R12.
♦ A/C systems developed and designed for refrigerant R12 can‐
not however simply be charged with refrigerant R134a. To
ensure trouble-free operation of the air conditioning system
even after conversion, various components of the refrigerant
circuit must be replaced.
♦ A precise description of the conversion procedure and infor‐
mation on the servicing of converted refrigerant circuits can be
found in Repair Manual: Air Conditioner with Refrigerant R12
Parts 2 and 3. This repair manual is only available in hard copy.

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Refrigerant, Keeping Records
tho
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s au ra
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The environmental statistics
s law requires records to be kept on
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the use of refrigerants.
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Consequently, motor vehicle workshops may well have to provide
rm
ab
the relevant local authorities with information on their use of re‐
pe
ility
frigerant. It is therefore recommended to keep records of the
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quantities used and operation and maintenance, so they can be
h re
hole
presented to the authorities upon request.
spec
es, in part or in w
t to the co
Note
rrectness of i
A record sheet no longer needs to be kept in the EU due to a
provision by the European Parliament in 2005. Other provisions
l purpos
may apply in countries that are not members of the EU.
nform
ercia
3.2 Recycling and Disposal Regulations

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Note
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in other countries. t. Cop py
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♦ Addresses in other countries can be obtained from the rele‐ pyri by
Vo
o
vant authorities.
by c lksw
cted agen
Prote AG.
Specifications and rules for handling and disposing of refrigerants

and refrigerant oils can be found in the chemical-climate protec‐
tion provision and recycling and disposal regulations. These are
valid in Germany. Different specifications and rules may apply in
other countries.
Refrigerant and Refrigerant Oil Disposal
Refrigerant
Refrigerants intended for disposal are to be transferred to marked
recycling containers, observing the permissible filling quantity.
Refer to the chemical-climate protection provision and the recy‐
cling and disposal regulations in Germany. Different specifica‐
tions and rules may apply in other countries.
Refrigerant Oil
Used oil disposal: Volkswagen InfoNet; Operations; Handbooks
& Dealer Literature; Service Handbook; 15. Environment Protec‐
tion. Follow the link “Environment Protection in Market- and Serv‐
ice Operations” under general information; 4. Waste Manage‐
ment; 6. Methods of Disposals; g. Disposing of Used Refrigerant
Oil
Used refrigerant oils from systems employing halogenated hy‐
drocarbons (at least one hydrogen atom is replaced, for example,
with the halogen elements fluorine, chlorine, bromine or iodine)
are to be disposed of as waste subject to special supervision.
They are not to be mixed with other oils or substances. Proper
storage and disposal must be ensured in line with local regula‐
tions. Refer to the chemical-climate protection provision and the
recycling and disposal regulations in Germany. Different specifi‐
cations and rules may apply in other countries.

German technical, work safety and accident prevention regula‐

tions can be obtained from
Addresses in other countries can be obtained from the relevant
authorities.
3.3 Refrigerant Circuit, Converting R12 to

R134a and Servicing
Note

in other countries.
vant authorities.
♦ For environmental reasons and on account of the correspond‐
ing legislation, refrigerant R12 can no longer be manufactured
or supplied. Refrigerant R134a has been developed as a re‐
placement for R12.
♦ A/C systems developed and designed for refrigerant R12 can‐
not however simply be charged with refrigerant R134a. To
ensure trouble-free operation of the air conditioning system
even after conversion, various components of the refrigerant
circuit must be replaced.
♦ A precise description of the conversion procedure and infor‐
mation on the servicing of converted refrigerant circuits can be
found in Repair Manual: Air Conditioner with Refrigerant R12
Parts 2 and 3. This repair manual is only available in hard copy.
3.4 Refrigerant,
en AG. V
olKeeping
kswagen AG Records
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in other countries.
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vant authorities.
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It is therefore recommended to keep a record of the quantities

es, in part or in w
used during operation and maintenance, so they can be presen‐

t to the co
ted to the authorities upon request. A record sheet no longer

needs to be kept in the EU due to a provision by the European
Parliament in 2005. Other provisions may apply in countries that
rrectness of i
are not members of the EU.

l purpos
nf
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4 Refrigerant Circuit
⇒ “4.1 A/C System Repair Information”, page 54
⇒ “4.2 Refrigerant Circuit, Converting R12 to R134a”, page 54
4.1 A/C System Repair Information

agen
AG. Volkswagen AG d
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• An A/C system made for refrigerant R12 bymust not be filled with
V gu
ara
ed
refrigerant R134a without making omodifications
ris to the refrig‐ nte
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erant circuit. Refer to aut
h
ra
⇒ “3.3 Refrigerant Circuit, Converting
ss R12 to R134a and Serv‐ c
ce
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icing”, page 53 .
un
pt
an
d
itte
• The refrigerant oils specifically developed for R134a and R12
y li
rm
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refrigerant circuits are never to be mixed.
pe
ility
ot
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• Service stations which come in contact with the refrigerant are
, is n
h re
only to be used for the intended refrigerant.
hole
spec
• Components of R134a refrigerant circuits can be identified by
es, in part or in w
t to the co
their markings, green labels or design (such as different
threads) to prevent interchanging with components designed
for refrigerant R12.
rrectness of i
• A label indicating the refrigerant used is provided in the engine
l purpos
compartment on the lock carrier or in the plenum chamber.

• Different refrigerants are never to be mixed.
nform
mercia
a
Note
com
tion in
r
te o
thi
When working on the refrigerant circuit, always heed the infor‐
s
iva
do
mation given in the sections on “Safety measures”. Refer to
r
rp
⇒ “1.11 A/C System and Refrigerant R134a Safety Precautions”, cum

fo
en
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page 14 and “Basic rules for working on refrigerant circuit”

n
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op
⇒ “1.12 Refrigerant Circuit, General Precautions”, page 15 . C py
ht. rig
rig ht
py by
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4.2 Refrigerant Circuit, Converting R12 to
by lksw
cted agen
Prote AG.
R134a
CFC refrigerants are no longer used in the automotive industry.
Converting refrigerant circuits from R12 refrigerant to R134a re‐
frigerant and servicing converted circuits
Repair Manual Air conditioner with refrigerant R12 Parts 2 and 3.
This repair manual is only available in hard copy.

5 A/C Service Station, Working with

⇒ “5.1 Important Information when Working with the A/C Service
Station”, page 55
⇒ “5.2 A/C Service Station, Connecting for Measuring and Test‐
ing”, page 57
⇒ “5.3 Discharge Refrigerant Circuit with A/C Service Station”,
page 59
⇒ “5.4 Refrigerant Circuit with A/C Service Station, Draining”,
page 60
⇒ “5.5 Refrigerant Circuit with A/C Service Station, Filling”,
page 62
⇒ “5.6 A/C System, Operating after Charging”, page 64
⇒ “5.7 Refrigerant in A/C Service station Container, Filling”,. Vpage
AG olkswagen AG d
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⇒ “5.8 A/C Service Station, Emptying”, page
ise
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5.1 Important Information when Working ss
a ac
with the A/C Service Station
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Caution
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♦ If it is suspected that chemicals were added to the refrig‐
h re
hole
erant circuit to seal leaks, do not connect the A/C service
spec
station and do not extract the refrigerant.
es, in part or in w
t to the co
♦ Chemicals that seal leaks in the coolant circuit form de‐
posits that affect the function of the A/C system and lead
to failure of the A/C system and the A/C service station.
rrectness of i
♦ Inform that customer that there are substances in the A/C
l purpos
system that are no approved by Volkswagen. This A/C

system cannot be drained or serviced in the workshop.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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t.
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Cop py
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Prote AG.
5. A/C Service Station, Working with 55

Note
♦ The chemical materials (stop leak additive) for sealing leaks

in the refrigerant circuit offered on the market are not approved
by VW Audi AG. There are no permanent- ,validity or material
compatibility tests. Therefore damage or malfunctions in the
A/C system or the A/C Service Station cannot be excluded.
♦ The stop leak additives offered on the open market have dif‐
ferent physical and chemical properties, which can impair the
function of the A/C system and the A/C Service Station and
can even shut down the system completely.
♦ VW does not approve the use of chemicals to seal leaks in the
refrigerant circuit.
♦ Chemicals used to seal leaks in the refrigerant circuit often
react with air and the moisture in it. They cause deposits in. Vthe
n AG olkswagen AG
refrigerant circuit and the A/C service station and l wage
ksmalfunctions
does
not
o
in valves and other components that they come d by V
in contact with. gu
ara
These deposits cannot be removed completely rise from the com‐ nte
ho eo
ponents. sa
ut ra
c
s
♦ Chemicals used to seal leaks in the refrigerant circuit usually
ce
le
un
pt
cannot be detected from outside. The label that should be ap‐
an
d
itte
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plied to identify it is often missing. Therefore be careful when
rm
ab
working with if you do not know its service history.
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♦ Accessories offer containers used to separate out these
h re
chemicals (used to seal leaks in the refrigerant circuit). Be‐
hole
spec
cause VW does not approve the use of these chemicals, there
es, in part or in w
is no evidence of the effectiveness of these filters.
t to the co
Note the following when operating the A/C service station -
VAS6007A- . This also applies to other service stations.
rrectness of i
l purpos
• The filters and dryers installed must be replaced at the latest

on completion of the service life specified in the relevant op‐ nform
ercia
erating instructions.
m
a
com
ti
• Only refrigerant oils that are approved for the refrigerant circuit
on in
in that vehicle may be added.

r
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Extracted refrigerant must not be reused under the following con‐

en
ng
t.
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ditions, even after cleaning in the station:
Co
Cop py
t. rig
gh
• In the case of A/C compressor damage in which the refrigerant
ht
pyri by
Vo
o
was disintegrated due to overheating.
c by lksw
cted agen
Prote AG.
• In the case of dark, sticky deposits in the refrigerant circuit
(these can only be found after opening the system).
• If there is any doubt as to the composition of the refrigerant
extracted from the refrigerant circuit.
The A/C service station is to be drained in all these cases. Refer
to
page 59 , the system cleaned if necessary and the filters, dryers
and refrigerant oil replaced.
For example, within Germany, contaminated refrigerant can be
returned to the supplier in recycling containers for recycling or for
environmentally safe disposal. Other or additional regulations
may apply in other countries.
Commercially available A/C service stations can be classified in
2 groups:

♦ A. A/C service stations which clean extracted refrigerant for

reuse (extraction and recycling a n AG. Volkssuch
gestations)
wagen AG
as the
doesA/C serv‐
ksw
ice station - VAS6007A-
by
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not
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♦ B. A/C service stations
tho
ri which transfer extracted refrigerant totee o
recycling containers
ss
au
(for large-scale recycling). These are re‐ r ac
ferred to as extraction systems.
ce
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un
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an
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itte
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5.2 A/C Service Station, Connecting for
erm
ab
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Measuring and Testing
ot p
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Caution
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atio
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Note
t.
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Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted
agen
Prote AG.
react with air and the moisture in it. They cause deposits in the
refrigerant circuit and the A/C service station and malfunctions
in valves and other components that they come in contact with.
These deposits cannot be removed completely from the com‐
ponents.
• Work procedure may vary depending on the type of tools se‐

lected (the tool-specific operating instructions should therefore
be followed).

olkswagen AG
wag en AG. V
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Refrigerant R134a Servicing - Edition 08.2015 se
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Note
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The work procedure is always to be performed as described in
rm
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the operating instructions for the A/C Service Station -
ot
VAS6007A- (or subsequent models).
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The charging hoses are to be connected as follows to prevent the
es, in part or in w
ingress of air or moisture into the refrigerant circuit:
t to the co
– Turn off the ignition.
rrectness of i
– Connect the A/C service station to the power supply.
l purpos
– Remove the cap from the service connections or connections
with a valve (see vehicle-specific refrigerant circuit).
nform
Refer to ⇒ Rep. Gr. 87 . mercia
– Evacuate the filler hose.
a
com
tion in
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thi
Note
s
iva
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Connect filler hose with quick-release couplings to refrigerant cir‐
en
ng
t.
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cuit service connections. . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted
Caution
agen
Prote AG.
Never open valves on low or high-pressure side with engine

running. Otherwise, compressor or service station could be
destroyed by a “short circuit” between high and low-pressure
sides of refrigerant circuit if air conditioning system is switched
on.
– Only tighten the handwheel in the quick-release coupling just

enough so the service connection is open. Watch the pressure
gauge and do not place too much pressure on the valve.
– Start the engine and perform the planned tests and measure‐
ments.
– Compare values determined to specified measured values.
Refer to
⇒ “10.1 Refrigerant Circuit Pressures (with A/C Service Sta‐
tion), Checking”, page 152 .
– Loosen the handwheel to close the quick-release coupling be‐
fore disconnecting it.

5.3 Discharge Refrigerant Circuit with A/C

Service Station
Caution

Note

AG. Volkswagen A
react with air and the moisture in it. They cause deposits
lksw
agenin the G do
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refrigerant circuit and the A/C service station dandby Vomalfunctions ua
ran
in valves and other components that they come oris
e in contact with.
tee
These deposits cannot be removed completelyau
th
from the com‐ or
ac
ponents. ss
ce
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un
pt

an
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rrectne
WARNING
ss
High voltage within the high voltage system. Danger of electric

o
cial p
shock in the A/C compressor!

inform
mer
Disable high voltage system. Refer to ⇒ Electric Drive; Rep.

atio
Gr. 93 ; High Voltage System, Disabling .

om
n
c
i
or
n thi
te
sd
va
• Work procedure may vary depending on the type of tools se‐

i
o
pr
cum
r
lected (the tool-specific operating instructions should therefore

fo
en
ng
be followed).
t.
yi Co
Cop py
• The refrigerant circuit is to be discharged if parts of the refrig‐
t. rig
gh ht
yri by
erant circuit are to be removed, if there is any doubt about the cop Vo
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lkswage es n
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ran
ir se
Refrigerant R134a Servicing - Edition 08.2015th o tee
or
au ac
ss
quantity of refrigerant in the circuit or if safety precautions so
ce
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un
pt
require.
an
d
itte
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erm
• All the necessary usage information for working with the re‐
ab
ility
frigerant service station can be found in the service station
ot p
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operating instructions.
is n
h re
ole,
Draining:
spec
t to the co
– Connect A/C service station in line with operating instructions
to vehicle service connections. Refer to ⇒ Rep. Gr. 87 and
rrectne
start up service station.
ss o
Note
cial p
f inform
mer
♦ There is a possibility of refrigerant oil being extracted from the
atio
m
refrigerant circuit together with the refrigerant. To ensure com‐

o
n
c
pressor lubrication, the refrigerant oil in the circuit must be
i
or
n thi
topped up with fresh oil. Refer to ⇒ Rep. Gr. 87 .
te
sd
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♦ On vehicles with an A/C compressor without a magnetic clutch
um
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fo
(with A/C Compressor Regulator Valve - N280- ), the engine
en
ng
t.
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should run < 10 minutes with the refrigerant circuit empty and
Co
Cop py
closed (the A/C compressor also runs continuously). The en‐
t. rig
gh ht
yri
gine RPM must not exceed 2000 RPM.
p by
co Vo
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♦ On vehicles equipped with an A/C compressor with A/C clutch,
Prote AG.
the engine must be started since the A/C Pressure Switch -

F129- or High Pressure Sensor - G65- (checks whether re‐
frigerant is present in the circuit) switches off the A/C clutch as
soon as there is no refrigerant in the refrigerant circuit.
5.4 Refrigerant Circuit with A/C Service Sta‐

tion, Draining
Caution


Note

ponents.
• The work procedure is always to be performed as described

in the operating instructions for the A/C service station.
• The procedure described here is for the A/C Service Station -
VAS6007A- . wage
e ks s no
Vol t
Before filling the refrigerant
d b circuit with refrigerant, it should be
y gu
ara
evacuated (vacuum)thfor rise45 minutes on systems with 1 evaporator nte
o e
and 60 minutes ons asystems with 2 evaporators. Moisture is also or ac
u
extracted from thes circuit.
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e
nl
pt
du
Leaks may be found when evacuating the refrigerant circuit.

an
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ab
Evacuating:
ility
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Caution
hole
spec
es, in part or in w
♦ Do not start the engine during the evacuation process or

t to the co
when there is a vacuum in the refrigerant circuit.

♦ The A/C compressor could be damaged if the engine is
rrectness of i
started when there is a vacuum in the refrigerant circuit.

l purpos
♦ Only start the engine when the refrigerant circuit is filled.

nf
ercia

rm
m
atio
m
– Check refrigerant oil quantity in refrigerant circuit if necessary,

o
n in
c
see vehicle-specific repair manual. Refer to ⇒ Rep. Gr. 87 .

or
thi
te
sd
a
– Connect the A/C service station to the power supply.

iv
o
r
rp
cu
o
– Check the amount of refrigerant in the A/C service station.

f
en
ng
t.
yi Co
op
– Connect charging hose of A/C service station to vehicle re‐ C py
t. rig
frigerant circuit with quick-release coupling adapter. Refer to
gh ht
pyri by
vehicle-specific refrigerant circuit.
co Vo
by lksw
cted agen
Prote AG.


– Only tighten the handwheel on the quick-release coupling
adapter just enough so the valves in the service connections
are securely open. Do not put too much pressure on the valve.
Note
If pressure is to be measured after charging system on vehicles

with a service connection on one side of the refrigerant circuit
only, use valve adapter and charging hose with valve opener .
– Initiate the vacuum phase on the A/C service station. The re‐
frigerant circuit is automatically evacuated. Check the preset
evacuating time if necessary.
When the vacuum phase ends, the refrigerant circuit leak test
begins. Pressure in bar (psi) and seconds are displayed.
Proceed as follows if the vacuum is not maintained:
– Initiate the vacuum phase on the A/C service station again.
The refrigerant circuit is automatically evacuated. Check the
preset evacuating time if necessary. Watch the vacuum indi‐
cator for an extended period of time. Onlyolkwhen
swagenthe vacuum
en AG. V AG do
is maintained can the refrigerant
olks
wagcircuit be charged. es n
o V t gu
by a
♦ If there is a leak that allowed
ris
ed enough air to enter during evac‐rante
uation that the A/Cuservice
tho station cannot generate a sufficient eo
ra
vacuum or that thes vacuum is lost immediately after switching
s a c
the A/C service station off:
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pt
an
d
– Determine the location of the leak in the refrigerant circuit.

itte
y li
rm
Refer to
ab
pe
ility
⇒ “6 Refrigerant Circuit, Detecting Leaks”, page 69 .

ot
wit
, is n
5.5 Refrigerant Circuit with A/C Service Sta‐

h re
hole
spec
tion, Filling
es, in part or in w
t to the co
Caution
rrectness of i

l purpos

nform
ercia

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com

tion in
r
te o

thi
s

iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

function of the A/C system and the A/C ServiceagenStation and AG does
AG. Volkswagen
can even shut down the system completely.olksw not
V gu
by ara
ed
♦ VW does not approve the use ofthchemicals to seal leaks in the
is nte
or e or
refrigerant circuit. au ac
ss
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
ponents.
h re
ole,
spec
t to the co
rrectne
ss
o
cial p
f inform
mer
atio
m
WARNING
o
n
c
i
or
n thi
e
High voltage within the high voltage system. Danger of electric

t
sd
va
shock in the A/C compressor!

i
o
pr
cum
r
fo
en
ng
Disable high voltage system. Refer to ⇒ Electric Drive; Rep.

t.
yi Co
Gr. 93 ; High Voltage System, Disabling . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
• Before pouring in refrigerant, correct the quantity of refrigerant
oil. Refer to ⇒ Rep. Gr. 87 .
• The entire refrigerant charge can be added to either the high
or low pressure side.
Refrigerant circuit, charging
– Drain the refrigerant circuit with A/C service station. Refer to
page 60 .
– Screw out handwheel at quick-release coupling adapter (to
close it).
– Allow refrigerant to flow into charging hose.
– Tighten the handwheel on the quick-release coupling adapter
without putting too much pressure on the valve and add the
specified amount of refrigerant.
– Switch off A/C service station.

lkswage es n
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Note d b ua
ran
ir se tee
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If A/C compressor was removed, it must
ss be cranked by hand at
a ac
ribbed belt pulley/freewheel approximately 10 rotations before
ce
e
nl
pt
bringing into operation for the first time. The electrically-driven A/
du
an
itte
C compressor is not affected by this. This prevents damage in the
y li
erm
ab
A/C compressor due to liquid when switching the A/C system on.
ility
If there is oil in the A/C compressor cylinder, it will be forced out. ot p
wit
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h re
hole
– Start engine with compressor switched off (version with A/C
spec
clutch).
es, in part or in w
t to the co
– Set the A/C compressor to minimum output, for example,
"ECON" mode or A/C off (version with no A/C clutch with reg‐
ulator valve).
rrectness of i
– Wait until idle speed has stabilized.
l purpos
– Switch on the compressor and operate the system for at least

two minutes at idling speed.
nf
ercia
orm
– If necessary, check pressures in refrigerant circuit using A/C
m
atio
m
service station.
o
n in
or c
– Turn engine off.
thi
te
sd
iva
o
– Screw out handwheel on quick-release coupling adapter.
r
rp
cu
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m
f
en
ng
– Disconnect charging hose from refrigerant circuit.

t.
yi Co
Cop py
– Screw protective caps back on.
t. rig
gh ht
pyri by
Vo
co
5.6 A/C System, Operating after Charging
by lksw
cted agen
Prote AG.
Caution


. Volkswage
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n AG n AG
es n 2012 ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
ol ot g
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ua
r
R134a Servicing - Edition 08.2015
e an
ris tee
tho or
au ac
ss
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss o
cial p
f
inform
mer
atio
m

o
n
c
i
or
n thi
e
ponents.
t
sd
iva
o
pr
c
um
r
fo
en
ng
t.
yi Co
plied to identify it is often missing. Therefore be careful when Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.

Note
If A/C compressor was removed, it must be cranked by hand at

ribbed belt pulley/freewheel approximately 10 rotations before
bringing into operation for the first time. This prevents damage in
the A/C compressor due to liquid when switching the A/C system
on. If there is oil in the A/C compressor cylinder, it will be forced
out.
– Start engine with compressor switched off (version with A/C

clutch).
– Set the A/C compressor to minimum output, for example,
"ECON" mode or A/C off (version with no A/C clutch with reg‐
ulator valve).
– Wait until idle speed has stabilized.
– Switch on the compressor and operate the system for at least
two minutes at idling speed.
– If necessary, check pressures in refrigerant circuit using A/C
service station.
– Turn engine off.
– Screw out handwheel on quick-release coupling adapter.
– Disconnect charging hose from refrigerant circuit.
– Screw protective caps back on.

5.7 Refrigerant in A/C Service station Con‐

tainer, Filling
Caution

Note

wage
lks es n
o ot g
yV
These deposits cannot be removed completelyisfrom ed
b the com‐ ua
ran
ponents. uthor tee
o ra
sa c
♦ Chemicals used to seal leaks in the refrigerant
s circuit usually
ce
e

nl
pt
du
an

itte
y li

erm
ab
ility
ot p

wit
, is n

h re

hole
spec

es, in part or in w
t to the co

rrectness of i
• A certain quantity of refrigerant is specified as charge for each

l purpos
air conditioning system. To ensure that the correct amount of

refrigerant is added and the cooling output is not reduced, the
charging cylinder stands on a scale indicating the weight.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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5.8 A/C Service Station, Emptying

lkswage es n
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Caution d byV ua
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♦ If it is suspected that chemicals
au were added to the refrig‐ ac
ss
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un
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es, in part or in w
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rrectness of i
Note
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ponents.

Note
♦ If it is necessary to evacuate the A/C service station (e.g. be‐

cause contaminated refrigerant was extracted), always re‐
place all filters and dryers. Only remove the filters and dryers
from their air-tight packaging immediately before installing
them to prevent moisture from entering.
♦ Refrigerant containers filled with contaminated used refriger‐
ant are referred to as “Recycling containers”.
♦ Always evacuate recycling cylinders before first charging with
refrigerant. Refrigerant cylinders in which there is air must not
be filled with refrigerant.
♦ Different refrigerant types must not be mixed together. Refrig‐
erant mixtures cannot be reprocessed but must be disposed
of. If there is any doubt about the composition of the contents
of the container, the refrigerant recycling company is to be in‐
formed accordingly.
WARNING
♦ When filling recycling containers (compressed-gas ves‐

sels), observe applicable regulations, technical rules and
laws.
♦ Recycling containers are never to be overfilled. Overfilled
containers do not have a sufficient gas cushion to accom‐
modate the liquid expansion caused by the effects of heat.
There is a danger of rupture.
♦ To ensure safety, make exclusive use of recycling con‐
tainers fitted with a safety valve.
♦ Recycling containers must be weighed on calibrated
scales during the filling process. The maximum permissi‐
ble capacity is 75% (charge factor 0.75) of the charge
weight indicated on the recycling container (the possibility gen AG. Volkswagen AG d
of refrigerant oil entering the recycling container along Vwith
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Rep. Gr.00 - General, Technical Data Prote
cted AG.
agen
6 Refrigerant Circuit, Detecting Leaks

⇒ “6.1 Searching for Refrigerant Circuit Leaks with Compressed
Air or Nitrogen”, page 69
Detector VAG1796 ”, page 72
⇒ “6.3 Refrigerant Circuit, Tracing Leaks, with Leak Detection
System VAS6196 or Leak Detection Kit VAS6201A or Succeed‐
ing Model”, page 74
AG. Volkswagen
6.1 SearchingVolfor
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agen AG do
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ot g
with Compressed Air or Nitrogen
by ua
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Note
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e
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♦ This repair manual describes different methods for detecting
erm
ab
leaks in the refrigerant circuit. These methods have been tes‐
ility
ot p
ted and result in success when used correctly.
wit
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♦ If when searching for compressed air / Nitrogen or vacuum
hole
spec
leaks none are found, add a leak detection additive i.e UV leak
es, in part or in w
detection additive, to the electric leak detecting unit.
t to the co
♦ Minor leaks can be detected using an electronic leak detector
or UV leak detector lamp.
rrectness of i
♦ Many methods for detecting leaks in the refrigerant circuit are
l purpos
offered in the open market. These methods do not always

have optimum results. If they are not used exactly according
to specifications, they can indicate refrigerant circuit compo‐
nf
ercia
nents have leaks even when they do not. Also, refrigerant

rm
m
circuit components can be damaged by some methods.

atio
om
n in
c
♦ Do not repair components with leaks. Replace them with new

or
thi
original parts.
te
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♦ Do not charge a leaking refrigerant circuit with refrigerant.

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Evacuate the circuit and check it for leaks before charging.

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Refer to
Co
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⇒ “5.4 Refrigerant Circuit with A/C Service Station, Draining”, ht. rig
rig ht
page 60 .
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Caution

6. Refrigerant Circuit, Detecting Leaks 69

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agen oes
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wit
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es, in part or in w
ponents, even by flushing.
t to the co
rrectness of i
l purpos

nf
ercia
orm
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or c
thi
te
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Prote AG.

Note
♦ A leak can be identified if a maximum of pressure of 15 bar

(218 psi) can be generated in the refrigerant circuit using
clean, dry compressed air or nitrogen. Refer to
Nitrogen”, page 81 . If the leak is large enough, the sound of
escaping air or gas can be heard at the location of the leak.
♦ Use the service connection for the compressed air or nitrogen.
♦ The quick-release coupling adapter for service connections
can be connected to the air compressor using a modified filler
hose -A- (for example, with 5/8" 18 UNF threads, different from
the threads on the quick-release coupling adapter) and a suit‐
able adapter -B-. Refer to
⇒ “12.1.3 Improvised Tools”, page 197 . This keeps humidity,
oil and dirt coming out of the workshop compressed air system
from getting into the A/C refrigerant circuit. Also use a combi‐
nation fine-gauge filter for compressed air systems such as agen
AG. Volkswagen AG d
oes
those that are standard in paint shops. Install it between the yV
olksw not
gu
compressed air system and the filler hose -A- . Refer to isedthe
b ara
nte
Special Tools and Equipment Catalog. thor eo
au ra
♦ A compressed gas cylinder filled with nitrogen -3-sscan be con‐
c
ce
le
nected to the closed refrigerant circuit using a pressure gauge

un
pt
battery with a pressure reducer for nitrogen (maximum reduc‐
an
d
itte
y li
tion pressure: 15 bar (218 psi)) -1- and a filler hose -2- (for
erm
ab
example, with 5/8" 18 UNF threads) connected to the service
ility
ot p
connection. A quick-release coupling adapter must also be
wit
is n
connected to the service connection. Refer to
h re
ole,
⇒ “12.1.3 Improvised Tools”, page 197 .
spec
t to the co
– Slowly increase the pressure in the refrigerant circuit to a max‐
imum of 15 bar (218 psi).
rrectne
WARNING
ss o
♦ The maximum permitted working pressure is 15 bar (218
cial p
f in
psi).
form
mer
♦ When testing for leaks with nitrogen, always work with a
atio
m
pressure reducer for nitrogen bottles.

o
n
c
i
or
n thi
te
sd
iva
o
r
– Find the location of the leak by listening for the sound of vent‐
p
cum
r
fo
ing gas. An Ultrasonic Tester VAG1842S - VAG1842S- will aid

en
ng
t.
yi
in detecting the origin of noise.
Co
Cop py
t. rig
gh
– Use clean, dry compressed air to force the nitrogen out of the
ht
pyri by
Vo
refrigerant circuit. The nitrogen must not get into the Service
o
by c lksw
cted agen
bottle. Reason: gases that do not condense do not get into the Prote AG.
Service bottle.
– Repair the leak.
– Evacuate and again observe the vacuum display over a period
of hours. Only when the vacuum is maintained can the refrig‐
erant circuit be charged.
♦ If there is a leak that is small enough that no air or very little
air vents through it and the A/C service station can generate
a sufficient vacuum. The vacuum indicator does not increase
after switching the A/C system service station or only increa‐
ses slowly, indicating that air is only entering through a small
leak.

– Add 100 grams of refrigerant to the circuit, find the location of

the leak using an electronic leak detector and repair it or add
UV contrast dye to the refrigerant and find the location of the
leak with the leak detection AsystemVAS6201
G. Volkswagen AG d or succeeding
model and repair it.olRefer agento oes
ksw not
⇒ “6.2 Refrigerant d by VCircuit, Tracing Leaks, with Electronic
gu
ara Leak
Detector VAG1796
orise
”, page 72 or nte
eo
⇒ “6.3 Refrigerant
aut
h
Circuit, Tracing Leaks, with Leak Detection ra
Systems VAS6196 or Leak Detection Kit VAS6201A or Suc‐c
s
ce
e
ceeding Model”, page 74 .

nl
pt
du
an
itte
– Empty the refrigerant circuit, if necessary. Refer to
y li
erm
ab
ility
ot p
page 59 .
wit
, is n
h re
– Evacuate and check the vacuum display again over several
hole
spec
hours. Only when the vacuum is maintained can the refrigerant
es, in part or in w
circuit be charged.
t to the co
6.2 Refrigerant Circuit, Tracing Leaks, with
rrectness of i
Electronic Leak Detector - VAG1796-
l purpos
Note
nform
mercia
♦ This repair manual describes different methods for detecting at

om
io
n
c
in t

or
his
ate
do
riv

p
cum
for
en
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n
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♦ Minor leaks can be detected using an electronic leak detector ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

to specifications, they can indicate refrigerant circuit compo‐
original parts.
Refer to
page 60 .
Caution


Note
♦ VW does not approve the use of chemicals

agen
toAseal
G. Volleaks
kswagein
n Athe
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refrigerant circuit. olks
w oes
not
byV gu
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♦ Chemicals used to seal leaksoriin s the refrigerant circuit often
e nte
eo
react with air and the moisture
aut in it. They cause deposits in the
h
ra
refrigerant circuit and thes A/C service station and malfunctions
s c
ce
in valves and other components that they come in contact with. le
un
pt
an
d
itte
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ponents, even by flushing.
rm
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ot
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
mercia
a
Minor leaks can be detected using an electronic leak detector for
com
tio
example.
n in
r
te o
thi
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iva
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– Discharge the refrigerant circuit with the A/C service station.
r
rp
cum
Refer to
fo
en
g

n
t.
yi Co
op
page 60 . C py
ht. rig
rig ht
py by
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Note Prote AG.
♦ Be ready to evacuate a large leak should one be found. Refer

to
page 60 .
♦ If no leak is found during evacuation or there is a leak that is
so small that the location cannot be found, proceed as follows.
Refer to
⇒ “6.1 Searching for Refrigerant Circuit Leaks with Com‐
pressed Air or Nitrogen”, page 69 .
♦ Currents of air quickly disperse refrigerant gas. Draughts must
therefore be avoided during leak detection.
♦ If the refrigerant circuit is completely empty, fill with refrigerant
to approximately 10% of the fill capacity (R134a label or vehi‐
cle-specific Repair Manual).
Leak detection:
– Start up leak detector in line with relevant operating instruc‐
tions.
– Always hold test probe beneath suspected leak.

Depending on the model, leak detection is indicated by an in‐

crease in clicking rate or a warning tone. Refer to operating
instructions for leak detector.
AG. Volkswagen AG d
agen oes
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nl
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6.3 Refrigerant Circuit, Tracing Leaks, with
erm
ab
ility
ot p
Leak Detection System - VAS6196- or
wit
, is n
Leak Detection Kit - VAS6201A- or Suc‐
h re
hole
spec
ceeding Model
es, in part or in w
t to the co
Note
rrectness of i
♦ This repair manual describes different methods for detecting
l purpos

nf
ercia
orm
m
atio
m

o
n in
or c
thi
♦ Minor leaks can be detected using an electronic leak detector
te
sd
a

iv
o
r
rp
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o
m
f
en
ng
t.
yi
Co
op py
t. C rig
gh ht
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to specifications, they can indicate refrigerant circuit compo‐ p by
o Vo
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lksw
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AG.

original parts.
Refer to
page 60 .
Caution


Note

in valves and other components
AG. Volkswagethat
n AGthey come in contact with.
These deposits lkswcannot be removed completely
agen does
not from the com‐
ponents,d beven by flushing.
o
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ris te
♦ Chemicals
ut
ho used to seal leaks in the refrigerant circuit
eo
r usually
cannot
ss
a
be detected from outside. The label that shouldac
be ap‐
ce
le
un
pt
an
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itte
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ab
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ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Small leaks can be detected using a UV-leak detection additive
for example.
l purpos
– Discharge the refrigerant circuit with the A/C service station.

nform
ercia
Refer to
m
a
com
page 60 .
ion in
r
te o
thi
s
iva
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Note
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t.
♦ Be ready to evacuate a large leak should one be found. Refer
yi Co
op py
to
. C rig
ht ht
rig by
opy Vo
page 60 .
by c lksw
cted agen
Prote AG.
♦ If no leak is found during evacuation or there is a leak that is
so small that the location cannot be found, proceed as follows.
Refer to
⇒ “6.1 Searching for Refrigerant Circuit Leaks with Com‐
pressed Air or Nitrogen”, page 69 .
♦ Currents of air quickly disperse refrigerant gas. Draughts must
therefore be avoided during leak detection.
♦ If the refrigerant circuit is completely empty, fill with refrigerant
to approximately 10% of the fill capacity (R134a label or vehi‐
cle-specific Repair Manual).
Leak Detection System - VAS6196-

or

Leak Detection System - VAS6201- or succeeding model

1- Leak Detection Kit - Hand Pump w/Cartridge - VAS6201/1-
2- Leak Detection Kit - Cartridge - VAS6201/2-
3- Leak Detection Kit - Cleaning Solution - VAS6201/3-
4- UV Leak Detection Lamp - VAS6201/4A-
5- Leak Detection Kit - Eye Protection - VAS6201/6-
6- Leak Detection Kit - Label - VAS6201/7-
n AG. Volkswagen A ge G do
swa es
7- Tube - VAS6201/8- by Volk not
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is nte
8- Leak DetectionthKit
o - Hand Protection - VAS6201/9-
r eo
au ra
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ss
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le
un
pt
an
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itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
Filling with leak detection additive when the refrigerant circuit is
empty
t to the co
The cartridge -A- contains 15.4 ml of leak detection additive (one
unit -B- corresponds to 2.5 ml).
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
– Assemble the Leak Detection Kit - VAS6201A- -1- with the

p
cum
r
fo
cartridge -2- Leak Detection Kit - Cartridge - VAS6201/2- .

en
ng
t.
yi Co
op
– Insert the Leak Detection Kit - Filler Tube - VAS6201/8- into C py
ht. rig
the hand pump. Refer to ⇒ page 76 -7- rig ht
py by
co Vo
by lksw
– Open the hand pump service valve. cted agen
Prote AG.

Leak detection additive is best added to empty refrigerant circuit

via opened connection.
– Open an easily accessible connection point on refrigerant cir‐
cuit
– Cover area around connection point with foil or absorbent pa‐
per.
– Hold tube upwards.
– Tighten the toggle on the hand pump until the leak detection
additive comes out of the tube.
– Add 2.5 ± 0.5 ml (milliliter = cm3) of leak detection additive to
the refrigerant circuit.
Note
If leak detection additive was already added to the refrigerant cir‐

cuit for an earlier repair, note the following: Only add new leak
detection additive if the refrigerant oil will be replaced. If only a
portion of the refrigerant oil was replaced, only add a proportion‐
ate amount of the leak detection additive. For example, if 100 ml
of refrigerant oil was replaced in a vehicle with 250 ml, add only
1 ml (cm3) of leak detection additive.
– Replace the O-rings on opened connection point.

– Assemble refrigerant circuit
– Apply a label near the service connection stating that leak de‐
tection additive was added to the refrigerant circuit.
AG. Volkswagen AG d
– Evacuate and recharge refrigerant circuit according kswto speci‐
agen oes
not
fication. Refer to y Vol gu
b ara
ed
⇒ “5.4 Refrigerant Circuit with A/C ServiceorisStation, Draining”, nte
eo
page 60 and aut
h
ra
⇒ “5.5 Refrigerant Circuit with A/C Service
ss Station, Filling”, c
page 62 . ce
e
nl
pt
du
an
itte
– Start the A/C system. y li

erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
The A/C system must run for at least 60 minutes so the additive
es, in part or in w
t to the co
distributes itself through the entire refrigerant circuit. The com‐

pressor must be running. Depending on the size of the leak, it may
become visible within that time.
rrectness of i
– Find the leak in the refrigerant circuit with the UV lamp‐

l purpos
VAS6196/4. Refer to ⇒ page 79 .

nform
ercia
Note
m
at
om
ion
c
Remove existing leak detection additive in the engine compart‐

in t
or
ment or from the refrigerant circuit components using Leak De‐

his
ate
tection Kit - Cleaning Solution - VAS6201/3- .

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

Leak detection additive with filled refrigerant circuit, filling
Note
♦ If leak detection additive was already added to the refrigerant

circuit for an earlier repair, note the following: Only add new
leak detection additive if the refrigerant oil will be replaced. If
only a portion of the refrigerant oil was replaced, only add a
proportionate amount of the leak detection additive. For ex‐
ample, if 100 ml of refrigerant oil was replaced in a vehicle with
250 ml, add only 1 ml (cm3) of leak detection additive.
♦ A small quantity of leak detection additive remains in the serv‐
ice connection. Carefully remove this residual amount so a
leaking area is not detected erroneously upon a later leak . de‐
Volkswagen AG
tection. wagen AG does
lks n o ot g
yV ua
edb ran
ris tee
The cartridge -A- contains 15.4 ml of leak ho
aut detection additive (one or
ac
unit -B- corresponds to 2.5 ml). ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Switch off ignition.
ss o
– Remove sealing cap from service connection of low pressure
cial p
f in
side in refrigerant circuit.
form
mer
– Assemble the Leak Detection Kit - VAS6201A- -1- with the atio
m
cartridge -2- Leak Detection Kit - Cartridge - VAS6201/2- .

o
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi Co
Make sure the hand pump hose is completely filled with leak de‐ Cop py
tection additive. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Place the quick-release coupling on the low pressure side Prote AG.
service connection and tighten the hand wheel to open the
service coupling. Hold the hose upward and tighten the handle
of the hand pump just enough until the leak detection additive
starts to emerge from the tube.
– Cover area around service connection on vehicle with foil or

absorbent paper.
– Tighten the toggle on the hand pump to add 2.5 ± 0.5 ml (mil‐
liliter = cm3) of leak detection additive to the refrigerant circuit.

n AG. VolkswagRefrigerant
en AG R134a Servicing - Edition 08.2015
wage
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doe s no
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by ara
– Close the service couplingrisand
ed remove it from the service nte
connection. tho eo
au ra
c
ss
– Remove the rest of the leak detection additive from the service
ce
le
un
connection, for example with absorbent paper.
pt
an
d
itte
y li
– Seal service connection with sealing cap.
rm
ab
pe
ility
– If necessary, clean area around service connection using
ot
wit
, is n
cleaning agents.
h re
hole
spec
– Place a label next to the service connection stating that leak
es, in part or in w
detection additive was added to the refrigerant circuit.
t to the co
– Start the A/C system.
rrectness of i
Note
l purpos
The A/C system must run for at least 60 minutes so the additive
nform
ercia

pressor must be running. Depending on the size of the leak, it may
m
a
become visible within that time.
com
tion in
r
te o
thi
– Find the leak in the refrigerant circuit with the UV lamp‐
s
iva
do
VAS6196/4. Refer to ⇒ page 79 .
r
rp
cum
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c
Remove existing leak detection additive in the engine compart‐
lksw
cted agen
Prote
ment or from the refrigerant circuit components using Leak De‐
AG.
tection Kit - Cleaning Solution - VAS6201/3- .
Detecting leaks in the refrigerant circuit using the UV Lamp‐

VAS6196/4
WARNING
Do not look into the UV lamp.

Do not direct UV lamp at other people.
Note
♦ The A/C system must run for at least 60 minutes so the additive
pressor must be running. Depending on the size of the leak, it
may become visible within that time.
♦ With leaks on evaporator, leak detection additive is possibly
washed off with condensation and flows out via evaporator
drain. Since the evaporator is not easily accessible on most
vehicles, checking the evaporator drain may indicate if the
evaporator is leaking. However, it is necessary for this purpose
that leak detection additive has already been in the refrigerant
circuit for a long period of time.
♦ Protective goggles do not only serve as eye protection but also
amplify the illumination of leak detection additive under UV
light.
♦ Depending on the accessibility of different components in the
refrigerant circuit, it may be necessary to remove some vehicle
components such as the bumper or air filter.

– Move vehicle into a slightly darker area of the workshop (with

daylight or bright lighting the effect of the UV light is diminish‐
ed).
– Check the accessibility of the various components in the re‐
frigerant circuit and remove any components in the area that
block access to the refrigerant circuit such as noise insulation
and the bumper.
– Wear protective eyewear to protect the eyes.
– Connect the UV-lamp to a 12 volt battery (vehicle battery).
Observe the correct polarity of connections.
– Switch on the UV lamp and illuminate the components of re‐
frigerant circuit. Locations where refrigerant, refrigerant oil and
leak detection additive has leaked out light up under fluores‐
cent UV light.
Note
♦ The leak detection additive can remain in the refrigerant cir‐

cuit.
♦ Remove existing leak detection additive in the engine com‐
partment or from the refrigerant circuit components using Leak
Detection Kit - Cleaning Solution - VAS6201/3- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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7 Refrigerant Circuit, Removing Con‐

taminants
⇒ “7.1 Refrigerant Circuit, Flushing with Compressed Air and Ni‐
trogen”, page 81
⇒ “7.2 Refrigerant Circuit, Flushing (Cleaning) with Refrigerant
R134a”, page 83
7.1 Refrigerant Circuit, Flushing with Com‐

pressed Air and Nitrogen
⇒ “7.1.1 General Information”, page 81
⇒ “7.1.2 Refrigerant Circuit, Flushing”, page 83
7.1.1 General Information

• In order to be able to force moisture and other contaminants
out of refrigerant circuit, compressed air and nitrogen (to force
moisture out of refrigerant circuit) are to be used.
• For the most part, blowing through the refrigerant circuit with
compressed air and nitrogen requires significantly more work
than flushing with refrigerant R134a. As flushing with refriger‐
ant r134a cleans the components more efficiently, always
flush in case of a complaint (blowing through should only be
used for certain complaints and individual components).
Only individual components should be flushed if:
♦ there is no possibility of flushing the refrigerant circuit with re‐
frigerant R134a.
♦ dirt or other contaminants are located in individual compo‐
nents of the circuit.
♦ vacuum reading is not maintained on evacuating a leak-free
refrigerant circuit (pressure build-up due to moisture in refrig‐
erant circuit). gen AG
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♦ refrigerant circuit
d b has been left open for longer than
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ara
(e.g. following
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ut or
♦ pressuress and temperature measurements in the refrigerantc
a a
circuit indicate the likelihood of moisture.
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♦ stipulated by the vehicle-specific repair manual Heating & Air

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Conditioning following replacement of certain components.

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ility
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♦ Blowing compressed air and nitrogen through the refrigerant

t to the co
circuit does not achieve the level of cleanliness as flushing with

refrigerant R134a. Flushing with refrigerant R134a loosens the
refrigerant oil and the components are then cleaner. Refer to
rrectne

R134a”, page 83 .
ss o
♦ When blowing, working pressure must not exceed a maximum

cial p
f in
of 15 bar (218 psi), (also use a pressure reducer for com‐

form
mer
pressed air if necessary).

atio
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or
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7. Refrigerant Circuit, Removing Contaminants
AG.
AG. Volkswagen AG d
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♦ Nitrogen can leak uncontrolled fromhothe
ris cylinder. nte
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♦ Make exclusive use of pressure reducers
ss for nitrogen cyl‐ c
inders (maximum work pressure 15 bar (218 psi)).
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♦ Use appropriate emissions extraction units to draw off gas
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mixture escaping from components. pe
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– Always flush components in direction opposite of refrigerant
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flow direction.
es, in part or in w
t to the co
Restrictor, expansion valve, compressor, receiver and reservoir
cannot be flushed with compressed air and nitrogen.
rrectness of i
– Remove this dryer cartridge on condensers that have one in‐
stalled in the integrated receiver/dryer.
l purpos
– First blow out dirt with compressed air, then remove moisture
from components with nitrogen.
nform
ercia
– Connect adapter to connect the pressure hose to the refriger‐

m
a
ant circuit. Refer to
com
tion in
⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, page 102
r
te o
and Heating & Air Conditioning.
thi
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Note the following points to prevent oil and moisture from entering
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the refrigerant circuit from the compressed air system.
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♦ The compressed air must be routed through a compressed air C py
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purifier for cleaning and drying. Use is therefore to be made of
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filter and dryer for compressed air (included in scope of deliv‐
o Vo
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ery as tool for painting work). Refer to the Workshop Equip‐
agen
Prote AG.
ment And Special Tools Catalog.
♦ For refrigerant lines with threads or union nut at connection,
make use of A/C Adapter Set - Adapter 1 - VAG1785/1-
through A/C Adapter Set - Adapter 8 - VAG1785/8- for con‐
nection of 5/8" -18 UNF charging hoses. This adaptor is
located in the Refrigerant Circuits Adapter Set 1 - VAS6338/1-
and Refrigerant Circuits Adapter Set 2 - VAS6338/50- .
♦ On refrigerant pipes without thread or union nut on the con‐
nection, use adapter from Refrigerant Circuits Adapter Set 1 -
VAS6338/1- or Refrigerant Circuits Adapter Set 2 -
VAS6338/50- or a commercially available pistol with rubber
mouthpiece.
Note
♦ Compressed air/nitrogen emerging from components is to be

drawn off by way of an appropriate system (e.g. workshop ex‐
traction system).
♦ Certain contaminants cannot be removed or can only be re‐
moved insufficiently from the refrigerant circuit with com‐
pressed air. These contaminants can only be removed by
flushing with refrigerant R134a. Refer to
R134a”, page 83 .

7.1.2 Refrigerant Circuit, Flushing
Note
♦ For vehicles in which no adapters fit on to the refrigerant pipes,

for example, a blower pistol with rubber mouthpiece is to be
used to blow through individual components. Special care
must be taken not to damage the connections (crushing or
scratching).
♦ Evaporator is to be flushed via the connection for low-pressure
pipe (large diameter) after removing expansion valve or re‐
moving restrictor.
♦ Always flush components in direction opposite of refrigerant
flow direction.
♦ Check expansion valve and replace if dirty or corroded.
♦ If there are dark, sticky deposits in the components that cannot
be removed with compressed air, replace these components.
♦ Thin, light grey deposits on the insides of refrigerant pipes do
not impair the function of the components.
♦ After flushing, always replace receiver/dryer or reservoir and
restrictor. Replace dryer cartridge or dryer on condensers with
attached dryer.
7.2 Refrigerant Circuit, Flushing (Cleaning)

with Refrigerant R134a swa
gen AG
. Volkswagen AG
does
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Vol gu
⇒ “7.2.1 General Information”, page 83 d by ara
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ris
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⇒ “7.2.2 Flushing Circuit Block Diagrams”, page 93au ra
c
ss
⇒ “7.2.3 Electrically Driven A/C Compressor, Flushing”,
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page 98
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7.2.1 General Information
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Vehicles with a high voltage system (hybrid vehicles)
es, in part or in w
t to the co
Observe all of the additional warnings for all work performed on
vehicles with the high voltage system. Refer to ⇒ Electrical
Equipment; Rep. Gr. 93 ; General Warnings when Working on rrectness of i
High Voltage System .
l purpos
WARNING
nform
ercia
Risk of unintended engine start

m
at
om
The ignition must be turned off and the ignition key must remain
ion
c
outside of the vehicle when working on vehicles with a high

in t
or
voltage system.
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ate
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7. Refrigerant Circuit, Removing Contaminants 83

WARNING
Handling high voltage cables:

• Do not stand on or place tools on high voltage cables and
their components as it may damage the cable insulation.
• Never bend or kink high voltage cables forcefully as it may
damage the cable insulation.
swage es n
• The round high voltage connectors are color coded with byV
olk ot g
ua
an external color ring and are mechanically coded using
ir se
d ran
tee
the guide- or code tabs. Always make certain thatutthe
h cod‐
o
or
ing matches when connecting the round connector
ss
a in ac
order to avoid any mechanical damage the high voltage
ce
le
un
pt
connector.
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pe
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DANGER!
h re
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spec
There is a risk of electrocution from damaged high voltage
es, in part or in w
t to the co
components.
Observe the following when working around high voltage com‐
ponents and high voltage wires:
rrectness of i
♦ Never work around high voltage components and cables
l purpos
with cutting, deformed, or sharp edged tools, or heat sour‐

ces such as welding or soldering tools, heated air, and
nform
ercia
thermal glue.
m
♦ Inspect the high voltage components visually before be‐
a
com
tio
ginning.
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♦ Perform a visual inspection of the Electric Drive Power and
s
iva
do
Control Electronics - JX1- , the Electro-Drive Drive Motor
r
rp
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- V141- , the Electrical A/C Compressor - V470- and the
fo
en
g
high voltage lines when working in the engine compart‐

n
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♦ Perform a visual inspection of the high voltage lines and
p by
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covers when working on the underbody. Prote
cted AG.
agen

the Electrobox with the High Voltage System Maintenance
Connector - TW- when working in the luggage compart‐
ment.
♦ Perform a visual inspection on all of the potential equali‐
zation cables.
Observe the following items when performing the visual in‐
spection:
♦ The components do not display any signs of external dam‐
age.
♦ The high voltage cable insulation and the potential equal‐
ization cables are not damaged.
♦ The high voltage cables do not display any abnormal de‐
formations.
♦ Every high voltage component is marked with a red warn‐
ing label.
If it is necessary to perform work in the vicinity of high voltage

components, perform a “visual inspection” of the high voltage
components and cables for damage and follow the “general warn‐
ings when working on the high voltage system”. Refer to ⇒

Electrical Equipment; Rep. Gr. 93 ; General Warnings for Work‐

ing on High Voltage System .
If it is necessary to perform work on the high voltage components,
disable the high voltage system. Refer to ⇒ Electrical Equipment;
Rep. Gr. 93 ; High Voltage System, Disabling and read and follow
the “high voltage electrical system general warnings” ⇒ Electrical
Equipment; Rep. Gr. 93 ; General Warnings for Working on High
Voltage System .
Caution
lkswage es n
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♦ If it is suspected dthat chemicals were added to the refrig‐
b ua
ran
ir se
erant circuit tto ho seal leaks, do not connect the A/C service tee
or
station and audo not extract the refrigerant. ac
ss
ce
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un
pt
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♦ Remind the customer that the refrigerant circuit contains
wit
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substances that VW has not approved. As such, the re‐
h re
ole,
frigerant circuit cannot be flushed. It is only possible to
spec
service the refrigerant circuit by replacing all the compo‐
nents which come in contact with this material.
t to the co
rrectne
Note
ss o
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refrigerant circuit. f inform

mer

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ponents, even by flushing. It is only possible to service the

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refrigerant circuit by replacing all the components which come
Co
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in contact with this material. t. C rig
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• Refrigerant circuit must be flushed with refrigerant R134a in

order to force out contaminants (e.g. abraded material from a
malfunctioning A/C compressor) as well as old refrigerant oil
as efficiently and as cleanly as possible and without the need
for extensive work.
For vehicles with an electrically-driven A/C compressor, pay at‐
tention to the notes for replacing the Electrical A/C Compressor -
V470-. If there is damage on the A/C compressor electronics, the
refrigerant circuit must not always be cleaned. Refer to
⇒ “11.3.1 Flushing Not Necessary”, page 189 .
The refrigerant circuit should be flushed with refrigerant R134a if:
♦ dirt or other contamination is in the refrigerant circuit.
♦ vacuum reading is not maintained on evacuating a leak-free
refrigerant circuit (pressure build-up due to moisture in refrig‐
erant circuit).
♦ refrigerant circuit has been left open for longer than normal
(e.g. following an accident).

♦ If pressure and temperature measurements in the refrigerant

circuit indicate the likelihood of moisture in the circuit.
♦ It is not clear how much refrigerant oil is in the refrigerant cir‐
cuit. If the A/C compressor should be reinstalled, the refriger‐
ant oil should be drained from the A/C compressor via the
block connections. To facilitate this, the ribbed belt pulley or
A/C clutch plate on the A/C compressor should be rotated by
hand. After flushing, the entire quantity of refrigerant oil speci‐
fied by the vehicle-specific repair manual should be added to
the refrigerant circuit (50 grams directly into the A/C compres‐
sor). Note additional oil quantity for systems with a 2nd evap‐
AG. Volkswagen AG d
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♦ A/C compressor had to be ris
edreplaced on account of internal
b ran
tee
damage (e.g. noise orutno
ho output). or
sa ac
♦ stipulated by the vehicle-specific
s
repair manual following re‐
ce
e
nl
placement of certain components.
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♦ Another compressor with different refrigerant oil should be in‐
erm
ab
stalled.
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Tools required
h re
hole
spec
♦ A/C Service Station with Flushing Device - VAS6381- or Air
es, in part or in w
Conditioning Flush Tool - VAS6337- . The auxiliary function
t to the co
“Flush refrigerant circuit” and the refrigerant circuit flushing
device required for it are present on these A/C service stations.
Refer to Special Tools Catalog.
rrectness of i
♦ Refrigerant Circuits Adapter Set 1 - VAS6338/1- . Refer to
l purpos

and Special Tools Catalog
nf
ercia
♦ Refrigerant Circuits Adapter Set 2 - VAS6338/50- . Refer to orm

m
atio
m
and Special Tools Catalog.

o
n in
or c
thi
te
sd
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Note
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♦ If neither of the two A/C service stations listed above are avail‐
yi Co
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able for use in the workshop, A/C Service Station with Flushing
C py
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Device - VAS6336/1- or Air Conditioning Flush Tool -
ht
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VAS6337/1- (depending on the workshop A/C service station
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version) (min. 7 kg refrigerant R134a in refrigerant bottle) can Prote AG.
also be used to flush the refrigerant circuit. However, the flush‐

ing procedure must then be performed manually. Refer to
⇒ page 91 .
♦ In vehicles with screw-connections on refrigerant circuit, A/C
Adapter Set - Adapter 1 - VAG1785/1- through A/C Adapter
Set - Adapter 2 - VAG1785/8- from the Refrigerant Circuits
Adapter Set 1 - VAS6338/1- or Refrigerant Circuits Adapter
Set 2 - VAS6338/50- may be used. In vehicles with screw-
connections on A/C compressor and on accumulator, two of
the A/C Adapter Set - Adapters 8 - VAG1785/8- are required.
♦ A Refrigerant Circuits Adapter Set 2 - Adapter 31 -
VAS6338/31- with 5/8 -18 UNF connections and large internal
diameter can be found in the adapter chests in order to be able
to bridge components (it is commercially available).
Preliminary work
– Discharge refrigerant circuit. Refer to
page 59 .
– Remove A/C compressor. Refer to Heating, Ventilation & Air
Conditioning.

On a vehicle with restrictor and reservoir.

– Remove restrictor (specific to vehicle) and .reconnect refriger‐
Volkswagen A
n AGVentilation
ant pipes to each other. Refer to kHeating, &GAir
l swage does
not
Conditioning. by
Vo gu
a d ran
ise
– Remove reservoir (specificut
ho to vehicle). Refer to Heating, Ven‐
r tee
or
tilation & Air Conditioning
ss
a and connect refrigerant pipes to ac
each other (to do this, use adapter and Refrigerant Circuits
ce
le
un
Adapter Set 1 - Adapter 31 - VAS6338/31- ) from Refrigerant
pt
an
d
itte
Circuits Adapter Set 1 - VAS6338/1- . Refer to
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erm
ab
⇒ “7.2.4 Adapter for Assembling Flushing Circuit”,
ility
ot p
page 102 .
wit
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ole,
spec
Note
t to the co
The reservoir could be flushed, but it requires too much refrigerant
due to its large volume. When this refrigerant is extracted, the
reservoir ices up severely and this prolongs the extraction proc‐
rrectne
ess significantly.
ss
On a vehicle with expansion valve and receiver/dryer.
o
cial p
f inform
– Remove receiver/dryer. Refer to Heating, Ventilation & Air
mer
Conditioning (specific to vehicle, not required for all vehicles)
atio
m
and connect refrigerant pipes to each other (for this, use

o
n
c
i
adapters and Refrigerant Circuits Adapter Set 1 - Adapter 31
or
n thi
e
- VAS6338/31- ). Refer to
t
sd
va

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pr
cum
r
page 102 .
fo
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ng
t.
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– Remove expansion valve. Refer to Heating, Ventilation & Air . Cop py
Conditioning (specific to vehicle) and install the adapter for it.
t rig
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Refer to cop Vo
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⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, cted agen
Prote AG.
page 102 .
Note
If no suitable adapter for the expansion valve is available in Re‐

frigerant Circuits Adapter Set 1 - VAS6338/1- or Refrigerant Cir‐
cuits Adapter Set 2 - VAS6338/50- , the remove expansion valve
can also be drilled open (the expansion valve must be replaced
with a new one).
Caution
♦ Make sure the sealing surfaces on the expansion valve

are not damaged when drilling open.
♦ Otherwise refrigerant leaks out.

Note
♦ Several components are to be removed from expansion valve

before drilling open. agen
AG. Volkswagen AG d
oes
lksw not
Expansion valves are available in different versions. For Vver‐
o
♦ d by gu
ara
sion -A-, components -B-, -C- and -D- must be removed.orise Then nte
eo
separate regulating element -E- from component aut -D-. Then
h
ra
drill open expansion valve in area -F- using a ssuitable drill (6
s c
ce
e
mm diameter).
nl
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itte
♦ For version -G-, parts -H-, -I- and -K- must be removed and
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ab
then drill open area -L- using suitable drill (6 mm diameter).
ility
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♦ Clean the drilled open expansion valve of residue from the
, is n
h re
work (shavings).
hole
spec
♦ Install parts -B-, -C- and -D- for version -A- or -H- for version
es, in part or in w
t to the co
-G-.
rrectness of i
Note
l purpos
In vehicles with two evaporators, the circuit to the second evap‐

orator must be disconnected from circuit of the first evaporator
nform
ercia
and must be flushed via a separate work procedure. Refer to

m
Heating, Ventilation & Air Conditioning and
at
om
io
⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, page 102 .
n
c
in t
or
his
ate
Drilling open the shut-off valve.
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. Volkswagen AG
gen AG d
Beetle
Vol 2012 ➤ , CC 2010 ➤ , CC o2012
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a oes
n t ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
by gu
ised Refrigerant
ara
n R134a Servicing - Edition 08.2015
r tee
ho
aut or
ac
ss
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e
Note
nl
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erm
♦ Two shut-off valves are required for flushing the refrigerant
ab
ility
circuit/ If the Refrigerant Circuits Adapter Set - Shut-Off Valve
ot p
wit
- VAS6338/42- is not available to flush the refrigerant circuit,
, is n
h re
than a shut-off valve is to be drilled out, for example.
hole
spec
♦ Remove the solenoid coil -A- and the solenoid valve -B- before
es, in part or in w
t to the co
drilling open.
♦ Drill open the shut-off valve -C- using a suitable drill (diameter
of the drill for example 5.0 mm).
rrectness of i
♦ Clean the shut-off valve -C- from shavings produced by drilling
l purpos
-D-.
♦ Install the solenoid valve -B- with the seals belonging to it
nform
ercia
-E- on the drilled open shut-off valve -C-.

m
at
om
ion
Flushing
c
in t
or
his
te
– Check refrigerant quantity in the refrigerant cylinder, there

a
do
riv
must be at least 7 kg of refrigerant R134a.

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cum
for
en
ng
t.
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op py
Note
t. C rig
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If necessary, switch on the heater installed on the refrigerant cyl‐ cted agen
Prote AG.
inder for 30 minutes before the first flushing procedure. This
increases pressure in the refrigerant cylinder and accelerates
charging of the flushing circuit.
– Evacuate the A/C service station old oil container.

– Connect the supply hose (high pressure side) of A/C service
station to the low pressure line leading to the A/C compressor
(line with larger diameter) using an adapter. Refer to
page 102 .
– Connect return hose (low pressure- or intake side) of A/C
service station to output of refrigerant circuit flushing device.
– Connect the input on the refrigerant circuit flushing device to
the high pressure line leading to the A/C compressor (line with
smaller diameter) using an adapter. Refer to
page 102 .

Note
♦ Components are always (with the exception of the electrically-

swa
gen AG
. Volkswagen AG
does
driven A/C compressor) flushed in the oppositebydirection
Vol
k of not
gu
refrigerant flow when the A/C system is operating.
ir se
d Refer to ara
nte
⇒ “7.2.2 Flushing Circuit Block Diagrams”,
ut page 93 .
ho eo
ra
sa c
♦ While flushing, contaminants from the srefrigerant circuit enter
ce
le
the refrigerant circuit flushing device and the A/C service sta‐
un
pt
an
d
tion and are absorbed by the filters and dryers installed there.
itte
y li
Depending on the contaminant, these components are to be
erm
ab
ility
replaced in shorter intervals in line with operating instructions
ot p
for A/C service station or refrigerant circuit flushing device.
wit
is n
h re
ole,
♦ The filter in the refrigerant circuit flushing device depends on
spec
the type and degree of contamination in the flushed refrigerant
t to the co
circuit. It should be replaced after 2 flushing cycles, at the
most. If a heavily contaminated refrigerant circuit is flushed
(the refrigerant oil from the circuit is black and viscous or there
are many shavings in the refrigerant circuit), the filter should
rrectne
be replaced after flushing. With a refrigerant circuit heavily
contaminated in this way, it is wise to flush the circuit again
ss
after changing the filter.
o
cial p
f in
♦ Depending on the type of contamination, dirt (old refrigerant
form
mer
oil and abraded material from A/C compressor) is deposited
atio
on the viewing glass(es). Clean viewing glass(es) after flush‐
om
n
ing and flush the refrigerant circuit once more with one flushing
c
i
or
n thi
procedure as a check.
te
sd
iva
o
r
♦ Fluid refrigerant cannot be conducted with the necessary

p
cum
r
fo
speed through the expansion valve, restrictor and desiccant
en
ng
t.
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bag of certain receiver/dryers, therefore these components
Co
op py
must be removed and replaced by an adapter. Refer to Heat‐ t. C rig
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ing, Ventilation & Air Conditioning. pyri by
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co lksw
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cted agen
♦ Adapters for connecting A/C service station and for bridging Prote AG.
certain components of refrigerant circuit. Refer to
page 102 .
– Switch on the service station and flush the refrigerant circuit

(duration for one flushing cycle with three flushing procedures
is approximately 1 to 1.5 hours for about 4Kg of coolant
R134a).

Note
♦ Perform flushing of refrigerant circuit according to operating

instructions of the A/C service station.
♦ Depending on A/C service station version, the old oil container
holds only approximately 125 cm 3 of refrigerant oil. In the
event a system with a larger volume of refrigerant oil must be
flushed, it may be necessary to empty the old oil container after
the first flushing procedure of a flushing cycle.
♦ Observe the refrigerant which flows back from the refrigerant
circuit. The refrigerant circuit is only clean when the refrigerant
flows clear and completely colorless through the viewing glass
(es) on the flushing device in the A/C service station.
♦ When flushing, the complete amount of refrigerant oil is wash‐
ed out of the refrigerant circuit (except for minor remains which
can be disregarded).
♦ If contamination is especially severe, it may be necessary to
perform the flushing cycle twice (two flushing cycles with three
flushing operations each). Before the second flushing cycle,
the filter on the flushing
olksdevice
wage must be replaced. es n
o
yV t gu
db ara
ir se nte
Sequence of flushingho procedure (sequence occurs automaticallyeo
according to the autA/C service station program) ra
ss c
ce
le
♦ After turning on, the flushing circuit (refrigerant circuit with

un
pt
connecting hoses and flushing equipment for refrigerant cir‐

an
d
itte
y li
cuits) is evacuated first and the refrigerant circuit is checked

erm
ab
for leaks during this. Depending on A/C service station ver‐

ility
ot p
sion, it is possible that manually switching to advance the

wit
is n
program is required.
h re
ole,
spec
♦ A prescribed amount of refrigerant (e.g. 4 kg) is filled into the

evacuated flushing circuit via the high pressure side of the A/

t to the co
C service station (opposite the normal direction of flow during

normal A/C system operation and thus on the low pressure
side of vehicle refrigerant circuit). Depending on the version of
rrectne
the A/C service station, refrigerant is added until the flushing

circuit is completely full. This can be detected by e.g. refriger‐
s
ant no longer flowing in after a certain period of time.

s o
cial p
f in
♦ After the prescribed quantity of refrigerant has been filled, for

form
mer
example. the heater for the refrigerant circuit flushing device

atio
is switched on (only in the event the refrigerant is extracted in

om
gaseous form from the refrigerant circuit flushing device), de‐

n
c
i
or
pending on version of A/C service station and refrigerant

thi
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a
circuit flushing device.

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♦ After the refrigerant has been extracted, the heater on the re‐
en
ng
t.
frigerant circuit flushing device (if applicable) switches off, the
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refrigerant circuit may be evacuated again (depending on the
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version), and the refrigerant oil extracted from the refrigerant
ht
pyri by
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circuit is separated by the A/C service station after evacuating.
c by lksw
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♦ The sequence of filling refrigerant, extracting (and evacuating)
is repeated twice (performed a total of three times).
♦ After the third extraction, the flushing circuit is evacuated de‐
pending on the version of the A/C service station.
– After the flushing cycle has ended, check the viewing glass
(es) on the flushing device. If they are dirty, clean them ac‐
cording to the instructions for the flushing device or A/C serv‐
ice station. Perform one addition flushing cycle as a check.
One flushing procedure is sufficient (approximately 30 min.)

. Volkswagen AG
gen AG
Refrigerant R134a Servicing - Editionlk08.2015 does
swa o n ot g
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edb ran
– Check pressure in refrigerant circuit, risthere must be no positive tee
tho
pressure in the refrigerant circuitau(evacuate refrigerant circuit or
ac
briefly once more if necessary).ss
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e
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pt
du
– Disconnect A/C service station connections from vehicle re‐
an
itte
y li
frigerant circuit. There must be no positive pressure in the
erm
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ility
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wit
– Replace these vehicle-specific components.
, is n
h re
hole
♦ Restrictor and reservoir
spec
es, in part or in w
♦ Expansion valve and receiver/dryer or dryer cartridge in re‐
t to the co
ceiver/dryer
– Refer to Heating, Ventilation & Air Conditioning and the Parts
rrectness of i
Catalog.
l purpos
– Depending on the complaint, replace A/C compressor. Refer

to Heating, Ventilation & Air Conditioning and the Parts Cata‐
log or drain the remaining refrigerant oil from the removed A/
nf
ercia
o
C compressor. Refer to
rm
m
⇒ “11 Components, Replacing”, page 187 (replace refrigerant
atio
m
circuit components) and refill the prescribed quantity of fresh

o
n in
or c
refrigerant oil. Refer to the vehicle-specific repair manual.
thi
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Cop py
♦ A certain prescribed quantity of refrigerant oil is in the A/C
t. rig
gh ht
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compressor original part. If the vehicle has two evaporators, op Vo
by c lksw
then the refrigerant circuit requires a specific quantity of re‐ cted agen
Prote AG.
frigerant oil. Refer to the vehicle-specific repair manual.
♦ If the A/C compressor is not be replaced, the quantity of re‐
frigerant oil in the A/C compressor must be topped off to the
prescribed capacity (tilt the refrigerant oil out and refill the pre‐
scribed quantity into the A/C compressor or refrigerant circuit).
Refer to ⇒ “11 Components, Replacing”, page 187 (replacing
refrigerant circuit components) and vehicle-specific repair
manual.
– Completely reassemble the refrigerant circuit. Refer to Heat‐

ing, Ventilation & Air Conditioning.
– Evacuate and recharge refrigerant circuit according to speci‐
fication. Refer to
page 60 and
⇒ “5.5 Refrigerant Circuit with A/C Service Station, Filling”,
page 62 .
– Start up A/C system according to specification. Refer to Heat‐
ing, Ventilation & Air Conditioning and
⇒ “5.6 A/C System, Operating after Charging”, page 64 .

7.2.2 Flushing Circuit Block Diagrams
Note
♦ The arrows in the following illustrations show the direction of

refrigerant flow while flushing. During flushing, refrigerant
flows in the opposite direction than during A/C system opera‐
tion, therefore the high pressure side of A/C service station is
connected to A/C compressor at low pressure side of refrig‐
erant circuit.
♦ These block diagrams indicate a refrigerant circuit with re‐
strictor and reservoir and a refrigerant circuit with expansion
valve, receiver/dryer and a second evaporator (optional equip‐
ment on certain vehicles)
♦ Depending on the design of the A/C service station, check
valves can be installed between the refrigerant circuit and the
A/C service station. They guarantee the correct direction of
refrigerant flow during flushing.
Refrigerant Circuit with Restrictor and Reservoir
Note
On vehicles with restrictor and reservoir, the restrictor and reser‐ . Volkswagen AG
voir are removed. Restrictor refrigerant pipes are reassembled. lkswagen AG does
The refrigerant pipe to the removed reservoir are connectedbwith o not
yV gu
ara
each other via two adapters and the Refrigerant CircuitsorAdapter
ise
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Set 2 - Adapter 31 - VAS6338/31- (from the Refrigerant uth Circuits eo
ra
Adapter Set 1 - VAS6338/1- ).
a c
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pt
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
r
te o
thi
s
iva
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en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
cted agen
Prote AG.

1 - A/C service station

❑ With electronics and a
flushing program, for ex‐
ample A/C Service Sta‐
tion with Flushing De‐
vice - VAS6380- or Air
Conditioning Flush Tool
- VAS6337- .
❑ If an A/C service station
without a flushing pro‐
gram is used, the proce‐
dure must be performed n AG. Volkswagen A
manually (evacuate, olks
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flush 3 times withd by at
V ua
ran
least 4 kg refrigerant
oris
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tee
each andauextract refrig‐
th or
ac
erant again,
ss evacuate).
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le
un
pt
2 - A/C service station refriger‐
an
d
itte
ant hose
y li
erm
ab
❑ From high pressure side
ility
ot p
of A/C service station
wit
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(mostly colored red) to
h re
ole,
low pressure side con‐
spec
nection of A/C compres‐
t to the co
sor on refrigerant circuit
(larger diameter).
3 - Adapter for connecting low rrectne
pressure side to refrigerant cir‐
cuit
ss
❑ Different versions de‐

o
cial p
pending on vehicle. Re‐

inform
fer to
mer
⇒ “7.2.4 Adapter for As‐

atio
m
sembling Flushing Cir‐

o
n
c
i
or
cuit”, page 102 .

thi
te
sd
a
❑ From the Refrigerant

iv
o
pr
Circuits Adapter Set 1 -

um
r
fo
VAS6338/1-
en
ng
t.
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op py
4 - Low pressure side connection on refrigerant circuit
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ht ht
rig by
❑ Different versions depending on vehicle. Refer to copy Vo
by lksw
⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, page 102 . cted agen
Prote AG.
❑ On refrigerant line from A/C compressor to reservoir.
5 - Connection to reservoir
❑ Different versions depending on vehicle. Refer to
❑ On refrigerant line from A/C compressor to reservoir.
6 - Adapter for bridging the removed reservoir
❑ From the Refrigerant Circuits Adapter Set 1 - VAS6338/1-
7 - Refrigerant charge hose. Refer to ⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, page 102 .
❑ For example Refrigerant Circuits Adapter Set 1 - Adapter 31 - VAS6338/31- (from the Refrigerant Circuits
Adapter Set 1 - VAS6338/1- )
8 - Adapter for bridging the removed reservoir

9 - Connection to reservoir
10 - Evaporator
11 - Component location of restrictor
❑ Restrictor is removed.
❑ Remove restrictor. Refer to Heating, Ventilation & Air Conditioning.
12 - Bolts in refrigerant line
❑ Bolt together again after removing restrictor. Refer to Heating, Ventilation & Air Conditioning.
13 - Condenser
14 - High pressure side connection on refrigerant circuit
15 - Adapter to connection for high pressure side on refrigerant circuit
16 - Charge hose for refrigerant circuit flushing device
AG. Volkswagen AG d
❑ From connection toolthe agen
ksw high pressure side of ethe
o s A/C compressor on the refrigerant circuit (smaller
no
diameter) to input
d by Vof Refrigerant Circuit Flushing tDevice
gu
ara - VAS6336/1- or Air Conditioning Flush Tool -
VAS6337/1A- or .
ise nte
e
h
ut or
17 - Flushing equipment
ss
a
for refrigerant circuits ac
ce
le
❑ Different versions and different construction, for example Refrigerant Circuit Flushing Device -
un
pt
an
VAS6336/1- or Air Conditioning Flush Tool - VAS6337/1- .

d
itte
y li
rm
ab
❑ With filter, viewing glass, security valve, heater, refrigerant container, etc. (depending on version).
pe
ility
❑ Depending on the construction of the A/C service station and of refrigerant circuit flushing device, a
ot
wit
, is n
check-valve may be installed at output of refrigerant circuit flushing device (to guarantee correct direction
h re
hole
of refrigerant flow during flushing).

spec
es, in part or in w
18 - A/C service station refrigerant hose

t to the co
❑ From the low pressure side of the service station (mostly blue) to the output of the flushing device for
refrigerant circuits.
rrectness of i
l purpos
Refrigerant circuit with expansion valve, receiver/dryer and sec‐

ond evaporator
nform
mercia
a
com
Note
tion in
r
te o
thi
♦ This block diagram shows a refrigerant circuit with expansion

s
iva
do
valve, receiver/dryer and second evaporator (optional equip‐

r
rp
cum
ment on certain vehicles).

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ng
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♦ On vehicles with an expansion valve and receiver/dryer, the Cop py
expansion valve is removed and replaced by an adapter. De‐
t. rig
gh ht
yri by
pending on vehicle, receiver/dryer is flushed or dryer cartridge
cop Vo
by lksw
is removed. Depending on receiver/dryer version, it is to be cted agen
Prote AG.
removed and line connections to receiver/dryer are to be con‐
nected to each other with two adapters and a charging hose.
♦ On a vehicle with only one evaporator, the components as of
position “16” are not installed or are not required.


❑ With electronics and a
flushing program, for ex‐
ample A/C Service Sta‐
tion with Flushing De‐
vice - VAS6380- or Air
Conditioning Flush Tool
- VAS6337- .
❑ If an A/C service station

without program is used
for flushing, the proce‐
dure should be per‐
formed manually.
– Extract the refrigerant, if
necessary.
– Set up the Refrigerant

Circuit Flushing Device -
VAS6336/1- or Air Con‐
ditioning Flush Tool - agen
AG. Volkswagen AG d
oes
VAS6337/1A- between olksw not
yV gu
the A/C service station ised b ara
nte
and refrigerant circuit ut
hor eo
return line. ss a ra
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le
un
– Evacuate refrigerant cir‐
pt
an
d
itte
cuit for 20 minutes and
y li
erm
ab
then charge with 4 kg re‐
ility
ot p
frigerant R134a. Then
wit
extract again and repeat
is n
h re
the procedure 2 more
ole,
spec
times. If the refrigerant
in the viewing glass(es)
t to the co
is not clear after the third
attempt, an additional
attempt is necessary.
rrectne
2 - A/C service station refriger‐
ant hose ss o
cial p
f
❑ From high pressure side of A/C service station (mostly colored red) to low pressure side connection of
inform
A/C compressor on refrigerant circuit (larger diameter).

mer
atio
3 - Adapter for connecting low pressure side to refrigerant circuit

om
n
c

i
or
n thi
e

t
sd
iva
o
r

p
cum
r
fo
en
ng
4 - Low pressure side connection on refrigerant circuit

t.
yi Co
Cop py
❑ Different versions depending on vehicle. Refer to ht. rig
rig ht
⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, page 102 . py by
co Vo
by lksw
cted agen
5 - Adapter for the removed expansion valve Prote AG.

6 - Evaporator
7 - Connection to receiver/dryer
❑ Not present on vehicles with a dryer cartridge in receiver/dryer on condenser or a receiver/dryer installed
in the condenser. Refer to Heating, Ventilation & Air Conditioning.

8 - Adapter for bridging the removed receiver/dryer

❑ Not required for all vehicles.
9 - Refrigerant charge hose. Refer to ⇒ “7.2.4 Adapter for Assembling Flushing Circuit”, page 102 .
❑ For example Refrigerant Circuits Adapter Set 1 - Adapter 31 - VAS6338/31- (from the Refrigerant Circuits
Adapter Set 1 - VAS6338/1- )
10 - Condenser
❑ If a receiver/dryer with dryer cartridge is installed on the condenser, dryer cartridge must be removed
(seal again the receiver/dryer on or in the condenser after removing). Refer to Heating, Ventilation & Air
Conditioning.
❑ If receiver/dryer is built directly on the condenser, receiver/dryer is to be removed and replaced only after
flushing. Refer to Heating, Ventilation & Air Conditioning.
11 - High pressure side connection on refrigerant circuit
AG. Volkswagen AG d
agen
❑ Different versions depending Volkswon vehicle. Refer to
oes
not
gu
⇒ “7.2.4 Adapter for Assembling
ed
by Flushing Circuit”, page 102 ara .
n is tee
or
12 - Adapter to connection
au
th for high pressure side on refrigerant circuit or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
❑ From connection to the high pressure side of the A/C compressor on the refrigerant circuit (smaller
h re
ole,
diameter) to input of refrigerant circuit flushing device.
spec
14 - Flushing equipment for refrigerant circuits
t to the co
VAS6336/1- or Air Conditioning Flush Tool - VAS6337/1- . rrectne
s
s o
cial p

f inform
mer

atio
m
o
n
c
i
or
n thi
te
sd
a
16 - Adapter to seal output to second evaporator

iv
o
pr
cum
r
❑ Only required for certain vehicles with optional equipment “second evaporator”.
fo
en
ng
t.
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❑ From the Refrigerant Circuits Adapter Set 2 - VAS6338/50- .
Co
Cop py
ht. rig
17 - Adapter to seal output to second evaporator rig ht
py by
co Vo
lksw
by
cted agen
Prote AG.
18 - Low pressure side connection on refrigerant circuit to second evaporator
❑ Only present on certain vehicles with optional equipment “second evaporator”.
19 - Connection of high pressure side on refrigerant circuit to second evaporator
20 - Adapter for the removed expansion valve on second evaporator

21 - Second evaporator
7.2.3 Electrically Driven A/C Compressor,

Flushing
Vehicles with a high voltage system
Observe all of the additional warnings for all work performed on
vehicles with the high voltage system. Refer to ⇒ Electrical
Equipment; Rep. Gr. 93 ; General Warnings when Working on
High Voltage System .
WARNING
Risk of unintended engine start

The ignition must be turned off and the ignition key must remain
outside of the vehicle when working on vehicles with a high
voltage system.
WARNING
Handling high voltage cables:

• Do not stand on or place tools on high voltage cables and
their components as it may damage the cable insulation.
• Never bend or kink high voltage cables forcefully as it may
damage the cable insulation.
• The round high voltage connectors are color coded with agen
AG. Volkswagen AG d
oes
an external color ring and are mechanically coded using y Volksw not
gu
the guide- or code tabs. Always make certain that the cod‐
ise
d b ara
nte
ing matches when connecting the round connector intho r eo
order to avoid any mechanical damage the high voltage
s au ra
c
connector.
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
98
Prote AG.
DANGER!
There is a risk of electrocution from damaged high voltage

components.
Observe the following when working around high voltage com‐
ponents and high voltage wires:
♦ Never work around high voltage components and cables
with cutting, deformed, or sharp edged tools, or heat sour‐
ces such as welding or soldering tools, heated air, and
thermal glue.
♦ Inspect the high voltage components visually before be‐
ginning.
♦ Perform a visual inspection of the Electric Drive Power and
Control Electronics - JX1- , the Electro-Drive Drive Motor
- V141- , the Electrical A/C Compressor - V470- and the
high voltage lines when working in the engine compart‐
ment.
. Volkswagen AG
covers when working on the underbody.kswagen AG does
n ol ot g
yV
♦ Perform a visual inspection of the edhigh voltage lines and
b ua
ran
ris
the Electrobox with the High Voltage
tho System Maintenance tee
or
Connector - TW- when working
ss au in the luggage compart‐ ac
ment.
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un
pt
an
♦ Perform a visual inspection on all of the potential equali‐
d
itte
y li
zation cables.
erm
ab
ility
ot p
Observe the following items when performing the visual in‐
wit
is n
spection:
h re
ole,
spec
♦ The components do not display any signs of external dam‐
age.
t to the co
♦ The high voltage cable insulation and the potential equal‐
ization cables are not damaged.
♦ The high voltage cables do not display any abnormal de‐ rrectne
formations.
ss o
♦ Every high voltage component is marked with a red warn‐

cial p
f in
ing label.
form
mer
atio
om
n
c
If it is necessary to perform work in the vicinity of high voltage

i
or
n thi
e
components, perform a “visual inspection” of the high voltage

t
sd
va
components and cables for damage and follow the “general warn‐
i
o
pr
cum
ings when working on the high voltage system”. Refer to ⇒

r
fo
en
ng
Electrical Equipment; Rep. Gr. 93 ; General Warnings for Work‐

t.
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op
ing on High Voltage System . C py
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If it is necessary to perform work on the high voltage components,
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disable the high voltage system. Refer to ⇒ Electrical Equipment; Prote
cted AG.
agen
Rep. Gr. 93 ; High Voltage System, Disabling and read and follow
the “high voltage electrical system general warnings” ⇒ Electrical
Equipment; Rep. Gr. 93 ; General Warnings for Working on High
Voltage System .

Note
The electrically driven A/C compressor is to be flushed when,

there is dirt, too much refrigerant oil is in the refrigerant circuit, or
is contaminated (with moisture debris) and to remove refrigerant
oil from the A/C compressor. In these cases the refrigerant circuit
must also be flushed, so that it will be cleaned and the correct
refrigerant oil quantity for the refrigerant circuit can be set.
If an electrically-driven A/C compressor is being replaced that

does not have a mechanical fault (for example, a faulty circuit
board), then determine how much refrigerant is in this A/C com‐
pressor.
Note
♦ This A/C compressor must be flushed to get all the refrigerant

oil out.
♦ The A/C compressor is flushed in the flow direction (from the
low pressure side input to the high pressure side output)
♦ So that as much refrigerant oil as possible is flushed out of the
A/C compressor, the A/C compressor must be positioned so
that the high pressure side output is as low as possible.
♦ If an A/C service station without a flushing program is used,
the procedure must be performed manually (evacuate, flush 3
times with at least 2 kg refrigerant each and extract refrigerant
again, evacuate).
Quantity: for example 50 cm³

AG. Volkswagen
Pour so much refrigerant oil lkswout of the new A/C compressor
agen AG do
es n so
ot g
(plus 10 cm 3) that had been
o
that only the amount remains
d by
V uflushed
ara
out of the old A/C ocompressor
ris
e
beforehand. If the new original nteA/
eo
th 3
C compressorshas au for example, 200 cm , then only pour out 140 ra
c
3
cm . s
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le
un
pt
– Pour old refrigerant oil out of A/C compressor. Handling re‐

an
d
itte
y li
frigerant oil.
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
In not enough refrigerant oil can be poured out from the A/C com‐
t to the co
pressor to be installed, flush the new A/C compressor. After

flushing, fill the A/C compressor to be installed with as much new
refrigerant oil as was flushed from the replaced A/C compressor.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
Flushing the A/C compressor is per‐

formed manually.
– Extract the refrigerant, if

necessary.
– Empty the Service Sta‐

tion old oil container.
Note
On some Service Stations, the oil is

first separated in the vacuum phase
and then it goes into the old oil con‐
tainer.
– Set the amount of refrig‐

erant on the Service
Station to 2 kg and the
oil quantity to 0.
– Set up the Refrigerant

Circuit Flushing Device -
VAS6336/1- or Air Con‐
ditioning Flush Tool -
VAS6337/1A- between
the A/C service station
and refrigerant circuit
return line.
– Evacuate the refrigerant

circuit for 10 minutes.
Then observegthe vac‐
AG. Volkswagen AG
a en does
uum display.Volksw If the vac‐ not
uumedremains constant,
by gu
ara
nte
then
horis
fill the circuit with 2 eo
autkg refrigerant R134a. Then extract again and repeat ra the procedure one more time.
s s c
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
3 - Flushing equipment for refrigerant circuits

is n
h re
ole,
spec
VAS6336/1- or Air Conditioning Flush Tool - VAS6337/1- .

t to the co
rrectne

ss o
❑ From the high pressure side connection of the A/C compressor on the refrigerant circuit (smaller diam‐
cial p
f in
eter) to input of Refrigerant Circuit Flushing Device - VAS6336/1- or Air Conditioning Flush Tool -
form
mer
VAS6337/1A- .
atio
om
5 - Adapter to connection for high pressure side on refrigerant circuit

n
c
i
or
n thi
❑ The Refrigerant Circuits Adapter Set 1 - Adapter 3 - VAS6338/3- from the Refrigerant Circuits Adapter
te
sd
a
Set 1 - VAS6338/1-
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

wage es n
Beetle 2012 y➤ Vo , CC 2010 ➤ , CC 2012 ➤ , oEos
lk s
t gu 2006 ➤ , Golf 1992 ➤ , G ...
b
Refrigerant
ir se R134a Servicing - Edition 08.2015 ante
d ar
tho eo
au ra
c
ss
Note
ce
e
nl
pt
du
an
itte
If the Refrigerant Circuits Adapter
y li
erm
ab
Set - Adapter 40 - VAS6338/40- is
ility
ot p
available, the filler hose can be di‐
wit
, is n
rectly attached to the A/C compres‐
h re
sor.
hole
spec
es, in part or in w
6 - High pressure side refrigerant line from A/C compressor
t to the co
Note
rrectness of i
Is not used if the Refrigerant Circuits
l purpos
Adapter Set - Adapter 40 -

VAS6338/40- is available.
nf
ercia
or
– Remove the centering pin from the refrigerant line so that the Refrigerant Circuits Adapter Set 1 - Adapter
m
m
atio
3 - VAS6338/3- fits.
om
n in
or c
7 - Electrically-driven A/C compressor
thi
te
sd
iva
❑ The A/C compressor is flushed in the flow direction (from the low pressure side input to the high pressure
o
r
rp
cu
side output)
o
m
f
en
ng
t.
yi
❑ So that as much refrigerant oil as possible is flushed out of the A/C compressor, the A/C compressor
Co
op py
must be positioned so that the high pressure side output is as low as possible.
t. C rig
gh ht
pyri by
Vo
8 - Low pressure side refrigerant line to A/C compressor
co lksw
by
cted agen
Prote AG.
Note
Is not used if the Refrigerant Circuits

Adapter Set - Adapter 41 -
VAS6338/41- is available.
– Remove the centering pin from the refrigerant line so that the Refrigerant Circuits Adapter Set 1 - Adapter
6 - VAS6338/6- fits.
9 - Adapter for connecting low pressure side to refrigerant circuit

❑ The Refrigerant Circuits Adapter Set 1 - Adapter 6 - VAS6338/6- from the Refrigerant Circuits Adapter
Set 1 - VAS6338/1-
Note
If the Refrigerant Circuits Adapter

Set - Adapter 41 - VAS6338/41- is
available, the filler hose can be di‐
rectly attached to the A/C compres‐
sor.

❑ From the A/C service station high pressure side (mostly colored red) to the connection on the low pres‐
sure line, or directly on the A/C compressor with the Refrigerant Circuits Adapter Set - Adapter 41 -
VAS6338/41- .
7.2.4 Adapter for Assembling Flushing Circuit

♦ The following table lists the different adapters necessary to
connect the service station to the refrigerant circuit, to flush
and to bypass the removed receiver/dryer or reservoir and ex‐
pansion valve (depending on the vehicle).
♦ Using a charge hose with 5/8 -18 UNF connections (short ver‐
sion, for example Refrigerant Circuits Adapter Set 1 - Hose 31
- VAS6338/31- ), connect the two adapters (contained in Re‐

frigerant Circuits Adapter Set 1 - VAS6338/1- ) which have

been installed for the removed reservoir or receiver/dryer.
♦ If a flushed refrigerant circuit is not reassembled immediately
after flushing, adapters remain at connections and seal the
connections at the adapters using Refrigerant Circuits Adapter
Set 1 - Adapter 30 - VAS6338/30- (from Refrigerant Circuits
Adapter Set 1 - VAS6338/1- ).
♦ Depending on the version of the A/C compressor and on the
time period of production, various connecting and sealing
technologies can be found on the refrigerant circuit. Refer to
Heating, Ventilation and Air Conditioning.
en AG. V
olkswagen AG
ag does
ksw not
Block or screw connectionsby Vol gu
ara
d
ise nte
Screw connection -A-
ut
ho
r eo
ra
sa c
Block connection -B-
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Block connections with different types of seals

Block connection with radially sealed connection -A- (with plastic
or metal guide -B-)
– Block connection with axial sealing connection -C- AG. Volkswagen AG d
agen oes
olksw not
Fox MY 2005 d by
V gu
ara
ise nte
or eo
Vehicle Required adapt‐ Required adapters for Miscella‐aut
h
ra
ers for refriger‐ refrigerant pipes to re‐ neouss s c
ce
ant pipes to A/C ceiver/dryer
e
nl
pt
du
compressor
an
itte
y li
erm
ab
Fox ♦ Low pressure – Remove dryer car‐ – Re‐
ility
ot p
from MY side Refriger‐ tridge and seal re‐ place
wit
, is n
2005 ant Circuits ceiver/dryer. the ex‐
h re
Adapter Set 1 pan‐
hole
spec
- Adapter 12 - – Install a new dryer sion
es, in part or in w
VAS6338/12- cartridge after valve
t to the co
flushing. with the
♦ High pres‐ Refrig‐
sure side Re‐ erant
rrectness of i
frigerant Cir‐ Circuits
cuits Adapter Adapt‐
l purpos
Set 1 - Adapt‐ er Set 1

er 2 - - Adapt‐
VAS6338/2-
nf
ercia
er 34 -
or
VAS63
m
m
atio
38/34-
om
n in
(or a
or c
drilled
thi
te
sd
a
open
iv
o
r
rp
cu
expan‐
o
m
f
sion
en
ng
t.
yi
valve
Co
Cop py
⇒
t. rig
gh ht
yri
pa
p by
o Vo
by c lksw
ge 87 ) Prote
cted AG.
agen
– Install a
new ex‐
pan‐
sion
valve
after
flush‐
ing.

Lupo MY 1999
Vehicle Required adapt‐ Required adapters for Miscella‐
ers for refriger‐ refrigerant pipes to re‐ neous
compressor
Lupo ♦ Low pressure – Remove receiver/ – Expan‐
from MY side Refriger‐ dryer and bridge sion
1999 ant Circuits coolant pipes. valve
through Adapter Set 1 ♦ Refrigerant Circuits re‐
VIN - Adapter 12 - Adapter Set 1 - placed
70000 VAS6338/12- Adapter 28 - by Re‐
VAS6338/28- friger‐
♦ High pres‐ ant Cir‐
sure side Re‐ ♦ Refrigerant Circuits cuits
frigerant Cir‐ Adapter Set 1 - Adapt‐
cuits Adapter Adapter 29 - er Set 1
Set 1 - Adapt‐ VAS6338/29- - Adapt‐
er 2 - er 19 -
VAS6338/2- – Install a new receiv‐ VAS63
er/dryer after flush‐
ing. 38/19-
(or a
drilled
open
expan‐
sion
agen AG. Volkswagen Avalve
G do
ksw es n
y Vol for ex‐ ot g
ua
rised b
ample ran
tee
ut
ho 6N0 or
ss
a 820 ac
679 C
ce
e
nl
pt
⇒
du
an
itte
pa
y li
erm
ab
ge 87 )
ility
ot p
wit
, is n
– Install a
h re
new ex‐
hole
spec
pan‐
es, in part or in w
sion
t to the co
valve
after
flush‐
rrectness of i
ing.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


ant pipes to A/C ceiver/dryer n AG. Volkswagen AG do
compressor olks
wage es n
o V t gu
by
Lupo ♦ Low pressure Receiver/Dryer rised – Re‐ ara
nte
from MY side Refriger‐ – May be flushed.
tho place eo
1999 ant Circuits au the ex‐
ra
c
ss
from Adapter Set 1 – Install a new receiv‐ pan‐
ce
e
nl
pt
VIN - Adapter 12 - er/dryer after flush‐ sion
du
an
itte
70001 VAS6338/12- ing. valve
y li
erm
ab
with the
ility
♦ High pres‐
ot p
Refrig‐
wit
sure side Re‐
, is n
erant
h re
frigerant Cir‐ Circuits
hole
spec
cuits Adapter Adapt‐
es, in part or in w
Set 1 - Adapt‐ er Set 1
t to the co
er 2 - - Adapt‐
VAS6338/2- er 19 -
or VAS63
rrectness of i
♦ Refrigerant 38/19-
(or a
l purpos
Circuits
Adapter Set 1 drilled
- Adapter 7 - open
nf
ercia
expan‐
o
VAS6338/7-
r
sion
m
m
atio
valve,
om
n in
for ex‐
or c
thi
ample
te
sd
a
6N0
iv
o
r
rp
cu
820
o
m
f
en
679 C
ng
t.
yi Co
⇒ Cop py
pa
ht. rig
rig ht
by
ge 87 ) copy Vo
by lksw
cted agen
Prote AG.
– Install a
new ex‐
pan‐
sion
valve
after
flush‐
ing.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Beetle 2012
autho
➤ , CC 2010 ➤ , CC 2012 ➤ , Eos 2006 ➤
e o , Golf 1992
ra ➤ , G ...
ss Refrigerant R134a Servicing c
- Edition 08.2015
ce
e
nl
pt
du
an
up! 2012; e-up! MY 2014
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
compressor
spec
es, in part or in w
up! e- ♦ Low pressure Receiver/Dryer – Re‐
t to the co
up! from side Refriger‐ – May be flushed. place
MY ant Circuits the ex‐
2012 Adapter Set 1 -– Install a new receiv‐ pan‐
rrectness of i
From Adapter 12 - er/dryer after flush‐ sion
MY VAS6338/12- ing. valve
l purpos
2014 with the

♦ High pressure Refrig‐
nform
ercia
side Refriger‐ erant

ant Circuits Circuits
m
at
Adapter Set 1 -
om
Adapt‐
io
Adapter 3 -
n
c
er 36 -
in t
or
VAS6338/3- VAS63
his
ate
38/36-
do
riv
♦ Flush electri‐
p
c
or Re‐
um
or
cally-driven A/
f
en
g
friger‐
n
t.
C compressor
yi Co
ant Cir‐
op
using Refriger‐
C py
t. rig
ant Circuits cuits yri
gh by
ht
Adapt‐
op Vo
Adapter Set -
c by lksw
er Set 1 cted agen
Adapter 40 - Prote AG.
VAS6338/40- - Adapt‐
and Refriger‐ er 34 -
ant Circuits VAS63
Adapter Set - 38/34-
Adapter 41 - (or a
VAS6338/41- . drilled
See notes open
here: expan‐
⇒ “7.2.3 Elec‐ sion
trically Driven valve,
A/C Compres‐ for ex‐
sor, Flushing”, ample
page 98 1S0
820
078
⇒
pa
ge 87 )
– Install a
new ex‐
pan‐
sion
valve
after
flush‐
ing.

Polo MY 1995
compressor
Polo Refrigerant Cir‐ – Remove receiver/ – Re‐
from MY cuits Adapter Set dryer and bridge place
1995 1 - Adapter 14 - coolant pipes. the ex‐
through VAS6338/14- ♦ Refrigerant Circuits pan‐
VIN Adapter Set 1 - sion
50000 Adapter 28 - valve
VAS6338/28- with
the Re‐
♦ Refrigerant Circuits friger‐
Adapter
agen
Set
AG. Vo1
lks-wagen AG
dant
oes Cir‐
VolAdapter 29 -
sw
k
cuitsnot
gu
edb
y
VAS6338/29- Adapt‐ ara
nte
ris
ut
ho
– Install a new receiv‐ er Set eo
ra
ss a
er/dryer after flush‐ 1 - c
Adapt‐
ce
le
ing.
un
pt
er 19 -
an
d
itte
VAS63
y li
erm
ab
38/19-
ility
ot p
(or a
wit
is n
drilled
h re
ole,
open
spec
expan‐
sion
t to the co
valve,
for ex‐
ample rrectne
6N0
820
s
679 C
s o
⇒ page
cial p
f in
87 )
form
mer
atio
– Install
om
a new
c
i
or
n thi
expan‐
te
sd
a
sion
iv
o
pr
valve
um
r
fo
en
after
ng
t.
yi Co
Cop
flush‐ py
ing.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


compressor
wage es n
Polo ♦ Low pressure Receiver/Dryer – yRe‐
Vol
ks ot g
ua
from MY side Refriger‐ – May be flushed. rise place
d b ran
tee
1995 ant Circuits tho the ex‐ or
from s au
Adapter Set 1 – Install a new receiv‐ pan‐ ac
s
VIN - Adapter 7 - er/dryer after flush‐ sion
ce
le
un
pt
50001 VAS6338/7- ing. valve
an
d
itte
with
y li
♦ High pres‐
erm
ab
the Re‐
ility
sure side Re‐
ot p
friger‐
frigerant Cir‐
wit
ant Cir‐ is n
h re
cuits Adapter cuits
ole,
Set 1 - Adapt‐
spec
Adapt‐
er 2 - er Set
t to the co
VAS6338/2- 1-
Adapt‐
er 19 -
rrectne
VAS63
38/19-
s
(or a
s o
drilled
cial p
f in
open
form
mer
expan‐
atio
sion
om
n
valve,
c
i
or
n
for ex‐
thi
te
sd
a
ample
iv
o
pr
c
6N0
um
r
fo
820
en
ng
t.
yi
679 C
Co
Cop py
⇒ page
t. rig
gh ht
yri
87 )
p by
o Vo
by c lksw
cted agen
Prote AG.
– Install
a new
expan‐
sion
valve
after
flush‐
ing.

Polo MY 2002
compressor
Polo ♦ Low pressure – Remove dryer car‐ – Re‐
flushing. with
♦ High pres‐ the Re‐
sure side Re‐ friger‐
frigerant Cir‐ ant Cir‐
cuits Adapter cuits
Set 1 - Adapt‐ Adapt‐
er 2 - er Set
VAS6338/2- 1-
Adapt‐
er 34 -
VAS63
38/33-
(or a
drilled
open
expan‐
sion
valve
⇒ page
olkswagen AG87 )
en AG. V wag does
olks not
ed
byV – Install guara
ho
ris a new nte
eo
au
t
expan‐ ra
c
ss sion
ce
le
valve
un
pt
an
d
after
itte
y li
flush‐
erm
ab
ing.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

. Volkswagen AG
a gen AG does
Caddy MY 1996; Caddy MY 2004; Caddy MY
Vo2011
lksw not
gu
by ara
d
Vehicle Required adapt‐ ise
Requiredthadapters for Miscella‐ nte
or eo
ers for refriger‐ refrigerant
au pipes to re‐ neous ra
c
ant pipes to A/C ceiver/dryer ss
ce
e
compressor
nl
pt
du
an
itte
y li
Caddy ♦ Low pressure – Remove receiver/ – Re‐
erm
ab
from MY side Refriger‐ dryer and bridge place
ility
ot p
1996 ant Circuits coolant pipes. the ex‐
wit
, is n
Adapter Set 1 ♦ Refrigerant Circuits pan‐
h re
hole
- Adapter 4 - Adapter Set 1 - sion
spec
VAS6338/4- Adapter 28 - valve
es, in part or in w
VAS6338/28- with
t to the co
sure side Re‐ ♦ Refrigerant Circuits friger‐
frigerant Cir‐ Adapter Set 1 - ant Cir‐
rrectness of i
cuits Adapter Adapter 29 - cuits
Set 1 - Adapt‐ VAS6338/29-
l purpos
Adapt‐
er 2 - er Set
VAS6338/2- – Install a new receiv‐ 1-
nform
ercia
or Refrigerant Adapt‐
Circuits ing.
er 19 -
m
at
Adapter Set 1
om
VAS63
ion
- Adapter 14 -
c
38/19-
in t
or
VAS6338/14-
his
(or a
ate
do
riv
drilled
p
cum
open
for
en
g
expan‐
n
t.
yi Co
op
sion C py
t. rig
valve, gh ht
yri by
for ex‐ cop Vo
by lksw
ample
cted agen
Prote AG.
6N0
820
679 C
⇒ page
87 )
– Install
a new
expan‐
sion
valve
after
flush‐
ing.


compressor
Caddy ♦ Sanden / Receiver/Dryer – Re‐
from MY Denso A/C – May be flushed. place
2004; compressor the ex‐
Caddy – Install a new receiv‐ pan‐
from MY ♦ Low pressure er/dryer after flush‐ sion
2011 side Refriger‐ ing. valve
ant Circuits with
Adapter Set 1 the Re‐
- Adapter 12 - friger‐
VAS6338/12- ant Cir‐
♦ High pres‐ cuits
sure side Re‐ Adapt‐
frigerant Cir‐ er Set
cuits Adapter 1-
er 3 - er 18 -
VAS6338/3- VAS63
38/18-
♦ 7H0 820 803 (or a
D A/C com‐ drilled
pressor open
expan‐
♦ Low pressure sion
side Refriger‐ ag en AG. Volkswagen AG dovalve
es
ant Circuits y Volksw ⇒ npage
ot g
Adapter Set ised1b
87
u
) arante
- Adapter tho 7 -
r eo
VAS6338/7-
ss au – Install
ra
c
a new
ce
e
♦ High pres‐
nl
pt
expan‐
du
an
sure side Re‐

itte
sion
y li
frigerant Cir‐
erm
ab
valve
cuits Adapter
ility
ot p
after
Set 1 - Adapt‐
wit
, is n
flush‐
er 2 -
h re
ing.
hole
VAS6338/2-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Polo MY 2010; Polo KH IN MY 2010; Polo KH IN MY 2015; Polo

Lim IN MY 2011; Polo Lim In MY 2016; Polo Lim RUS MY 2011;
Polo Lim RUS MY 2016; Polo KH MY 2014; Polo KH MY 2015;
Polo Lim MY 2014; Polo Lim MY 2016
ant pipes to A/C lkceiver/dryer
swage es n
compressor by Vo ot g
ua d ran
ise
Polo ♦ Low tpressure
ho
r
– Remove dryer car‐ – Re‐ tee
or
from MY side
ss
au
Refriger‐ tridge and seal re‐ place ac
2010; ant Circuits ceiver/dryer. the ex‐
ce
le
un
Polo KH Adapter Set 1 pan‐
pt
an
d
IN from - Adapter 12 - – Install a new dryer sion

itte
y li
erm
MY VAS6338/12- cartridge after valve
ab
ility
2010; flushing. with
ot p
Polo KH ♦ High pres‐
wit
the Re‐
is n
sure side Re‐
h re
IN from friger‐
ole,
frigerant Cir‐
spec
MY ant Cir‐
2015; cuits Adapter cuits
t to the co
Polo Set 1 - Adapt‐ Adapt‐
Lim IN er 3 - er Set
from MY VAS6338/3- 1-
rrectne
2011; ♦ For A/C com‐ Adapt‐
Polo pressors 6Q0 er 34 -
Lim IN VAS63
s
820 808 F
s o
from MY 38/34-
cial p
f
and 6Q0 820
in
2016; (or a
form
808 G, high
mer
Polo pressure side drilled
atio
Lim open
m
Refrigerant
o
RUS expan‐ n
c
Circuits i
or
n
from MY sion
thi
Adapter Set 1
te
sd
a
2011; valve
v
- Adapter 2 -
i
o
r
Polo ⇒ page
p
cum
VAS6338/2- .
r
fo
Lim 87 )
en
ng
t.
yi
RUS
Co
op py
from MY – Install
t. C rig
gh ht
yri
2016; a new p by
o Vo
by c
Polo KH expan‐
lksw
cted agen
Prote
from MY sion
AG.
2014; valve
Polo KH after
from MY flush‐
2015; ing.
Polo
Lim
from MY
2014;
Polo
Lim
from MY
2016

Polo 2014
compressor
Polo ♦ Low pressure – Remove the dryer – Re‐
from MY side: Refrig‐ cartridge and seal place
2014 erant Circuits off the receiver/dry‐ the ex‐
Adapter Set 1 er. pan‐
- Adapter 12 - sion
VAS6338/12- – Install a new dryer valve
cartridge after with
♦ High pres‐ flushing. the Re‐
sure side: Re‐ friger‐
cuits Adapter cuits
er 3 - er Set
VAS6338/3- AG. Vol1
ks-wagen AG
gen does
♦ For A/C com‐ Volksw
a
Adapt‐ not
pressors 6Q0 edb
y er 17 - gu
ara
820 808 F horis VAS63 nte
eo
ut 38/17- ra
and 6Q0 820 ss a c
808 G, high (or a
ce
le
drilled
un
pt
pressure
an
d
open
itte
side: Refrig‐
y li
expan‐
erm
ab
erant Circuits
ility
sion
ot p
Adapter Set 1
valve.
wit
is n
- Adapter 2 -
h re
Refer
ole,
VAS6338/2- .
to
spec
⇒ page
t to the co
87 .)
– Install
a new rrectne
expan‐
sion
ss
valve
o
cial p
f i
after
nform
flush‐
mer
ing.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf MY 1992; Vento MY 1992; Passat MY 1994

compressor
Golf Refrigerant Cir‐ – Remove receiver/ – Re‐
from MY cuits Adapter Set dryer and bridge place
1992; 1 - Adapter 14 - coolant pipes. the ex‐
Vento VAS6338/14- ♦ Refrigerant Circuits pan‐
from MY Adapter Set 1 - sion
1992; Adapter 28 - valve
Passat VAS6338/28- with the
from MY Refrig‐
1994 ♦ Refrigerant Circuits erant
Adapter Set 1 - Circuits
Adapter 29 - Adapt‐
VAS6338/29- er Set 1
– Install a new receiv‐ - Adapt‐
n AGer/dryer
. Volkswagafter
en AGflush‐ er 19 -
olks
wage
ing.
does
not VAS63
byV gu 38/19-
d ara
ris
e
(or
nte a
utho eo
drilledra
a
ss open c
ce
le
expan‐
un
pt
sion an
d
itte
y li
valve,
erm
ab
for ex‐
ility
ot p
ample
wit
is n
6N0
h re
ole,
820
spec
679 C
t to the co
⇒
pa
ge 87 )
rrectne
– Install a
new ex‐
ss
pan‐
o
cial p
sion
inform
valve
mer
after
atio
m
flush‐
o
n
c
ing.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Beetle 2012 ➤ , CC 2010 ➤ , CC 2012 ➤ , Eos gen2006
AG. Vo➤ , aGolf
lksw gen A1992
G do ➤ , G ...
swa es n
y Volk ot g
u
b ara
ed nte
ris
Touran MY 2003; Golf MY 2004; Golf Plus
au
th MY 2005; Golf Plus
o e or
ac
MY 2009; Jetta MY 2005; Eos MY 2006;
ss Golf Variant MY 2007;
Tiguan MY 2008; Scirocco MY 2009; Scirocco MY 2015; Golf MY
ce
le
un
pt
2009; Golf Variant MY 2010; Jetta MY 2011; Golf Cabrio MY
an
d
itte
y li
2012; NMS MY 2012; Beetle MY 2012 and The Beetle Cabriolet
erm
ab
2012
ility
ot p
wit
is n
h re
ers for refriger‐ refrigerant pipes to re‐ neous ole,
spec
compressor
t to the co
Touran ♦ Low pressure There are two versions – Re‐
from MY side Refriger‐ of the receiver/dryer: place
rrectne
2003; ant Circuits Refer to the vehicle the ex‐
Golf Adapter Set 1 specific repair manual. pan‐
from MY - Adapter 12 - ♦ Receiver/dryer with sion
ss
2004; VAS6338/12- an installed dryer. valve
o
cial p
f i
Golf with the
nform
Plus ♦ High pres‐ – May be flushed. Refrig‐
mer
sure side Re‐ – Install a new receiv‐
atio
from MY erant
m
frigerant Cir‐ er/dryer after flush‐

o
2005; Circuits
n
c
i
cuits Adapter ing.
or
n
Golf Adapt‐
thi
e
Set 1 - Adapt‐ ♦ receiver/dryer with

t
sd
Plus er Set 1
va
er 3 - dryer bag / car‐

i
o
r
from MY - Adapt‐
p
cum
r
VAS6338/3- tridge
fo
2009; er 18 -
en
ng
t.
yi
Jetta VAS63
Co
– Remove the dryer
op py
from MY 38/18-
. C rig
bag / cartridge and
ht ht
rig
2005; (or a py by
close the receiver/ co Vo
Eos drilled
by lksw
dryer. cted agen
Prote
from MY open
AG.
2006; – Install a new dryer expan‐

Golf bag / cartridge after sion
Variant flushing. valve
from MY ⇒
2007; pa
Tiguan ge 87 )
from MY
2008; – Install a
Sciroc‐ new ex‐
co from pan‐
MY sion
2009; valve
Sciroc‐ after
co from flush‐
MY ing.
2015;
Golf
from MY
2009;
Golf
Variant
from MY
2010;
Jetta
from MY
2011;
Golf
Cabrio
from MY
2012;
NMS
from MY
2012;
Beetle
from MY
2012
and The
Beetle
Cabrio‐
let from


compressor
MY
2012
Golf 2013; Golf Variant 2014; Golf 2014 (NAR); Golf Sportsvan
2015; Jetta 2015 and Touran 2016
compressor
Golf ♦ Low pressure – Remove the dryer – Re‐
from MY side Refriger‐ bag / cartridge and place
2013; ant Circuits close the receiver/ G . Volkswthe
ageex‐
n
Golf Adapter Set 1 dryer. lkswagen A pan‐ AG does n
Variant - Adapter 12 - yV
o sion ot g
ua
db
from MY VAS6338/12- – Installo ris
e a new dryer valve ran
tee
2014; uthbag / cartridge after with the or
Golf ♦ High pres‐ a
ss flushing. Refrig‐
ac
from MY sure side Re‐ erant
ce
le
un
pt
2014 frigerant Cir‐ – If the condenser by Circuits
an
d
itte
cuits Adapter
y li
(NAR); Showa is installed, Adapt‐
rm
ab
Golf Set 1 - Adapt‐ leave the receiver/ er Set 1
pe
ility
Sports‐ er 3 - dryer installed and - Adapt‐
ot
wit
, is n
van VAS6338/3- flush the refrigerant er 38 -
h re
hole
from MY circuit. VAS63
spec
2015; 38/38-
es, in part or in w
Jetta – Install a new receiv‐ (or a
t to the co
from MY er/dryer after flush‐ drilled
2015 ing. open
and expan‐
rrectness of i
Touran sion
l purpos
from MY valve
2016 ⇒
pa
nform
ercia
ge 87 )
m
a
com
– Install a
ion in
new ex‐
r
te o
thi
pan‐
s
iva
do
sion
r
rp
cum
valve
fo
en
g
after
n
t.
yi Co
op
flush‐
C py
t. rig
gh
ing.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf MY 1998; Golf Wagon MY 1998; Vento MY 1999; New Beetle

MY 1999; New Beetle Cabrio MY 2003; Bora MY 1999;
Golf ♦ Low pressure – Remove receiver/ – Re‐
1998; ant Circuits coolant pipes. the ex‐
Golf Adapter Set 1 pan‐
Wagon - Adapter 7 - – Connect with two sion
from MY VAS6338/7- Refrigerant Circuits valve
1998; Adapter Set 1 - with the
Vento ♦ High pres‐ Adapter 2 - Refrig‐
from MY sure side Re‐ VAS6338/2- and erant
1999; frigerant Cir‐ with Refrigerant Circuits
New cuits Adapter Circuits Adapter Adapt‐
Beetle Set 1 - Adapt‐ Set 1 - Hose 31 - er Set 1
from MY er 2 - VAS6338/31- . - Adapt‐
1999; VAS6338/2- er 19 -
New – Install a new receiv‐ VAS63
Beetle er/dryer after flush‐ 38/19-
Conver‐ ing. (or a
tible drilled
from MY open
2003; expan‐
Bora sion
from MY valve
1999 ⇒
pa
ge 87 )
– Install a
new ex‐
pan‐
sion
valve
after
flush‐
ing.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
118
AG.
Phaeton MY 2003
ant pipes to A/C ceiver/dryer/reservoir
compressor
Phaeton ♦ Low pressure – Remove the reser‐ – Restric‐
from MY side Refriger‐ voir (dryer) and tor re‐
2003 ant Circuits bridge coolant moved
Adapter Set 1 pipes. and re‐
- Adapter 12 - friger‐
VAS6338/12- – Connect with two ant pipe
Refrigerant Circuits recon‐
♦ High pres‐ Adapter Set 1 - nected.
sure side for Adapter 6 -
12-, 8- and 6- VAS6338/6- and – Install a
cylinder gas‐ with Refrigerant new re‐
oline en‐ Circuits Adapter strictor
gines, Refrig‐ Set 1 - Hose 31 - after
erant Circuits VAS6338/31- . flush‐
Adapter Set 1 ing.
- Adapter 2 - – Install a new reser‐
VAS6338/2- ; voir after flushing.
high pressure
side for 10-
and 6-cylin‐
der diesel en‐
gines, Refrig‐
erant Circuits
Adapter Set 1
- Adapter 3 - agen
AG. Volkswagen AG d
oes
VAS6338/3- yV
olksw not
g b ua
ed ran
oris tee
th or
au ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
Passat MY 1997 agen oes
olksw not
y V gu
d b ara
e
Vehicle Required adapt‐ hoRequired
ris adapters for Miscella‐ nte
eo
ers for refriger‐
s a refrigerant pipes to re‐ neous
ut ra
c
ant pipes to A/C
s ceiver/dryer/reservoir
ce
compressor le
un
pt
an
d
itte
Passat ♦ A/C Adapter There are two different – Restric‐
y li
erm
ab
from MY Set - Adapter container versions. tor re‐
ility
ot p
1997 7- – Remove reservoir moved
wit
is n
through VAG1785/7- and bridge coolant and re‐
h re
ole,
09/2000 pipes. friger‐
spec
♦ A/C Adapter ant line
Set - Adapter – Connect Refriger‐ recon‐
t to the co
8- ant Circuits Adapter nected.
VAG1785/8- Set 1 - Adapter 9 -
VAS6338/9- and – Install a
rrectne
♦ Low pressure
side Refriger‐ Refrigerant Circuits new re‐
ant Circuits Adapter Set 1 - strictor
s
Adapter 8 - after
s
Adapter Set 1
o
cial p
VAG1785/8- or Re‐ flush‐
f
- Adapter 12 -
in
frigerant Circuits ing.
form
VAS6338/12-
mer
Adapter Set 1 -
atio
m
♦ High pres‐ Adapter 10 -

o
n
c
sure side Re‐ VAS6338/10- with
i
or
n thi
frigerant Cir‐ Refrigerant Circuits
te
sd
a
Adapter Set 1 -
v
cuits Adapter
i
o
pr
c
Hose 31 -
um
Set 1 - Adapt‐
r
fo
en
ng
er 2 - VAS6338/31- .
t.
yi Co
op
VAS6338/2- C py
t. rig
– Install a new reser‐ yri
gh by
ht
voir after flushing. cop Vo
by lksw
cted agen
Passat ♦ A/C Adapter – Remove reservoir – Restric‐
Prote AG.
from MY Set - Adapter and bridge coolant tor re‐

1997, 7- pipes. moved
from VAG1785/7- and re‐
10/2000 – Connect with two friger‐
♦ A/C Adapter Refrigerant Circuits ant line
Set - Adapter Adapter Set 1 - recon‐
8- Adapter 10 - nected.
VAG1785/8- VAS6338/10- and
♦ Low pressure with Refrigerant – Install a
side Refriger‐ Circuits Adapter new re‐
ant Circuits Set 1 - Hose 31 - strictor
Adapter Set 1 VAS6338/31- . after
- Adapter 12 - flush‐
VAS6338/12- – Install a new reser‐ ing.
voir after flushing.
♦ High pres‐
sure side Re‐
frigerant Cir‐
cuits Adapter
Set 1 - Adapt‐
er 2 -
VAS6338/2-

Passat MY 2006; Passat CC MY 2009; CC MY 2010; Passat MY

2011; CC FL
ant pipes to A/C ceiver/dryer/reservoir
compressor
Passat ♦ Low pressure – Remove dryer car‐ – Re‐
2006; ant Circuits ceiver/dryer. the ex‐
Passat Adapter Set 1 pan‐
CC from - Adapter 12 - – Install a new dryer sion
MY VAS6338/12- cartridge after valve
2009; flushing. with the
CC from ♦ High pres‐ Refrig‐
MY sure side Re‐ – If the condenser by erant
2010; frigerant Cir‐ Showa is installed, Circuits
Passat cuits Adapter leave the receiver/ Adapt‐
from MY Set 1 - Adapt‐ dryer installed and er Set 1
2011; er 3 - flush the refrigerant - Adapt‐
CC FL VAS6338/3- circuit. er 18 -
VAS63
– Install a new receiv‐ 38/18-
er/dryer after flush‐ (or a
ing. drilled
open
expan‐
sion
valve
⇒
pa
ge
age87 ) . Volkswagen AG doe
n AG
w s no
olks t gu
yV
ed
b – Install a ara
nte
ris
tho new ex‐ eo
ss
au pan‐ ra
c
sion
ce
e
nl
valve
pt
du
an
after
itte
y li
erm
flush‐
ab
ility
ing.
ot p
wit
, is n
Passat 2015; Passat Wagon 2015 and Passat (NMS-US) 2016 h re

hole
spec
es, in part or in w
t to the co
Note
The Passat 2015 and Passat Wagon 2015 with a Biturbo engine
rrectness of i
are not flushed. The amount of work to remove the expansion

valve is too excessive. If there is A/C compressor damage, check
l purpos
whether there are shavings in the condenser and whether there

are shavings on the condenser output. If there are shavings on
nform
ercia
the input and not on the output, then only the condenser and A/C
Compressor need to be replaced.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


compressor
Passat ♦ Low pressure – Remove the dryer – Re‐
from MY side Refriger‐ bag / cartridge and place
2015; ant Circuits close the receiver/ the ex‐
Passat Adapter Set 1 dryer. pan‐
Wagon - Adapter 12 - sion
from MY VAS6338/12- – Install a new dryer valve lkswagen AG
2015 bag / cartridge after with the swagen AG. Vo does
and ♦ High pres‐ flushing. Refrig‐ olk not
yV gu
Passat sure side Re‐ erant
ed b ara
nte
is
(NMS- frigerant Cir‐ r
th Circuits
o eo
US) cuits Adapter s au
Adapt‐
ra
c
from MY Set 1 - Adapt‐ s
er Set 1
ce
er 3 - le
un
pt
2016 - Adapt‐
an
d
VAS6338/3-
itte
er 17 -
y li
rm
ab
VAS63
pe
ility
38/17-
ot
wit
, is n
or Re‐
h re
friger‐
hole
spec
ant Cir‐
es, in part or in w
cuits
t to the co
Adapt‐
er Set 2
- Adapt‐
rrectness of i
er 33 -
VAS63
l purpos
38/33-
(or a
nform
ercia
drilled
open
m
a
expan‐
com
tion in
sion
r
te o
thi
valve.
s
iva
Refer to
do
r
rp
c
⇒
um
fo
en
pa
ng
t.
yi Co
ge 87 .) ht. Cop py
rig
rig ht
by
– Install acopy Vo
by lksw
new ex‐
cted agen
Prote AG.
pan‐
sion
valve
after
flush‐
ing.
Sharan MY 1996
Note
On vehicles with second evaporator (Sharan), the front and rear

refrigerant circuits must be flushed individually. Seal the front re‐
frigerant circuit using A/C Adapter Set - Adapter 1 - VAG1785/1- ,
A/C Adapter Set - Adapter 3 - 1785/3- and Closure Cap‐
sVAS6338/30.


ers for refrigerant refrigerant pipes to re‐ neous
pipes to A/C com‐ ceiver/dryer and sec‐
pressor ond Evaporator
Sharan ♦ Low pressure – Remove the receiv‐ – Re‐
from side Refriger‐ er/dryer and con‐ place
MY ant Circuits nect the refrigerant the
1996 Adapter Set 1 pipes to the Refrig‐ front
through - Adapter 7 - erant Circuits and
05/200 VAS6338/7- Adapter Set 1 - rear
0 Adapter 37 - expan‐
♦ High pressure VAS6338/37- sion
side Refriger‐ – Install a new receiv‐ valve
ant Circuits er/dryer (dryer) af‐ with
Adapter Set 1 ter flushing. the Re‐
- Adapter 2 - ♦ Low pressure line friger‐
VAS6338/2- for second evapo‐ ant Cir‐
♦ or Refrigerant rator Refrigerant cuits
Circuits Circuits Adapter Adapt‐
Adapter Set 1 Set 1 - Adapter 7 - er Set
- Adapter 14 - VAG1785/7- 2-
VAS6338/14- ♦ High pressure Adapt‐
AG . Volkswagline
en AG er 35 -
ksw for second evapo‐
ag en does
l nVAS63
ot g
db
yV
o
rator Refrigerant 38/35-
ua
ran
oris
e Circuits Adapter (or a tee
auth Set 1 - Adapter 5 - drilled
or
ac
ss VAG1785/5- open ce
e
expan‐
nl
pt
♦ A/C Adapter Set -
du
an
sion
itte
Adapter 3 -
y li
valve
erm
ab
VAG1785/3- with
ility
⇒ page
ot p
Closure Cap -
87 )
wit
, is n
VAS6338/30- to
h re
seal the front refrig‐

hole
– Install
spec
erant circuit.
a new
es, in part or in w
t to the co
♦ A/C Adapter Set - expan‐

Adapter 1 - sion
VAG1785/1- with valve
rrectness of i
Closure Cap - after

VAS6338/30- to flush‐
l purpos
seal the front refrig‐ ing.

erant circuit.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Sharan ♦ Low pressure – Remove dryer car‐ – Re‐
from side Refriger‐ tridge and seal re‐ place
MY ant Circuits ceiver/dryer. the
1996 Adapter Set 1 – Install a new dryer front
from - Adapter 7 - cartridge after and
June VAS6338/7- flushing. rear
2000 ♦ Low pressure line expan‐
♦ High pressure for second evapo‐ sion
side Refriger‐ rator Refrigerant valve
ant Circuits Circuits Adapter with
Adapter Set 1 Set 1 - Adapter 7 - the Re‐
- Adapter 2 - VAG1785/7- friger‐
VAS6338/2- ant Cir‐
♦ High pressure line cuits
for second evapo‐ Adapt‐
rator Refrigerant er Set
Circuits Adapter 2-
Set 1 - Adapter 5 - Adapt‐
VAG1785/5- er 35 -
♦ A/C Adapter Set - VAS63
Adapter 3 - 38/35-
VAG1785/3- with (or a
Closure Cap - drilled
VAS6338/30- to open
seal the front refrig‐ expan‐
erant circuit. sion
valve
♦ A/C Adapter Set - ⇒ page
Adapter 1 - 87 )
VAG1785/1- with
Closure Cap - – Install
. Volkswagen AG
gen AG
VAS6338/30- to Volkswa a new
does
not
seal the front erefrig‐
d by expan‐ gu
ara
erant circuit.
horis sion nte
eo
aut
valve ra
c
ss after
ce
e
flush‐
nl
pt
du
an
ing.
itte
y li
erm
ab
Sharan MY 2011 and Sharan MY 2016

ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
On vehicles with second evaporator (Sharan), the front and rear

refrigerant circuits must be flushed individually. Seal the front re‐
frigerant circuit using A/C Adapter Set - Adapter 1 - VAG1785/1- ,
rrectness of i
A/C Adapter Set - Adapter 3 - 1785/3- and Closure Cap‐

sVAS6338/30.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


Sharan ♦ Low pressure – Remove dryer car‐ – Re‐
from side Refriger‐ tridge and seal re‐ place
and - Adapter 12 - cartridge after expan‐
Sharan VAS6338/12- flushing. sion
from ♦ Low pressure line valve
MY ♦ High pressure for second Evapo‐ with
2016 side Refriger‐ rator Refrigerant the Re‐
ant Circuits Circuits Adapter friger‐
Adapter Set 1 Set 1 - Adapter 3 - ant Cir‐
- Adapter 3 - VAS6338/3- cuits
VAS6338/3- Adapt‐
♦ High pressure line er Set
for secondgeEvapo‐
n AG. Volkswage1n -AG do
rator Refrigerant
Vol
kswa e
Adapt‐ s not gu
eCircuits Adapter
y
d b
er 18 - ara
ho Set 1 - Adapter 4 -
ris nte
t VAS63 eo
au VAS6338/4- 38/18-
ra
c
ss
(or a
ce
le
♦ Loosen the refriger‐

un
pt
ant lines to the sec‐ drilled
an
d
itte
open
y li
ond evaporator just
erm
ab
enough so that the expan‐
ility
ot p
adapter can be in‐ sion
wit
is n
stalled without de‐ valve
h re
⇒ page
ole,
forming the refriger‐
spec
87 )
ant lines.
t to the co
♦ Refrigerant Circuits – Re‐
Adapter Set 1 - place
Adapter 5 - the
rrectne
VAS6338/5- for the rear
front refrigerant cir‐ expan‐ s
cuit. sion
s o
valve
cial p
f i
♦ Refrigerant Circuits
n
with
form
Adapter Set 1 -
mer
the Re‐
atio
Adapter 11 - friger‐
om
VAS6338/11- for
n
ant Cir‐
c
i
or
the front refrigerant cuits

thi
te
sd
circuit.
a
Adapt‐
iv
o
pr
er Set
um
r
fo
2-
en
ng
t.
yi
Adapt‐
Co
Cop py
er 33 -
t. rig
gh ht
yri
VAS63
p by
co Vo
by lksw
Prote
cted 38/33-
AG.
agen
(or a
drilled
open
expan‐
sion
valve
⇒ page
87 )
– Install
a new
expan‐
sion
valve
after
flush‐
ing.

Touareg MY 2003; Touareg MY 2010; Touareg MY 2015; Touar‐

eg MY Hybrid 2010
Note
On vehicles with second evaporator (Touareg), the front and rear

refrigerant circuits must be flushed individually. Seal the front re‐ wage
es n
frigerant circuit using Refrigerant Circuits Adapter Set 1 - Adapter by Volks ot g
ua
5 - VAS6338/5- and Refrigerant Circuits Adapter Set 1 - Adapter rised ran
tee
11 - VAS6338/11- . ut
ho
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

wage es n
Beetle 2012 ➤ , CC 2010 ➤ ,y CC Vo 2012 ➤ , Eos 2006 ➤ , Golf
lks ot g1992 ➤ , G ...
b
d Refrigerant R134a Servicing - Edition ua
ran 08.2015
ir se tee
tho
u or
s a ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Touar‐ ♦ Low pressure – Remove dryer car‐ – Re‐
wit
, is n
eg from side Refriger‐ tridge and seal re‐ place
h re
hole
spec
es, in part or in w
through - Adapter 12 - cartridge after expan‐
t to the co
VIN VAS6338/12- flushing. sion
50000 ♦ Low pressure line valve
♦ High pressure for second Evapo‐ with
rrectness of i
side Refriger‐ rator Refrigerant the Re‐
ant Circuits Circuits Adapter friger‐
l purpos
Adapter Set 1 Set 1 - Adapter 3 - ant Cir‐

- Adapter 2 - VAS6338/3- cuits
nf
ercia
VAS6338/2- Adapt‐
o
♦ High pressure line
rm
er Set
m
♦ Engine code
atio
for second Evapo‐
m
BJN 6.0L 1-
o
rator Refrigerant
n in
c
Adapt‐
or
through VIN Circuits Adapter
thi
er 17 -
e
20000 to high
t
sd
a
Set 1 - Adapter 4 - VAS63

iv
o
pressure side
r
VAS6338/4-
rp
cu
38/17-
o
m
Refrigerant
f
en
ng
(or a
t.
Circuits ♦ Refrigerant Circuits
yi Co
drilled
op
Adapter Set 1 Adapter Set 1 -
C py
. rig
open
t
gh
- Adapter 3 - Adapter 5 -
ht
yri by
expan‐
op Vo
VAS6338/3- . VAS6338/5- for the
c by lksw
sion cted agen
front refrigerant cir‐ Prote AG.
cuit. valve
⇒ page
♦ Refrigerant Circuits 87 )
Adapter Set 1 -
Adapter 11 - – Install
VAS6338/11- for a new
the front refrigerant expan‐
circuit. sion
valve
after
flush‐
ing.
– Drill a
hole
for the
expan‐
sion
valve
on the
sec‐
ond
evapo‐
rator
⇒ page
87 .
– Install
a new
expan‐
sion
valve
after
flush‐
ing.


Touar‐ ♦ Low pressure – Remove dryer car‐ – Re‐
eg from side Refriger‐ tridge and seal re‐ place
2003 Adapter Set 1 – Install a new dryer front gen AG. Volkswagen AG d
from - Adapter 12 - cartridge after and
V l
o ksw
a oes
not
VIN VAS6338/12- flushing. d b rear
y gu
ara
50001; ♦ Low pressure line rise expan‐ nte
o eo
Touar‐ ♦ High pressure for second Evapo‐
au th
sion ra
eg from side Refriger‐ s
rator Refrigerant
s valve
c
ce
MY ant Circuits Circuits Adapter with e
nl
pt
du
Adapter Set 1
an
2010; Set 1 - Adapter 3 - the Re‐
itte
y li
Touar‐ - Adapter 2 - VAS6338/3- friger‐
erm
ab
VAS6338/2-
ility
eg MY ant Cir‐
ot p
2015; or Refrigerant ♦ High pressure line cuits
wit
, is n
Circuits for second Evapo‐
h re
Touar‐ Adapt‐
hole
eg Hy‐ Adapter Set 1 rator Refrigerant er Set
spec
brid - Adapter 3 - Circuits Adapter 1-
es, in part or in w
t to the co
from VAS6338/3- Set 1 - Adapter 4 - Adapt‐
MY VAS6338/4- er 17 -
♦ Electrically-
2010 driven A/C ♦ Refrigerant Circuits VAS63
rrectness of i
compressor Adapter Set 1 - 38/17-
Refrigerant Adapter 5 - or Re‐
l purpos
Circuits VAS6338/5- for the friger‐

Adapter Set - front refrigerant cir‐ ant Cir‐
cuits
nform
ercia
Adapter 40 - cuit.
VAS6338/40- Adapt‐
m
er Set
at
and Refriger‐ ♦ Refrigerant Circuits
om
io
Adapter Set 1 - 2-
n
ant Circuits
c
in t
r
Adapter 11 - Adapt‐
o
Adapter Set -
his
te
VAS6338/11- for er 33 -
a
Adapter 41 -
do
riv
the front refrigerant VAS63

p
c
VAS6338/41-
um
or
circuit. 38/33-
f
en
ng
t.
(or a
yi Co
op py
drilled t. C rig
gh ht
open yri
p by
o Vo
expan‐
c by lksw
cted agen
sion
Prote AG.
valve
⇒ page
87 )
– Install
new
expan‐
sion
valves
after
flush‐
ing.
Transporter MY 1991
Note
On vehicles with second evaporator, the front and rear refrigerant

circuits must be flushed individually. Seal the front refrigerant cir‐
cuit using Refrigerant Circuits Adapter Set 1 - Adapter 5 -
VAS6338/5- and Refrigerant Circuits Adapter Set 1 - Adapter 11
- VAS6338/11- .


ant pipes to A/C ceiver/dryer and sec‐
compressor ond Evaporator
Trans‐ ♦ A/C compres‐ • For vehicles on – Re‐
porter sor D0 820 which the receiver/ place
from MY 805 B and dryer is mounted the
1991 701 820 805 below the condens‐ front
through Q Refrigerant er, it may be flush‐ and
2012 Circuits ed. rear
1995 Adapter Set 2 n AGexpan‐
. Volkswagen AG
- Adapter 54 - – On the other over‐ ag e does
lksw sion not
VAS6338/54- sions, thed breceiver/
y V
valve
gu
ara
dryer should
orise
be re‐ with
nte
eo
♦ On vehicles moved.
aut
h
the Re‐ ra
c
with auxiliary ♦ Refrigerant
ss
Circuits friger‐
ce
e
evaporator Adapter Set 1 -

nl
ant Cir‐
pt
du
on the roof, Adapter 20 -
an
cuits
itte
y li
the Refriger‐ VAS6338/20- for
erm
Adapt‐
ab
ant Circuits receiver/dryer.
ility
er Set
ot p
Adapter Set 2
wit
2-
, is n
- Adapter 51 - ♦ Refrigerant Circuits
h re
Adapter Set 1 - Adapt‐
hole
VAS6338/51-
spec
Adapter 29 - er 55 -
and Refriger‐
es, in part or in w
VAS6338/29- for VAS63
t to the co
ant Circuits 38/55-
Adapter Set 2 receiver/dryer.
(or a
- Adapter 52 - ♦ Refrigerant Circuits drilled
rrectness of i
VAS6338/52- Adapter Set 1 - open
should be Adapter 26 - expan‐
l purpos
used. VAS6338/26- and sion

with Closure Cap - valve
⇒ page
nform
ercia
VAS6338/30- to
seal the front refrig‐ 87 )
m
at
erant circuit.
om
io
– Install
n
c
in t
r
♦ Refrigerant Circuits a new

o
his
e
Adapter Set 1 -
t
expan‐
a
do
riv
Adapter 27 - sion
p
cum
or
VAS6338/27- and valve

f
en
ng
t.
with Closure Cap -
yi
after
Co
op
VAS6338/30- to
py
flush‐
t. C rig
gh
ht
ing.
pyri by
Vo
o
erant circuit. by c lksw
cted agen
Prote AG.
Adapter Set 2 -
Adapter 57 -
VAS6338/57- for
refrigerant line of
second evaporator.
Adapter Set 2 -
Adapter 58 -
VAS6338/58- for
refrigerant line of
second evaporator.
– Install a new receiv‐
ing.


Trans‐ ♦ A/C compres‐ • For vehicles on – Re‐
porter sor 7D0 820 which the receiver/ place
from MY 805 E Refrig‐ dryer is mounted the
91 as of erant Circuits below the condens‐ front
01 1996 Adapter Set 2 er, it may be flush‐ and
- Adapter 53 - ed. rear
VAS6338/53- expan‐
– On the other ver‐ sion AG. Volkswagen AG d
♦ A/C compres‐ sions, the receiver/ valve lksw
agen oes
not
sor 7D0 820 dryer should be re‐ with d by Vo gu
ara
805 H low moved. the Re‐thoris
e nte
eo
pressure side ♦ Refrigerant Circuits friger‐au ra
Refrigerant Adapter Set 1 - s
ant sCir‐
c
ce
e
Circuits Adapter 20 - cuits
nl
pt
du
Adapter Set 1 VAS6338/20- for
an
Adapt‐ itte
y li
- Adapter 7 - receiver/dryer. er Set
erm
ab
VAS6338/7-
ility
2-
ot p
Adapt‐
wit
, is n
♦ High pres‐ Adapter Set 1 -
h re
sure side Re‐ Adapter 29 - er 55 -
hole
VAS63
spec
frigerant Cir‐ VAS6338/29- for
38/55-
es, in part or in w
cuits Adapter receiver/dryer.
t to the co
Set 1 - Adapt‐ (or a
er 2 - ♦ Refrigerant Circuits drilled
VAS6338/2- Adapter Set 1 - open
rrectness of i
Adapter 26 - expan‐
♦ On vehicles VAS6338/26- and sion
l purpos
with auxiliary with Closure Cap - valve

evaporator VAS6338/30- to ⇒ page
on the roof, seal the front refrig‐ 87 )
nform
ercia
the Refriger‐ erant circuit.

m
– Install
at
ant Circuits
om
i
Adapter Set 2 ♦ Refrigerant Circuits
o
a new
n
c
in t
Adapter Set 1 -
r
- Adapter 51 - expan‐
o
his
e
Adapter 27 -
t
VAS6338/51- sion
a
do
riv
and Refriger‐ VAS6338/27- and valve

p
cum
or
ant Circuits with Closure Cap - after

f
en
ng
VAS6338/30- to
t.
flush‐
yi
Adapter Set 2
Co
op
py
- Adapter 52 - ing. t. C rig
gh
erant circuit.
ht
VAS6338/52- pyri by
Vo
co
should be
by lksw
♦ Refrigerant Circuits cted agen
Prote
used.
AG.
Adapter Set 2 -
Adapter 57 -
VAS6338/57- for
refrigerant line of
second evaporator.
Adapter Set 2 -
Adapter 58 -
VAS6338/58- for
refrigerant line of
second evaporator.
– Install a new receiv‐
ing.

Transporter MY 2004
Note

cuit using Refrigerant Circuits AAdapter
G. VolkswaSet
gen A1G- Adapter 5 -
VAS6338/5- and Refrigerant agen Circuits Adapter Setno1t - Adapter 11
does
olksw
- VAS6338/11- .ed b y V gu
ara
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


AG. Volkswagen AG d
Trans‐ ♦ A/C compres‐ – Remove dryer car‐ – Throu wage
n oes
olks not
porter sor 7H0 820 tridge and seal re‐ gh db
y V gu
ara
7H from 805 E low ceiver/dryer. VINorise nte
eo
MY pressure side – Install a new dryer 20000
au
th ra
2004 Refrigerant cartridge after ss , drill c
ce
le
Circuits Adapt‐ flushing. out
un
pt
er Set 1 - ♦ Refrigerant Circuits the
an
d
itte
y li
Adapter 12 - Adapter Set 1 - ex‐
rm
ab
VAS6338/12- , Adapter 5 - pan‐
pe
ility
ot
high pressure VAS6338/5- for the sion
wit
side Refriger‐ front refrigerant cir‐ valve , is n
h re
hole
ant Circuits cuit. ⇒
spec
Adapter Set 1 - pa
es, in part or in w
t to the co
Adapter 3 - ge 87 .
VAS6338/3- Adapter Set 1 -
Adapter 11 - – From
♦ A/C compres‐ VAS6338/11- for VIN
rrectness of i
sor 7H0 820 the front refrigerant 20001
803 C low circuit.
l purpos
, re‐
pressure side place
Refrigerant ♦ Low pressure line
for second Evapo‐ the
nform
ercia
Circuits Adapt‐ front

er Set 1 - rator Refrigerant
ex‐
m
a
Adapter 7 - Circuits Adapter
com
ti
pan‐
o
Set 1 - Adapter 3 -
n in
VAS6338/7- , sion
r
VAS6338/3-
te o
thi
high pressure valve
s
iva
side Refriger‐ ♦ High pressure line
do
with
r
rp
c
ant Circuits
um
for second Evapo‐ Re‐
fo
en
Adapter Set 1 - rator Refrigerant
g
friger‐
n
t.
yi Co
Adapter 2 - Circuits Adapter ant Cop py
VAS6338/2-
t. rig
Cir‐
gh
Set 1 - Adapter 4 -
ht
pyri by
VAS6338/4- cuits
co Vo
by lksw
cted
Adapt
agen
Prote AG.
er Set
2-
Adapt
er 56 -
VAS6
338/5
6-
– Install
a new
ex‐
pan‐
sion
valve
after
flush‐
ing.
– Drill a
hole
for the
ex‐
pan‐
sion
valve
Re‐
place
the
evap‐
orator
with
Re‐

. Volkswagen AG
gen AG does
swa
Beetle 2012 ➤ , CC 2010 ➤ , CC 2012 y V ➤ , Eos 2006 ➤ , Golf 1992 t➤
olk no
gu , G ...
b ara
Refrigerant
rised
R134a Servicing - Edition 08.2015 nte
ho eo
aut ra
s c
Vehicle Required adapt‐ Required adapters for s Miscella‐
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
friger‐
wit
, is n
ant
h re
Cir‐
hole
spec
cuits
es, in part or in w
Adapt
t to the co
er Set
2-
Adapt
rrectness of i
er 33 -
VAS6
l purpos
338/3
3- .
nform
ercia
– Install
m
at
a new
om
ion
ex‐
c
in t
or
pan‐
his
ate
sion
do
priv
c
valve
um
for
en
after
ng
t.
yi Co
flush‐ Cop py
ing.
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Trans‐ ♦ A/C compres‐ – Remove dryer car‐ – Throu
porter sor 7H0 820 tridge and seal re‐ gh
7J from 805 E low ceiver/dryer. VIN
MY pressure side – Install a new dryer 5000,
2004 Refrigerant cartridge after drill
Circuits Adapt‐ flushing. out
er Set 1 - ♦ Refrigerant Circuits the
VAS6338/12- , Adapter 5 - pan‐
high pressure VAS6338/5- for the sion
side Refriger‐ front refrigerant cir‐ valve
ant Circuits cuit. ⇒
Adapter Set 1 - pa
Adapter 3 - ♦ Refrigerant Circuits ge 87 .
VAS6338/3- Adapter Set 1 -
Adapter 11 - – From
♦ A/C compres‐ VAS6338/11- for VIN
sor 7H0 820 the front refrigerant 5001,
803 C low circuit. re‐
pressure side place
Refrigerant ♦ Low pressure line
for second Evapo‐ the
Circuits Adapt‐ front
er Set 1 - rator Refrigerant
Circuits Adapter ex‐
Adapter 7 - pan‐
VAS6338/7- , Set 1 - Adapter 3 -
VAS6338/3- sion
high pressure valve
side Refriger‐ ♦ High pressure line with
ant Circuits for second Evapo‐ Re‐
Adapter Set 1 - rator Refrigerant friger‐
Adapter 2 - agen ACircuits
G. Volkswagen AG d
Adapter o ant
VAS6338/2- Vol
ksw
Set 1 - Adapter 4
es n
- ot g Cir‐
by u
♦ A/C ed
ris compres‐ VAS6338/4- cuits
ara
nte
utho
sor 7H0 820 Adapt eo
ra
a
s 805 D low
s er Set c
2-
ce
le
pressure side
un
pt
Refrigerant Adapt
an
d
itte
er 56 -
y li
Circuits Adapt‐
erm
ab
er Set 2 - VAS6
ility
ot p
Adapter 52 - 338/5
wit
is n
VAS6338/12- , 6- .
h re
ole,
high pressure
spec
– Install
side Refriger‐
a new
t to the co
ant Circuits
Adapter Set 2 - ex‐
Adapter 51 - pan‐
sion
rrectne
VAS6338/51-
valve
after
s
flush‐
s o
ing.
cial p
f inform
mer
– Drill a
atio
hole
om
for the
c
i
or
n thi
ex‐
te
sd
a
pan‐
iv
o
pr
sion
um
r
fo
en
valve
ng
t.
yi Co
Cop
Re‐ py
place
t. rig
gh ht
yri by
the
cop Vo
by lksw
cted evap‐
agen
Prote AG.
orator
with
Re‐

. Volkswagen AG
gen AG does
swa
Vehicle Required adapt‐ Required adapters by for
Volk Miscella‐ not
gu
ers for refriger‐ refrigerant pipesrisedto re‐ neous ara
nte
ant pipes to A/C ceiver/dryeruthand sec‐
o eo
ra
ss a c
ce
e
friger‐
nl
pt
du
ant
an
itte
y li
Cir‐
erm
ab
cuits
ility
ot p
Adapt
wit
, is n
er Set
h re
hole
2-
spec
Adapt
es, in part or in w
t to the co
er 56 -
VAS6
338/5
rrectness of i
6- .
l purpos
– Install
a new
ex‐
nf
ercia
o
pan‐
rm
sion
m
atio
m
valve
o
n in
c
after
or
thi
e
flush‐
t
sd
iva
ing.
o
r
rp
cu
o
m
f
en
ng
Transporter MY 2010; Multivan MY 2010; California MY 2010;

t.
yi Co
op
Caravelle MY 2010 C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note Prote AG.

cuit using Refrigerant Circuits Adapter Set 1 - Adapter 5 -
VAS6338/5- and Refrigerant Circuits Adapter Set 1 - Adapter 11
- VAS6338/11- .


Trans‐ ♦ Low pressure – Remove dryer car‐ – Re‐
porter side Refriger‐ tridge and seal re‐ place
from MY ant Circuits ceiver/dryer. the
2010; Adapter Set 1 – Install a new dryer ex‐
Multivan - Adapter 12 - cartridge after pan‐
from MY VAS6338/12- flushing. sion
2010; ♦ Refrigerant Circuits valve
Califor‐ ♦ High pres‐ Adapter Set 1 - with
nia from sure side Re‐ Adapter 5 - the
MY frigerant Cir‐ VAS6338/5- for the Re‐
2010; cuits Adapter front refrigerant cir‐ friger‐
Cara‐ Set 1 - Adapt‐ cuit. ant
velle er 3 - Cir‐
from MY VAS6338/3- ♦ Refrigerant Circuits cuits
2010 Adapter Set 1 - Adapt
Adapter 11 - er Set
VAS6338/11- for 2-
the front refrigerant Adapt
circuit. er 56 -
♦ Low pressure line VAS6
for second Evapo‐ 338/5
rator Refrigerant 6- (or
Circuits Adapter a dril‐
Set 1 - Adapter 3 - led
VAS6338/3- open
ex‐
♦ High pressure line pan‐
for second Evapo‐ sion
rator Refrigerant valve
Circuits Adapter ⇒
agenSet
AG. V1ol-ksAdapter
wagen AG4 -
does
pa
olksw VAS6338/4- not ge 87 )
y V g ua
db ran
ise
tho
r – Re‐ tee o
au move r ac
ss
the
ce
e
nl
ex‐
pt
du
an
pan‐
itte
y li
erm
sion
ab
ility
valve
ot p
wit
for the
, is n
h re
rear
hole
spec
evap‐
es, in part or in w
orator
t to the co
and
drill
open
rrectness of i
⇒
pa
l purpos
ge 87 .
– Install
nf
ercia
a new
rm
m
atio
ex‐
om
pan‐
n in
or c
sion
thi
te
sd
valve
iva
o
r
after
rp
cu
o
flush‐
f
en
ng
t.
yi
ing.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006; LT 2 from MY 1997
Note

AG. Volkswagen
cuit using Refrigerant Circuits
kswagenAdapter Set 1A-GAdapter
does
n 5-
y Vol
VAS6338/5- and Refrigerant Circuits Adapter Set 1 o-t Adapter
gu 11
b ara
- VAS6338/11- o.rise
d
nte
th e or
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen
Beetle 2012 ➤ , CC ksw2010 ➤ , CC 2012 ➤ ,esEos
agen AG do
no 2006 ➤ , Golf 1992 ➤ , G ...
Vol
Refrigerant R134a
db
y Servicing - Edition 08.2015 t guara
e nte
ris
tho eo
Vehicle Required adapt‐ au Required adapters for Miscella‐
ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Crafter ♦ A/C compres‐ Receiver/Dryer – Drill a
ility
ot p
from MY sor 2E0 820 – May be flushed. hole
wit
, is n
2006 803 A low – Install a new receiv‐ for the
h re
hole
pressure side er/dryer after flush‐ ex‐
spec
Refrigerant ing. pan‐
es, in part or in w
t to the co
Circuits Adapt‐♦ Refrigerant Circuits sion
er Set 1 - Adapter Set 1 - valve
Adapter 12 - Adapter 5 - ⇒
rrectness of i
VAS6338/12- , VAS6338/5- for the page
high pressure front refrigerant cir‐ 87
l purpos
side Refriger‐ cuit.

ant Circuits – Install
Adapter Set 1 -♦ Refrigerant Circuits a new
nform
ercia

Adapter 11 -
m
VAS6338/3- pan‐
at
om
VAS6338/11- for
io
sion
n
c
♦ A/C compres‐ the front refrigerant
in t
r
valve
o
his
sor 2E0 820 circuit.
e
after
at
do
riv
805 low pres‐ flush‐

p
c
♦ Low pressure line
um
sure side Re‐
or
ing.
f
for second Evapo‐

en
g
frigerant Cir‐
n
t.
yi
rator Refrigerant
Co
op
cuits Adapter C py
Set 1 - Adapter Circuits Adapter
t. rig
gh ht
yri
Set 1 - Adapter 3 -
by
7-
op Vo
by c lksw
VAS6338/7- , VAS6338/3- Prote
cted AG.
agen
high pressure ♦ High pressure line

side Refriger‐ for second Evapo‐
ant Circuits rator Refrigerant
Adapter Set 1 - Circuits Adapter
Adapter 3 - Set 1 - Adapter 4 -
VAS6338/3- VAS6338/4-


LT 2 ♦ Low pressure – Remove receiver/ – Re‐
1997 ant Circuits coolant pipes. the
Adapter Set 1 ex‐
- Adapter 7 - – Connect with two pan‐
VAS6338/7- Refrigerant Circuits sion
Adapter Set 1 - valve
♦ High pres‐ Adapter 29 - with
sure side Re‐ VAS6338/10- and the
frigerant Cir‐ with Refrigerant Re‐
cuits Adapter Circuits Adapter friger‐
Set 1 - Adapt‐ Set 1 - Hose 31 - ant
er 2 - VAS6338/31- . Cir‐
VAS6338/2- cuits
♦ Refrigerant – Install a new receiv‐ Adapt
Circuits er/dryer after flush‐ er Set
Adapter Set 1 ing. 2-
- Adapter 20 - Adapt
VAS6338/20- aer
gen56AG-. Volkswagen AG d
oes
olksw VAS6 not
y V gu
ise
d b 338/5 ara
nte
thor
6- (or eo
ss au
a dril‐ ra
c
led
ce
le
un
open
pt
an
d
ex‐
itte
y li
erm
pan‐
ab
ility
sion
ot p
wit
valve
is n
h re
⇒
ole,
spec
pa
ge 87 )
t to the co
– Install
a new
rrectne
ex‐
pan‐
sion
valve ss o
cial p
f in
after
form
mer
flush‐
atio
ing.
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok MY 2011
compressor
Amarok ♦ Low pressure – Remove dryer car‐ – Re‐
flushing. with
sure side Re‐ , friger‐
cuits Adapter cuits
er 3 - er Set
VAS6338/3- 2-
Adapt‐
er 33 -
VAS63
38/33-
(or a
drilled
open
expan‐
sion
valve
⇒ page
87 )
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
140
cted agen
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Golf blue e-Motion MY 2009

compressor and
on A/C compres‐
sor
Golf ♦ Low pressure – Remove dryer car‐ – Re‐
blue e- side Refriger‐ tridge and seal re‐ place
Motion ant Circuits ceiver/dryer. the ex‐
from MY Adapter Set 1 -– Install a new dryer pan‐
2009 Adapter 12 - cartridge after sion
VAS6338/12- flushing. valve
♦ Refrigerant Circuits with the
♦ High pressure Adapter Set - Shut- Refrig‐
side Refriger‐ Off Valve - erant
ant Circuits VAS6338/42- Circuits
Adapter Set 1 - Adapt‐
Adapter 3 - er Set 1
VAS6338/3- - Adapt‐
♦ Flush electri‐ er 34 -
cally-driven A/ VAS63
C compressor 38/34-
using Refriger‐ (or a
ant Circuits drilled
Adapter Set - open
Adapter 40 - expan‐
VAS6338/40- sion
and Refriger‐ valve
ant Circuits ⇒
Adapter Set - pa
Adapter 41 - ge 87 )
AG. Volkswagen AG d
VAS6338/41- . ksw
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See notes yV
ol – Install sanot gu
here: ris
ed
b
new ex‐ ara
nte
⇒ “7.2.3 Elec‐ ut
ho pan‐ eo
ra
ss a
trically Driven sion c
valve
ce
e
A/C Compres‐
nl
pt
after
du
sor, Flushing”,
an
itte
flush‐
y li
page 98
erm
ab
ing.
ility
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– Re‐
h re
move
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the
es, in part or in w
High
t to the co
Voltage
Battery
Heater
rrectness of i
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Refrig‐
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erant
Cut-Off
nf
ercia
Valve -
or
N542-
m
m
atio
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stall the
or c
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cted Valve -
AG.
agen
VAS63
38/42- .


compressor and
on A/C compres‐
sor
– Re‐
move
the
Heater
and A/
C Unit
Refrig‐
erant
Cut-Off
. Volkswage
Valve -
gen AG n AG d
olks
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not
byV and gin‐
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orised
stall the
ran
tee
auth Refrig‐ or
ac
ss erant
Circuits
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Adapt‐
an
itte
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er Set -
erm
ab
Shut-
ility
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Off
wit
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Valve -
h re
hole
VAS63
spec
38/42- .
es, in part or in w
Note t to the co
Warn‐
ings
⇒
rrectness of i
page
l purpos
146
– If the
nf
ercia
Refrig‐
orm
erant
m
atio
m
Circuits
o
n in
c
Adapt‐
or
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er Set -
te
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iva
Shut-
o
r
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Off
o
m
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en
ng
Valve -
t.
yi Co
op
VAS63
C py
ht. rig
38/42-
rig ht
py by
is not
co Vo
by lksw
availa‐
cted agen
Prote AG.
ble, a
voltage
of 12 V
can be
applied
to the
Cut-Off
Valves
-N541-
und -
N542-.

AG. Volkswagen AG d
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eGolf MY 2014 and eGolf MY 2014 with Heat
Vol Pump
ksw not
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Vehicle Required adapt‐ Required thoriadapters for Miscella‐ eo
ers for refriger‐ refrigerant
s au pipes to re‐ neous ra
c
ant pipes to A/C ceiver/dryer s
ce
le
compressor and
un
pt
an
d
on A/C compres‐
itte
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erm
sor
ab
ility
ot p
e-Golf ♦ Low pressure – Remove dryer car‐ – Re‐
wit
is n
h re
ole,
spec
Adapter Set 1 - pan‐
t to the co
Adapter 12 - – Install a new dryer sion
flushing. with the
♦ High pressure Refrig‐
rrectne
side Refriger‐ erant
ant Circuits Circuits
s
Adapter Set 1 -
s
Adapt‐
o
Adapter 3 -
cial p
f
er Set 1
in
VAS6338/3-
form
- Adapt‐
mer
er 34 -
atio
m
VAS63
o
cally-driven A/
n
c
38/34-
i
or
n
C compressor
thi
e
(or a
t
sd
using Refriger‐
va
drilled
i
o
r
ant Circuits
p
cum
r
open
fo
Adapter Set -
en
ng
expan‐
t.
yi
Adapter 40 -
Co
op
sion
py
VAS6338/40-
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ht
valve
rig ht
and Refriger‐ py by
⇒
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ant Circuits
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cted
pa
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Adapter Set -
AG.
Adapter 41 - ge 87 )
VAS6338/41- .
See notes – Install a
here: new ex‐
⇒ “7.2.3 Elec‐ pan‐
trically Driven sion
A/C Compres‐ valve
sor, Flushing”, after
page 98 flush‐
ing.

wage es n
Beetle 2012 ➤ , CC 2010 ➤ , CC 2012y➤ Vo , Eos 2006 ➤ , Golf 1992 ➤o,t gG
lks ...
b ua
Refrigerant R134a Servicing - Editionir se 08.2015
d ran
tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
compressor and
erm
ab
on A/C compres‐
ility
ot p
sor
wit
is n
h re
ole,
eGolf ♦ Low pressure – Remove the reser‐ – Using
spec
from MY side Refriger‐ voir (dryer) and the Ve‐
2014 ant Circuits bridge coolant hicle
t to the co
with Adapter Set 1 - pipes. Diag‐
Heat Adapter 12 - nostic
Pump VAS6338/12- – Connect with two Tester ,
rrectne
Refrigerant Circuits then
♦ High pressure Adapter Set 1 - start
side Refriger‐
s
Adapter 6 - the
s o
ant Circuits
cial p
VAS6338/6- and “Refrig‐
f in
Adapter Set 1 - with Refrigerant erant
form
mer
Adapter 3 - Circuits Adapter circuit,
atio
VAS6338/3-
m
Set 1 - Hose 31 - charg‐

o
n
c
VAS6338/31- . ing”
i
or
n
thi
func‐
e
cally-driven A/
t
sd
a
– Install a new reser‐ tion in

iv
o
C compressor
pr
c
using Refriger‐ voir after flushing. the “Ba‐
um
r
fo
en
ng
sic set‐
t.
ant Circuits
yi Co
ting”.
op
Adapter Set -
C py
. rig
♦ Doing
t
gh
Adapter 40 -
ht
yri by
so
op Vo
VAS6338/40-
c by lksw
opens cted agen
and Refriger‐ Prote AG.
ant Circuits the
Adapter Set - electric
Adapter 41 - valves
VAS6338/41- . on the
See notes refrig‐
here: erant
⇒ “7.2.3 Elec‐ circuit.
trically Driven ♦ Keep
A/C Compres‐ the Ve‐
sor, Flushing”, hicle
page 98 Diag‐
nostic
Tester
con‐
nected
so that
the
valves
stay
open.

Golf Hybrid MY 2014

compressor and
on A/C compres‐
sor
G. Volkswagen
Golf Hy‐ ♦ Low pressure There ksw are two versions ♦ Replace
agen
A AG do
es n the
brid side Refriger‐byof Volthe receiver/dryer: expansion
ot g
ua
from MY ant Circuits or
ise Refer to the vehicle
d
valve with ran
tethe
2014 Adapter authSet 1 - specific repair manual. Refrigerant eo
ra
Adapter
ss 12 - ♦ Receiver/dryer with Circuits Adapt‐c
VAS6338/12- an installed dryer. er Set 1 -
ce
e
nl
pt
du
Adapter 38 -
an
itte
♦ High pressure – May be flushed.
y li
VAS6338/38-
erm
ab
side Refriger‐ – Install a new receiv‐ (or a drilled
ility
ot p
ant Circuits er/dryer after flush‐ open expan‐
wit
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Adapter Set 1 - ing. sion valve
h re
Adapter 3 - ♦ receiver/dryer with
hole
⇒ page 87 )
spec
VAS6338/3- dryer bag / car‐
es, in part or in w
tridge ♦ Replace the
t to the co
♦ Flush electri‐ Heater and A/
cally-driven A/ – Remove the dryer C Unit Refrig‐
C compressor bag / cartridge and erant Shut-Off
rrectness of i
using Refriger‐ close the receiver/ Valve -N541-
ant Circuits dryer. and High-Volt‐
l purpos
Adapter Set - age Battery

Adapter 40 - – Install a new dryer Heater Core
VAS6338/40- bag / cartridge after
nf
ercia
Refrigerant
o
and Refriger‐ flushing.
r
Shut-Off Valve
m
m
ant Circuits
atio
-N542- with
m
Adapter Set -
o
two Shut-Off n in
or c
Adapter 41 - Valves -
thi
te
VAS6338/41- .
sd
a
VAS6338/42- .
iv
o
r
See notes
rp
cu
Refer to the in‐

o
here:
f
formation
en
ng
t.
⇒ “7.2.3 Elec‐
yi
found here
Co
op py
trically Driven
C
⇒ page 146 .
t. rig
gh ht
A/C Compres‐ yri
p by
o Vo
sor, Flushing”, ♦ The restrictor by c lksw
cted agen
page 98 in the refriger‐
Prote AG.
ant line to the

High-Voltage
Battery Heat
Exchanger is
removed and
drilled out. Re‐
fer to the notes
below
⇒ page 146

Note
The refrigerant circuit is flushed in 2 phases for the Golf Hybrid

2014. In the first flushing cycle the adapter for the heater and a/c
unit refrigerant cut-off valve - N541 is opened and the adapter for
the high voltage battery heater core refrigerant cut-off valve -
N542 is closed. From this, the refrigerant circuit with the evapo‐
rator in the Heater and A/C Unit is flushed. In the second flushing
cycle the adapter for the heater and a/c unit refrigerant cut-off
valve - N541 is closed and the adapter for the high voltage battery
heater core refrigerant cut-off valve - N542 is open. From this, the
refrigerant circuit with the evaporator in the high voltage battery
heat exchanger is flushed. Refer to Heating, Ventilation and Air
Conditioning, Repair group 87, System Overview - Refrigerant
Circuit (vehicle-specific repair manual). AG. Volkswagen AG d
agen oes
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d by ara
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Note ss a c
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nl
pt
du
♦ This illustration shows a refrigerant line -A- with a permanently
an
itte
installed restrictor -B- (without a strainer) This refrigerant line
y li
erm
ab
is to be drilled open to 5.0 mm using a suitable drill to flush the
ility
ot p
refrigerant circuit (an inserted restrictor is to be removed) and
wit
, is n
is to be cleaned in the flushing circuit before installing. The
h re
drilled refrigerant line is replaced after flushing. Refer to the
hole
spec
Parts Catalog.
es, in part or in w
t to the co
♦ The diameter of the illustrated restrictor bore -B- is approxi‐
mately 0.7 mm. Depending on the version of the refrigerant
line this constriction is either installed fixed in the refrigerant
rrectness of i
line or only inserted. For the inserted version a strainer for
flowing deposits may be installed, which can be blocked by the
l purpos
variable orifice.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V
Beetle
d by 2012 ➤ , CC 2010 ➤ , CC 2012
gu
ara ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
ise nte
thor Refrigerant e oR134a Servicing - Edition 08.2015
au ra
ss c
ce
e
nl
8 Concerns
pt
du
an
itte
y li
erm
ab
⇒ “8.1 Possible Refrigerant Circuit Concerns”, page 147
ility
ot p
wit
⇒ “8.2 Odor from the Heater and A/C Unit”, page 148
, is n
h re
hole
8.1 Possible Refrigerant Circuit Concerns
spec
es, in part or in w
t to the co
⇒ “8.1.1 Test Requirements”, page 147
⇒ “8.1.2 Possible Concerns”, page 147
rrectness of i
8.1.1 Test Requirements
l purpos
Note
nf
ercia
orm
m
atio
♦ The A/C system is functioning correctly when the air flowing
om
from the instrument panel vents has a temperature of 70C or
n in
or c
lower.
thi
te
sd
iva
o
r
♦ Setting on Climatronic “LO”.

rp
cu
o
m
f
en
ng
♦ Setting on A/C system “AC” on; “max”; “cold”.

t.
yi Co
Cop py
t. rig
gh ht
yri
• The A/C system OBD cannot find malfunctions with the Vehi‐ p by
co Vo
cle Diagnostic Tester in “Guided Fault Finding”. The measured
by lksw
cted agen
Prote
value block does not show any shut-off condition for the A/C
AG.
compressor (only on vehicles with “A/C system” OBD).

8.1.2 Possible Concerns
Note
♦ The A/C system is functioning correctly when the air flowing

from the instrument panel vents has a temperature of 70C or
lower.
Note
With all complaints marked with *. Refer to

♦ Total cooling system failure. *

♦ Insufficient cooling performance at all vehicles speeds or en‐
gine speeds. *
♦ None or insufficient cooling after driving a few miles. *
♦ A/C compressor, A/C Clutch - N25- or A/C Compressor Reg‐
ulator Valve - N280- are switched off by A/C Refrigerant Low
Pressure Switch - F73- , A/C Refrigerant High Pressure Switch
- F118- , A/C Pressure Switch - F129- or by A/C Control Head
- E87- or Climatronic Control Module - J255- due to excessive
or insufficient pressure. *
♦ None or sharp decrease in fresh-air supply after driving sev‐
eral miles (evaporator iced up). *
From these, the following complaints may also occur:
8. Concerns 147
The A/C compressor makes noises

– Re-tighten compressor securing bolts and compressor brack‐
et using a torque wrench.
– Check routing of refrigerant lines; they must not touch other
components and must not be subject to strain (align if neces‐
sary).
Noise (refrigerant hammer) occurring immediately after switching
on air conditioner and/or when cornering or braking:
– Discharge, evacuate and charge refrigerant circuit (too much
refrigerant in circuit).
Note
♦ Too much refrigerant oil in the circuit could also cause this
problem. This could occur if the amount of refrigerant oil was
not adjusted when replacing the A/C compressor. If this oc‐
curs, flush the refrigerant circuit with refrigerant R134a. Refer
to
R134a”, page 83 .
♦ Drain the refrigerant from the A/C compressor. To facilitate
this, the ribbed belt pulley or magnetic clutch plate on the A/C
compressor should be rotated by hand. After flushing, the en‐
tire quantity of refrigerant oil specified by vehicle-specific re‐
pair manual should be added to the refrigerant
lkswage circuit (50 es n
ot g
grams directly in the A/C compressor).
o
byV ua
d r e an
ris tee
tho or
Water sprays out of vents or footwell) although air (insdash
sa
u
panel ac
conditioning system is otherwise functioning properly:
ce
e
nl
pt
du
an
– Check proper routing of condensate drain; it must not be

itte
y li
crushed or kinked.
erm
ab
ility
ot p
– Check condensation drain valve, it must not be clogged by wax

wit
, is n
or underbody sealant and must open and close properly.

h re
hole
spec
– Check plenum chamber cover; it must not be damaged and

es, in part or in w
must be properly installed (to stop water running into evapo‐

t to the co
rator).
– Check water drains in plenum chamber; they must not be
rrectness of i
blocked (e.g. by leaves).

l purpos
8.2 Odor from the Heater and A/C Unit

⇒ “8.2.1 Odor from Evaporator or Heat Exchanger?”, page 148
nform
ercia
⇒ “8.2.2 Ultrasound A/C Cleaner VAS6189B ”, page 150

m
at
om
io
⇒ “8.2.3 Evaporator, Cleaning with Suction Feed Spray Gun

n
c
in t
or
VAG1538 and Spray Nozzle”, page 150

his
ate
do
riv
8.2.1 Odor from Evaporator or Heat Exchang‐

p
cum
for
en
g
er?
n
t.
yi Co
Cop py
t. rig
♦ Fishy smell
gh ht
pyri by
Vo
co lksw
by
– From leak at cooling system of engine or of A/C system heater Prote
cted AG.
agen
core.

Beetle 2012 ➤ , CC 2010 ➤ , CC A2012
. Volk➤
sw,ag
Eos 2006 ➤ , Golf 1992 ➤ , G ...
en AG
gen G
waRefrigerant R134a Servicing
does - Edition 08.2015
olks no
yV t gu
db ara
ir se nte
ho eo
ut ra
Note ss
a c
ce
e
nl
pt
du
If the fishy smell gets weaker when the temperature is set to “cold”
an
itte
y li
and stronger when it is set to “warm”, then check the heat ex‐
erm
ab
changer for leaks.
ility
ot p
wit
, is n
h re
♦ Smells like a burned clutch.
hole
spec
♦ Evaporation from floor mats, decorative seat covers, etc. es, in part or in w
t to the co
♦ Musty smell
– Due to various contaminants, such as leaves, pine needles,
rrectness of i
etc. collecting.
l purpos
Note
nform
ercia
Clean the plenum chamber.

m
at
om
ion
c
in t
r
– Due to water that cannot drain out of the plenum chamber.

o
his
ate
do
priv
cum
for
Note
en
ng
t.
yi Co
Cop py
Check that the plenum chamber water is draining.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ Odor from the Heater and A/C Unit Prote AG.
Note
Odors originating in the heating and A/C unit can mainly be de‐
tected in fresh air mode and recirculated air mode.
– Due to too much condensation water in A/C unit.
Note
Check the condensation water drain. Refer to ⇒ Rep. Gr. 87 in

the vehicle-specific Repair Manual.
– Due to an old or heavily contaminated dust and pollen filter.
Note
Check the dust and pollen filter. Refer to ⇒ Rep. Gr. 80 in the
vehicle-specific Repair Manual.
– Due to deposits on evaporator fins.
Note
Clean the evaporator using the Ultrasound A/C Cleaner -

VAS6189A- . Refer to
⇒ “8.2.2 Ultrasound A/C Cleaner VAS6189B ”, page 150 or the
Suction Feed Spray Gun - VAG1538- and a suitable spray nozzle.
Refer to
⇒ “8.2.3 Evaporator, Cleaning with Suction Feed Spray Gun
VAG1538 and Spray Nozzle”, page 150 .
8. Concerns 149
8.2.2 Ultrasound A/C Cleaner - VAS6189B-

– The Ultrasonic HVAC Cleaning System - VAS6189A- is placed
in the front passenger footwell and sprays Aero-Clean. Aero- G. Volkswagen AG d
Clean neutralizes microbes and bacteria inside the gen Aand
kheater
swa oes
ol not
A/C unit. db
y V gu
ar
e an
ris tee
The unit comes with Operating Instructions.
ut
ho or
a ac
ss
8.2.3 Evaporator, Cleaning with Suction Feed
ce
le
un
pt
Spray Gun - VAG1538- and Spray Noz‐
an
d
itte
y li
rm
zle
ab
pe
ility
ot
wit
, is n
Spray off the evaporator directly with Contra Sept using a spray
h re
nozzle (approximately 10 bar (145 psi)). Contra Sept neutralizes
hole
spec
microbes and bacteria directly on the evaporator.
es, in part or in w
t to the co
To make it possible to access the evaporator, some prework and
different spray nozzles are needed, for example
VAG1538/5;VAG1538/6 orVAG1538/7.
rrectness of i
A vehicle-specific instruction booklet is included with the evapo‐
l purpos
rator cleaning solution D 600 100 A2
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9 Connecting Service Station

⇒ “9.1 Refrigerant Circuit, Connection on Low and High Pressure
Side”, page 151
9.1 Refrigerant Circuit, Connection on Low

and High Pressure Side
⇒ “9.1.1 A/C Service Station, Connecting for Measuring and Test‐
ing”, page 151
9.1.1 A/C Service Station, Connecting for

Measuring and Testing
– Connect the A/C service station to the power supply. AG. Volkswagen AG d
agen oes
olksw not
– Connect quick-release coupling adapter to charging d bhoses
y V of gu
ara
service station (handwheels not screwed in/hand orisshut-off
e nte
eo
valve not open). auth
ra
ss c
– Switch on service station and evacuate charging hoses (only
ce
le
un
pt
necessary if there is air in charging hoses).
an
d
itte
y li
rm
– Switch off A/C service station.
ab
pe
ility
ot
– Remove caps from service connections (with valve).
wit
, is n
h re
– Connect the A/C service station to the refrigerant circuit using
hole
spec
service connections with quick-release coupling adapters.
es, in part or in w
t to the co
– Screw in handwheel of quick-release coupling adapters only
until valves are definitely open at refrigerant circuit connection
(observe pressure gauge, do not strain valves).
rrectness of i
– Perform planned tests and measurements.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Connecting Service Station 151

AG. Volkswagen AG d
agen oes
olksw not
yV g
Beetle 2012 ➤ , CC 2010 ➤ , CC 2012 s➤ ed , Eos 2006 ➤ , Golf 1992 ➤ , G ... uara
b
nte
ri
Refrigerant R134a Servicing - Editionut
ho08.2015 eo
ra
s a c
s
ce
e
nl
pt
10 Pressures, Checking
du
an
itte
y li
erm
ab
⇒ “10.1 Refrigerant Circuit Pressures (with A/C Service Station),
ility
ot p
Checking”, page 152
wit
, is n
h re
⇒ “10.2 Checking with Restrictor and Reservoir, with Internally
hole
spec
Regulated A/C Compressor”, page 156
es, in part or in w
t to the co
⇒ “10.3 Checking with Expansion Valve and Receiver/Dryer, with
Internally Regulated A/C Compressor”, page 161
⇒ “10.4 Checking with Expansion Valve and Receiver/Dryer, with‐
rrectness of i
out Regulated A/C Compressor”, page 168
l purpos
⇒ “10.5 Checking with Restrictor, Reservoir and A/C Compressor

Regulator Valve N280 , Externally Regulated A/C Compressor”,
nf
ercia
page 169
orm
m
⇒ “10.6 Checking with Expansion Valve, Receiver/Dryer and A/C
atio
m
Compressor Regulator Valve N280 , Externally Regulated A/C

o
n in
or c
Compressor”, page 175
thi
te
sd
iva
⇒ “10.7 With Expansion Valve, Receiver/Dryer and Electrically-
o
r
rp
cu
Driven A/C Compressor”, page 186
o
m
f
en
ng
t.
yi Co
10.1 Refrigerant Circuit Pressures (with A/C Cop py
ht. rig
ht
Service Station), Checking
rig by
copy Vo
by lksw
cted agen
Prote
AG.
⇒ “10.1.2 Pressures, Checking”, page 154

⇒ “10.1.3 Compressor Types, Checking Pressures”, page 156
Note
♦ Check cooling performance. The A/C system is functioning

correctly when the air flowing from the instrument panel vents
has a temperature of 70C or lower.
♦ Connections with valve and service connections for measuring
and checking.
• Radiator and condenser are clean (clean if necessary).

• Thermal insulation at expansion valve OK and properly instal‐
led. Refer to ⇒ Rep. Gr. 87 for the vehicle-specific repair
manual.
• Ribbed belt is OK and properly tensioned. Ribbed belt for A/C
compressor and generator are OK and correctly tensioned.
• All air ducts, covers and seals OK and properly installed.
• Fault finding on the electrical equipment and vacuum system
found no malfunction. Refer to ⇒ Rep. Gr. 87 for the vehicle-
specific repair manual.
• The A/C system OBD cannot find malfunctions with the Vehi‐
cle Diagnostic Tester in “Guided Fault Finding”. The measured
value block does not show any shut-off condition from the A/
C compressor (only on vehicles with “A/C system” OBD).

• Air flow through dust and pollen filter not obstructed by dirt.
• The heater and A/C unit does not draw in any secondary air
at the highest fresh air blower speed. Evaporator and heater
not drawing in secondary air at maximum fresh-air blower
speed. Refer to ⇒ Rep. Gr. 87 for the vehicle-specific repair
manual.
• The air flaps in the heater and A/C unit reach their end position.
• Fresh-air intake ducts beneath hood and in passenger com‐
partment as well as corresponding water drain valves OK, see
vehicle specific Repair Manual. Refer to ⇒ Rep. Gr. 87 .
• The engine is warm.
• Vehicle is not exposed to direct sunlight.
• Ambient temperature greater than 15 °C (60 °F).
• All instrument panel vents are open.
• With engine running and maximum cooling output set on air
conditioning system:
Maximum cooling output, setting
Setting on Front A/C Display Control Head - E87- .
– Preselect “Auto” mode (A/C compressor on).
– Set the temperature preset “LO” for the driver and front
olks
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Setting on heater controls: tho or
au ac
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– A/C button and Rec- or recirculated air button pressed.
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– Temperature dial in the “Cold” position.
itte
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– Fresh-air blower dial in “4” position.
ility
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• The Coolant Fan - V7- runs (the fans run) (at least in level 1).*
, is n
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hole
spec
es, in part or in w
Note
t to the co
For some versions, the fan is switched on only once the pressure
in refrigerant circuit has exceeded a specified value.
rrectness of i
l purpos
• The Fresh Air Blower - V2- runs at maximum speed.

• Recirculated/fresh-air door set to “air recirculation
nform
ercia
mode” (within 1 min. after starting vehicle, air-flow door is

closed and recirculated air door opened).*
m
at
om
ion
c
• Is the coolant shut-off valve closed?*

in t
or
his
te
• Are the valves on the pump valve unit closed and the coolant
a
do
riv
circulation pump is not pumping? *

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10. Pressures, Checking 153

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10.1.2 Pressures, Checking
itte
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ility
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Note
h re
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spec
es, in part or in w
t to the co
rrectness of i
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and checking.
nform
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a
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ion in
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– Connecting service station. Refer to
thi
s
iva
⇒ “9 Connecting Service Station”, page 151 .
do
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– Take pressure gauge readings (two possible results).
en
ng
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Ambient Temperature in °C (°F) Pressure in Refrigerant Circuit
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20 (68) 4.7 (68.17)
25 (77) 5.6 (81.22)
30 (86) 6.7 (97.18)
35 (95) 7.8 (113.13)
40 (104) 9.1 (131.98)
45 (113) 10.5 (152.28)
Note
♦ Temperature of refrigerant circuit components should be equal

to ambient temperature.
♦ Pressure will deviate from values in table if individual compo‐
nents of refrigerant circuit are warmer or colder.
♦ At absolute pressure, 0 bar/psi corresponds to absolute vac‐
uum. Normal ambient pressure (positive pressure) corre‐
sponds to 1 bar (14.5 psi) absolute pressure. 0 bar/psi
pressure corresponds to an absolute pressure of 1 bar (14.5
psi) on most pressure gauges (indicated by 1 bar (14.5 psi)
below 0).
♦ On vehicles with High Pressure Sensor - G65- with which the
measured pressure is displayed in the measured value block,
the measured pressure should correspond to the values in the
table.

The refrigerant circuit pressure is lower than indicated in table
Not enough refrigerant in refrigerant circuit
– Determine refrigerant circuit leaks. Refer to
Detector VAG1796 ”, page 72 .
– Check the pressure relief valve.
If pressure relief valve has responded:

– Check the coolant fan activation.

– Check refrigerant lines and hoses for cross-section constric‐
tions caused by inadequate bending radii.
– Check refrigerant pipes and hoses for external damage.
– If no malfunction is found, flush refrigerant circuit with com‐
pressed air and nitrogen.
The refrigerant circuit pressure is in line with table or is higher
– Start the engine.
– For vehicles with an electrically-driven A/C compressor, switch
on the ignition.
WARNING
Hybrid vehicles have a high voltage system. Danger of elec‐

trical shock! Inspect the high voltage components visually
before beginning. Follow the General Warnings. Refer to ⇒
Hybrid Electric Equipment; Rep. Gr. 93 ; General Warnings
When Working on High Voltage Electrical System .
. Volkswagen AG
gen AG does
– Set the A/C system to maximum cooling output.
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If the low pressure switch was removed to connect the service
du
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station, bridge the electrical connections in the corresponding
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connector for the pressure measurement.
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• A/C compressor is driven by the engine via A/C Clutch - N25- .
h re
hole
spec
• The A/C Compressor Regulator Valve - N280- is activated by
es, in part or in w
the Climatronic Control Module - J255- .
t to the co
If A/C compressor is not driven with the engine running or regu‐ rrectness of i
lating valve is not actuated:
l purpos
– Determine and eliminate cause e.g. by checking air condition‐

er DTC memory.
nf
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– Observe test conditions.

m
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atio
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– Check the A/C Clutch - N25- voltage supply. If it is OK, repair

o
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or c
the A/C clutch.

thi
te
sd
iva
– Check activation of A/C Compressor Regulator Valve - N280- .

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10.1.3 Compressor Types, Checking Pres‐

sures
Note

and checking.
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♦ Check on vehicles with restrictor and reservoir yV
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lksw internally not
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regulated A/C compressor). Refer to ed
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⇒ “10.2 Checking with Restrictor and Reservoir,
tho with Internally eo
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c
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♦ Check on vehicles with expansion valve and receiver/dryer

un
pt
an
d
(with internally regulated A/C compressor). Refer to

itte
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⇒ “10.3 Checking with Expansion Valve and Receiver/Dryer,
erm
ab
with Internally Regulated A/C Compressor”, page 161 .
ility
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♦ On vehicles with expansion valve and receiver/dryer (without
h re
ole,
regulated A/C compressor). Refer to
spec
⇒ “10.4 Checking with Expansion Valve and Receiver/Dryer,

without Regulated A/C Compressor”, page 168 .
t to the co
♦ Checking pressures for vehicles with restrictor, reservoir and
A/C Compressor Regulator Valve - N280- (externally regula‐
rrectne
ted A/C compressor). Refer to
⇒ “10.5 Checking with Restrictor, Reservoir and A/C Com‐
s
pressor Regulator Valve N280 , Externally Regulated A/C
s o
Compressor”, page 169 .
cial p
10.2 Checking with Restrictor and Reservoir, f inform

mer
atio
m
with Internally Regulated A/C Compres‐

o
n
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i
or
sor
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Note
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♦ Connecting service station. Refer to
rig ht
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by
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♦ Observe test requirements. Refer to
– Bring engine speed up to 2000 RPM.

– Pay attention to the A/C service station pressure gauge.
Note
♦ Switching pressures for refrigerant circuit switches are vehi‐

cle-specific.
♦ Connection with valve for low-pressure switch or at evaporator
is only to be used for vehicles with no service connection on
low-pressure side and inaccessible connection at compressor
or accumulator (measurement accuracy). Only applies to cer‐
tain vehicles.

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Refer to ⇒ Rep. Gr. 87 . au
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Specified Values
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High-pressure side:
itte
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Increasing from initial pressure (when connecting the pressure
ility
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gauges) to a maximum of 20 bar (290 psi).
wit
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h re
Low-pressure side:
hole
spec
es, in part or in w
Decreasing from initial pressure (when connecting pressure
t to the co
gauges) to the value in the graph.
A - High pressure (measured at service connection) in bar
rrectness of i
B - Low pressure (measured at connection with valve at com‐
pressor or accumulator) in bar l purpos
C - Permissible tolerance range
nf
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D - Low pressure (measured at connection with valve for low-
rm
m
pressure switch or at service connection) in bar
atio
om
n in
c
E - Permissible tolerance range

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Possible deviation from specification Possible cause of fault Corrective action

• High pressure remains constant or in‐ Not enough refrigerant in re‐ – Check for leaks and correct.
creases only slightly (above pressure frigerant circuit
with engine stopped), – Charge the refrigerant circuit.
• Low pressure quickly drops to value
in graph or below
• Required cooling output is not at‐
tained
• High pressure normal

• Low pressure in line with value in
graph
tained
• High pressure normal

• Low pressure too low (see graph)
tained

Note
If no malfunction is found with this complaint, flush (clean) refrig‐

erant circuit with refrigerant R134a. Refer to
R134a”, page 83 . If that is not possible in this workshop, flush
the refrigerant circuit with compressed air and remove moisture
with nitrogen. Refer to
trogen”, page 81 .

• High pressure only increases slightly A/C compressor faulty. – Flush (clean) refriger‐
above pressure with engine stopped ant circuit. Refer to
⇒ “7.2 Refrigerant Cir‐
• Low pressure drops only slightly cuit, Flushing (Clean‐
• Required cooling output is not at‐ ing) with Refrigerant
tained R134a”, page 83 .
– Replace A/C compres‐

sor.
Possible deviation from specification Possible cause of fault

AG. Volkswagen
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• High pressure increases above Constrictiony Vorolkobstruction in refrigerant cir‐ot –g Run hand over re‐
ua
specification cuit ised b rfrigerant
an
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circuit to
thor
check or for differen‐
• Low pressure quickly drops to value au
ces inactemperature
in graph or below ss
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nl
pt
• If difference in tem‐
du

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perature is found at
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tained
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one component:
ility
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– Replace the hose or

wit
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pipe if kinked or h re
hole
constricted. spec
es, in part or in w
t to the co
– In the event of an
obstruction, flush
refrigerant circuit
rrectness of i
with compressed air

and nitrogen
l purpos
– Repeat test if func‐

tion is not OK.
nf
ercia
orm
m
– Flush (clean) refrig‐

atio
m
erant circuit. Refer

o
n in
or c
to
thi
e
t
sd
iva
Circuit, Flushing
r
rp
cu
o
(Cleaning) with Re‐

f
en
ng
t.
frigerant R134a”,
yi Co
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page 83 .
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High and low pressure normal at first Moisture inlkrefrigerant – Flush refrigerant
swa s no
After some time, d by
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• high pressure increases above utho eo
trogen.
ra
specification ss a c
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• Low pressure quickly drops to value – Replace receiver/
un
pt
dryer.
an
d
in graph or below,
itte
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rm
ab
• Required cooling output is no longer – Repeat test if func‐
pe
ility
ot
attained. tion is not OK.
wit
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h re
hole
spec
es, in part or in w
t to the co
to
Circuit, Flushing
rrectness of i
frigerant R134a”,
l purpos
page 83 .
– Charge the refriger‐
nform
ercia
ant circuit.
m
a
com
ti
– Repeat the test.
on in
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• High pressure normal A/C compressor faulty. – Flush (clean) refrig‐
thi
s
iva
do
• Low pressure too low (see graph)
r
to
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en
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• The required cooling performance is

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Circuit, Flushing
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obtained
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frigerant R134a”,
p by
o Vo
by c
page 83 .
lksw
cted agen
Prote AG.
– Replace A/C com‐

pressor.
Note
♦ For the malfunction “high pressure normal, low pressure too

low”, note the following:
♦ This fault may cause the evaporator to ice up or the A/C Re‐
frigerant Low Pressure Switch - F73- to shut off the compres‐
sor although the amount of refrigerant in the circuit is OK.

Possible deviation Possible cause of fault Corrective

from specification action
• High pressure nor‐ Too much refrigerant in – Extract
mal or too high the circuit. refriger‐
ant from
• Low pressure too the refrig‐
high (see graph) erant cir‐
• A/C compressor cuit
noise (particularly
after switch-on) • If quantity
of refrig‐
• Required cooling erant ex‐
output is not at‐ tracted
tained roughly
corre‐
sponds to
specified
capacity:
– Replace gen AG
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swa
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olk not
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• If quantity
ce
le
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pt
of refrig‐
an
d
itte
erant ex‐
y li
rm
ab
tracted is
pe
ility
substan‐
ot
wit
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tially
h re
greater
hole
spec
than
es, in part or in w
specified
t to the co
capacity:
– Charge
rrectness of i
the refrig‐
erant cir‐
l purpos
cuit.
– Repeat nform
ercia
the test.
m
a
com
tio

n in
r
te o
thi
• High and low pressure normal To much refrigerant oil in the circuit. – Discharge the refrig‐
s
iva
do
erant circuit.
r
rp

um
fo
en
g
tained
n

t.
yi Co
op
erant circuit. Refer to
C py
ht. rig
rig ht
py by
Circuit, Flushing
co Vo
by lksw
cted agen
Prote AG.
frigerant R134a”,
page 83 .
• High and low pressure normal
• A/C compressor noise (particu‐
larly after switch-on)
• The required cooling perform‐
ance is obtained

Note
♦ Overfilling with refrigerant oil can occur in the event, for ex‐
ample, the compressor has nbeen
AG. Voreplaced without
lkswagen AG adjusting
wage does
the quantity of refrigerant
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♦ If the A/C compressor
ho
ris is not replaced, the refrigerant oil should
nte
e
be drainedsa
ufrom
t
the A/C compressor via the oil drain plug. Out
or
ac
of the entire quantity of refrigerant oil, 50 grams should be put
s
ce
e
in the A/C compressor and the rest in the refrigerant circuit.

nl
pt
du
an
itte
♦ If the A/C compressor is not replaced, the refrigerant oil should
y li
erm
ab
be drained from the A/C compressor via the block connec‐
ility
ot p
tions. Out of the entire quantity of refrigerant oil, 50 grams
wit
, is n
should be put in the A/C compressor and the rest in the re‐
h re
frigerant circuit. Refer to the vehicle-specific repair manual.
hole
spec
es, in part or in w
t to the co
10.3 Checking with Expansion Valve and Re‐
rrectness of i
ceiver/Dryer, with Internally Regulated
l purpos
A/C Compressor
nf
ercia
orm
Note
m
atio
om
n in
c

or
thi
e

t
sd
iva
o
r
rp
cu

o
m
f
en
ng

t.
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Cop py
t. rig
gh
ht
pyri by
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by
cted
– Observe manometer battery.
agen
Prote AG.
Note
Switching pressures and design of refrigerant circuit switches are

vehicle-specific.
The pressures should be measured at the service connections.

The location of these connections is vehicle-specific.
Specified Values
High-pressure side:
Increasing from initial pressure (when connecting the pressure
gauges) to a maximum of 20 bar (290 psi).

Low-pressure side:
A - High pressure in bar
B - Low pressure in bar
• High pressure re‐ Not enough refrigerant in – Extract
mains constant or circuit or expansion valve refriger‐
increases only malfunctioning. ant from
slightly (above the refrig‐
pressure with en‐ erant cir‐ AG. Volkswagen AG d
gine stopped), cuit lkswagen oes
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• Low pressure db ara
•ri If quantity
se nte
quickly drops to ut
ho of refrig‐ eo
ra
value in graph or ss
a
erant ex‐ c
below
ce
e
tracted
nl
pt
du
roughly
an
• Required cooling
itte
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corre‐
erm
output is not at‐
ab
sponds to
ility
tained
ot p
specified
wit
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capacity:
h re
hole
spec
– Replace
es, in part or in w
expan‐
t to the co
sion
valve
rrectness of i
– Charge
the refrig‐
l purpos
erant cir‐
cuit.
nform
ercia
– Repeat
m
at
the test.
om
ion
c
• High pressure • If quantity in t

or
his
e
normal of refrig‐
at
do
riv
erant ex‐
p
• Low pressure in
um
or
tracted is
f
en
g
line with value in

n
substan‐
t.
yi Co
graph
op
tially less
C py
t. rig
gh
than
ht
yri
• Required cooling p by
specified
co Vo
output is not at‐
by lksw
cted agen
tained capacity: Prote AG.
– Localize
the leak
with leak
detector
and elimi‐
nate
– Charge
the refrig‐
erant cir‐
cuit.
– Repeat
the test.

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Refrigerant R134a Servicing - Edition 08.2015 ra
ss c
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itte
Note
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ility
ot p
If no malfunction can be found and the function of the A/C system
wit
is n
is not correct after repeating the test, flush (clean) refrigerant cir‐
h re
ole,
cuit with refrigerant R134a. Refer to
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


• High pressure in‐ ♦ Constriction or ob‐ – Run hand
creases above struction in refrigerant over re‐
specification circuit frigerant
circuit to
• Low pressure ♦ Expansion valve faulty check for
quickly drops to differen‐
value in graph or ces in
below tempera‐
• Required cooling ture
output is not at‐
tained • If differ‐
ence in
tempera‐
ture is
found at
one com‐
ponent:
– Replace
the hose
or pipe if
kinked or
constric‐
ted.
– If there is
an ob‐ n AG. Volkswagen AG do
struction,
lkswage es n
Vo ot g
flush
ed
by re‐ ua
ran
ir sfrigerant tee
tho
or
au circuit ac
ss with com‐
ce
e
pressed
nl
pt
du
an
air and ni‐
itte
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trogen
erm
ab
ility
and re‐
ot p
place ex‐
wit
, is n
h re
pansion
hole
valve.
spec
es, in part or in w
t to the co
• If no mal‐
function
can be
rrectness of i
found.
l purpos
– Flush
(clean)
refriger‐
nform
ercia
ant cir‐
cuit. Re‐
m
at
om
fer to
on
c
⇒
in t
or
his
e
“7.2 Re‐
at
do
riv
frigerant
p
cum
or
Circuit,
f
en
g
Flushing
n
t.
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op
(Clean‐
C py
t. rig
ing) with
gh ht
pyri by
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co Vo
by lksw
cted
ant
agen
Prote AG.
R134a”,
page 83 .
– Repeat
the test.

Note
If the function is not correct after flushing the refrigerant circuit,

the expansion valve must be replaced.

• High and low pressure normal at ♦ Expansion valve faulty – Examine expansion
first valve for dirt or cor‐
♦ Moisture in refrigerant circuit rosion; replace if
• After some time, high pressure necessary.
increases above specification
and low pressure drops to value – Flush refrigerant
in graph or below circuit with com‐
• Required cooling output is no lon‐ pressed air and ni‐
ger attained. trogen.
AG. Volkswagen AG d
lksw
agen – Replace
oes
not receiver/
y Vo
dryer. gu
db ara
rise nte
o
auth – Repeat test ife func‐
or
ac
ss tion is not OK.
ce
e
nl
pt
du
an
itte
y li
erm
ab
to
ility
ot p
wit
, is n
Circuit, Flushing
h re
hole
spec
frigerant R134a”,
es, in part or in w
page 83 .
t to the co
ant circuit.
rrectness of i
l purpos
nf
ercia
o
Note
rm
m
atio
om
Always replace receiver/dryer in case of this malfunction.
n in
or c
thi
te
sd
iva
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o
m
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en
ng
t.
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pyri by
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by
cted agen
Prote AG.


• High pressure normal or too high ♦ Too much refrigerant in the circuit. – Extract refrigerant
(see diagram), from the refrigerant
♦ Expansion valve or A/C compressor faulty. circuit
tained • If quantity of refrig‐
• A/C compressor noise (particu‐ erant extracted
larly after switch-on) roughly corre‐
sponds to specified
capacity:
– Replace expansion
valve

ant circuit.
– Repeat test
• If quantity of refrig‐
erant extracted is
substantially great‐
er than specified ca‐
pacity:
AG. Volkswagen AG d – Charge the refriger‐

agen oes ant circuit.
olksw not
y V gu
db ara
rise – Repeat
nte the test.
tho e or
s au ac
s
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
If the function of the A/C system is not correct when the test is
ility
ot p
repeated, re-install old expansion valve and flush refrigerant cir‐
wit
, is n
cuit with compressed air and nitrogen. Then replace A/C com‐
h re
pressor and receiver/dryer.
hole
spec
es, in part or in w
Possible deviation from specification Possible cause of fault Corrective action t to the co
rrectness of i
• High pressure only increases ♦ A/C compressor faulty. – Flush (clean) refrig‐
l purpos
slightly above pressure with en‐ erant circuit. Refer to

gine stopped ⇒ “7.2 Refrigerant
Circuit, Flushing
nf
ercia
• Low pressure drops only slightly (Cleaning) with Re‐

orm
frigerant R134a”,
m
atio

m
page 83 .
o
tained
n in
or c
thi
e

t
sd
iva
pressor and receiv‐

o
r
rp
cu
er/dryer.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


• High pressure ♦ Expansion valve or A/ – Replace
normal C compressor faulty expansion
valve
• Low pressure too
low (see graph) – Charge
• The required the refrig‐
cooling perform‐ erant cir‐
ance is obtained cuit.
– Repeat
the test.
AG. Volkswagen AG d
agen
Note olksw
oes
not
byV gu
ara
ed
is nte
♦ If A/C system function is not OKuthwhen the test is repeated,
or eo
flush (clean) refrigerant circuit.
ss a Refer to ra
c
ce
le
un
R134a”, page 83 . Then replace A/C compressor and receiver/
pt
an
d
dryer.
itte
y li
rm
ab
pe
♦ With this malfunction, evaporator may ice up although quantity
ility
ot
of refrigerant in circuit is OK.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
• High and low pressure normal To much refrigerant oil in the circuit. – Discharge the refrig‐
erant circuit.
rrectness of i
tained – Flush (clean) refrig‐
l purpos
Circuit, Flushing
nform
ercia

frigerant R134a”,
m
a
page 83 .
com
tion in
• High and low pressure normal
r
te o
thi
s
iva
• A/C compressor noise (particu‐

do
r
rp
larly after switch-on)

um
fo
en
ng
t.
yi Co
op py
ance is obtained
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
♦ Overfilling with refrigerant oil can occur in the event, for ex‐
ample, the compressor has been replaced without adjusting
the quantity of refrigerant oil.

10.4 Checking with Expansion Valve and Re‐

ceiver/Dryer, without Regulated A/C
Compressor
⇒ “10.4.2 Checking”, page 168
⇒ “10.4.3 Specified Values”, page 169

• Radiator and condenser are clean (clean if necessary).
• The ribbed belt for the A/C compressor and alternator ten‐
sioned correctly.
• All air ducts, covers and seals are OK and installed correctly.
• The doors reach their end position.
• The engine is warm.
• Evaporator and heater not drawing in secondary air (at maxi‐
mum fresh-air blower speed).
With engine running and A/C system set to maximum cooling
output, pay attention to the following points:
• The fresh air blower is running.
• The coolant fan must be running or it must be switched on.
• The recirculation/fresh air door must be in the “recirculation”
position. gen AG
. Volkswagen AG
does wa
not olks
• Ambient temperature bisy greater than 15 0C.
V gu
ara
ed nte
oris
• The A/C Evaporatoruth Temperature Switch - E33- is installed eo
ra
s a switch temperatures are correct.
correctly and sits c
ce
e
nl
pt
10.4.2 Checking
du
an
itte
y li
erm
ab

ility
ot p
wit
– Connect pressure gauge battery (A/C service station).

, is n
h re
hole
– Take pressure gauge readings. There are two possible results

spec
A and B.
es, in part or in w
t to the co
Ambient Temperature in °C (°F) Pressure in Refrigerant Circuit

in Bar (psi) Positive Pressure
rrectness of i
15 (60) 3.9 (57)

l purpos
20 (68) 4.7 (68)

30 (86) 6.7 (97)
nf
ercia
40 (104) 9.1 (132)

rm
m
atio
m
♦ A- The pressure in the refrigerant circuit is lower than the

o
n in
c
pressure specified in the table. There is not enough refrigerant

or
thi
e
in the circuit.
t
sd
iva
o
r
rp
cu
- Search for leak with leak detection device.

o
m
f
en
ng
t.
yi
- The pressure release valve is open, check coolant fan activation
Co
op py
according to the wiring diagram.
t. C rig
gh ht
pyri by
Vo
o
Check refrigerant pipes and hoses to see if they are bent too
c by lksw
cted agen
sharply (cross-section constrictions) or have external damage. If Prote AG.
no malfunction is found, flush refrigerant circuit.
♦ B - The pressure in the refrigerant circuit matches the table or
is higher.

– Start the engine.

– Set A/C system to maximum cooling output.
– Open doors.
– Open vents in instrument panel.
The A/C compressor is driven by the engine via the magnetic
clutch using the ribbed belt.
Note
♦ If the A/C compressor is not driven, check A/C Clutch - N25-

voltage supply.
♦ If the voltage supply is OK, repair the magnetic clutch.
If the A/C compressor is driven, check refrigerant circuit:

– Observe manometer battery:
10.4.3 Specified Values

High-pressure side:
Increasing from pressure with engine not running to a maximum
of 20 bar (290 psi).
Low-pressure side:
Decreasing from pressure with engine not running down to 1.3
bar (18.9 psi).
10.5 Checking with Restrictor, Reservoir and

A/C Compressor Regulator Valve -
N280- , Externally Regulated AG. VA/C
olkswaCom‐
gen AG
agen does
pressor by Volksw not
gu
a
ed ran
oris tee
th or
au ac
Note ss
ce
e
nl
pt
du

an
itte
y li

erm
ab
ility
ot p

wit
, is n

h re
hole
spec

es, in part or in w
t to the co

rrectness of i
Note
l purpos
Switching pressures for actuation of A/C Compressor Regulator

Valve - N280- and Coolant Fan - V7- are vehicle-specific.
nform
mercia
at
om

ion
c
in t
or
Specified Values
his
ate
do
riv
High-pressure side:
p
cum
for
en
g
Increasing from initial pressure (when connecting pressure

n
t.
yi Co
gauges) to 20 bar (290 psi). Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
169
AG.
10. Pressures, Checking
Low-pressure side:
A - Low pressure (measured at service connection) in bar abso‐
lute gen AG
. Volkswagen AG
a does
lksw not
B - Control current for A/C Compressor Regulator Valve
db
y V- N280- .
o gu
ara
e nte
ris
C - Permissible tolerance range utho eo
ra
a c
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
♦ Under unfavorable conditions (very high ambient tempera‐
pe
ility
ot
tures, high humidity), pressure on high-pressure side may
wit
, is n
increase to max. 29 bar (421 psi).
h re
hole
spec
♦ The control current -B- is shown in the measured value block.
es, in part or in w
t to the co
♦ The high pressure is shown in the measured value block. Re‐
fer to ⇒ Rep. Gr. 87 .
rrectness of i
♦ Low pressure settles as a function of control current for A/C
Compressor Regulator Valve - N280- within compressor out‐
l purpos
put range in tolerance range.

nform
ercia
tures, high humidity), compressor output may not always be

sufficient to attain the specified value.
m
a
com
tio
♦ The specified operating current for the regulator valve must be
n in
r
te o
greater than 0.3 A in order to ensure reliable valve activation.
thi
s
iva
do
♦ In the setting “maximum cooling output” control current is
r
rp
cum
fo
regulated to approximately 0.8 A (displayed in measured value
en
ng
t.
block). Refer to ⇒ Rep. Gr. 87 .
yi Co
Cop py
t. rig
gh ht
yri by
uum. Normal ambient pressure corresponds to 1 bar (14.5 psi) cop Vo
by lksw
absolute pressure. 0 bar/psi pressure corresponds to an ab‐
cted agen
Prote AG.
solute pressure of 1 bar (14.5 psi) on most pressure gauges
(indicated by 1 bar (14.5 psi) below 0 bar/psi).

Possible deviation Possible cause of fault Corrective ac‐

from specification tion
• High pressure ♦ Activation of A/C – Check acti‐
remains con‐ Compressor Regula‐ vation of A/C
stant or increa‐ tor Valve - N280- is Compressor
ses only slightly faulty. Regulator
(above pressure Valve -
with engine stop‐ ♦ Not enough refriger‐ N280- .
ped), ant in refrigerant cir‐
cuit – Localize the
• Low pressure leak with
quickly drops to leak detector
value in graph or and elimi‐
below nate
AG. Volkswagen AG d
agen oes
ksw
• Required cooling Vol not
output is not at‐ d by – Charge the gu
ara
rise refrigerant nte
tained tho eo
s au circuit. ra
c
s
• High pressure
ce
le
un
pt
normal
an
d
itte
y li
rm
• Low pressure in
ab
pe
ility
line with value in
ot
wit
graph
, is n
h re
hole
spec
output is not at‐
es, in part or in w
t to the co
tained
• High pressure
rrectness of i
normal
l purpos
• Low pressure
too low (see
graph)
nform
ercia
m
a
output is not at‐
com
tained tion in
r
te o
thi
s
• High pressure
iva
do
r
normal
rp
cum
fo
en
ng
• Low pressure
t.
yi Co
op
too low (see C py
t. rig
gh
graph)
ht
pyri by
Vo
co lksw
by
• Required cooling cted agen
Prote AG.
output is not at‐
tained
Note
If no malfunction is found with this complaint, flush (clean) refrig‐

erant circuit with refrigerant R134a. Refer to

olkswagen AG
en AG. V
Possible deviation from specifica‐
olks
wag Possible dcause
oes
not of fault Corrective action
tion ed
byV gu
ara
ris nte
• High pressure only increases
ut
ho ♦ Activation of A/C Compressor Regulator
eo
ra – Check activation of
slightly above pressure
ss
a
with en‐ Valve - N280- is faulty. c A/C Compressor
gine stopped Regulator Valve -
ce
e
nl
♦ A/C compressor faulty.
pt
du
N280- .
an
• Low pressure drops only slightly
itte
y li
erm
ab
• Required cooling output is not – Flush (clean) refrig‐
ility
ot p
attained erant circuit. Refer
wit
, is n
to
h re
hole
spec
Circuit, Flushing
es, in part or in w
t to the co
frigerant R134a”,
page 83 .
rrectness of i
pressor.
l purpos
• High pressure increases above ♦ Constriction or obstruction in refrigerant cir‐ – Run hand over re‐
specification cuit frigerant circuit to
nf
ercia
o
check for differen‐
rm
• Low pressure drops only slightly
m
ces in temperature
atio
om
n in
• Required cooling output is not
or c
attained • If difference in tem‐
thi
e
t
sd
iva
o
one component:
r
rp
cu
o
m
f
en
ng

t.
yi Co
op
pipe if kinked or
C py
t. rig
constricted.
gh ht
pyri by
Vo
co lksw
by
cted
– In the event of an
agen
Prote AG.
obstruction, flush
refrigerant circuit
with compressed air
and nitrogen
• If no malfunction
can be found:
to
Circuit, Flushing
frigerant R134a”,
page 83 .

Possible deviation from specifica‐ Possible cause of fault Corrective action

tion
• High and low pressure normal at ♦ Moisture in refrigerant circuit – Flush refrigerant
first, after some time high pres‐ circuit with com‐
sure increases above specifica‐ pressed air and ni‐
tion trogen.
• Low pressure quickly drops to – Replace reservoir.
value in graph or below,
• Required cooling output is no – Repeat test if func‐
longer attained. tion is not OK.

to
. Volkswagen AG
Circuit, Flushing
wagen AG does no (Cleaning) with Re‐
olks t gu frigerant R134a”,
byV ara
ir se
d
nte page 83 .
ho
t e or
au
ss –ac Charge the refriger‐
ant circuit.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
• High pressure normal ♦ Activation of A/C Compressor Regulator – Check activation of
ot
Valve - N280- is faulty. A/C Compressor
wit
, is n
• Low pressure too low (see
h re
Regulator Valve -
hole
graph) ♦ A/C compressor faulty. N280- .
spec
es, in part or in w
t to the co
ance is obtained – Flush (clean) refrig‐
to
rrectness of i
Circuit, Flushing
l purpos

frigerant R134a”,
page 83 .
nform
mercia
– Replace A/C com‐ a

com
tio
pressor.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
♦ For the malfunction “high pressure normal, low pressure too cop Vo
by lksw
low”, note the following: faulty, the evaporator can ice up or
cted agen
Prote AG.
the cooling output is not reached.
♦ Check measured values of Evaporator Vent Temperature
Sensor - G263- or Evaporator Temperature Sensor - G308- .
♦ Check the A/C Compressor Regulator Valve - N280- activa‐
tion.

Possible deviation from specifi‐ Possible cause of fault Corrective action

cation
• High pressure normal or too ♦ Too much refrigerant in the circuit. – Extract refrigerant
high from the refrigerant
circuit
• Low pressure too high (see
graph) • If quantity of refriger‐
• A/C compressor noise (partic‐ ant extracted roughly
ularly after switch-on) corresponds to
specified capacity:
attained – Replace the A/C
compressor.
• If quantity of refriger‐
ant extracted is sub‐
stantially greater
than specified ca‐
pacity:
ant circuit.
agen
AG. Volkswagen AG d
oes
lksw not
• High and low pressure normal ♦ bTo y V much refrigerant oil in the circuit.
o gu
ara – Discharge the refrig‐
ised
nte erant circuit.
ut
hor eo
ra
attained ss a c – Flush (clean) refrig‐
ce
e
nl
pt
du
an
itte
y li
Circuit, Flushing
erm
ab
ility
ot p
frigerant R134a”,
wit
, is n
page 83 .
h re
hole
• High and low pressure normal spec

es, in part or in w
• A/C compressor noise (partic‐

t to the co
ularly after switch-on)

rrectness of i
ance is obtained
l purpos
nf
ercia
Note
orm
m
atio
m
♦ Overfilling with refrigerant oil can occur if, for example, the
o
n in
c
compressor has been replaced without adjusting the quantity

or
thi
e
of refrigerant oil.
t
sd
iva
o
r
rp
cu

o
m
f

en
ng
t.
yi Co
tions. Out of the entire quantity of refrigerant oil, 50 grams Cop py
t. rig
gh ht
yri by
frigerant circuit. Refer to the vehicle-specific repair manual. op Vo
by c lksw
cted agen
Prote AG.

olkswagen AG
wag en AG. V
Beetle 2012 ➤ ,VCC
olks 2010 ➤ , CC 2012 ➤ , Eos
does
not 2006 ➤ , Golf 1992 ➤ , G ...
gu
sed by
ara
n
- Edition 08.2015
ri tee
ho
ut or
10.6 Checking with Expansion Valve, Re‐
a ac
ss
ce
le
ceiver/Dryer and A/C Compressor Reg‐
un
pt
an
d
itte
ulator Valve - N280- , Externally Regu‐
y li
rm
ab
pe
lated A/C Compressor
ility
ot
wit
, is n
h re
⇒ “10.6.1 Specified Values”, page 175 hole
spec
10.6.1 Specified Values
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Note Cop py
ht. rig
rig ht
py by
♦ Switching pressures for actuation of A/C Compressor Regu‐
co Vo
by lksw
cted agen
lator Valve - N280- and Coolant Fan - V7- are vehicle-specific. Prote AG.
♦ The pressures should be measured at the service connec‐

tions. The location of these connections is vehicle-specific.
High-pressure side:
Increasing from initial pressure (when connecting pressure
gauges) to 20 bar (290 psi).

Low-pressure side:
A - Low pressure (measured at service connection) in bar abso‐
lute
B - Control current for A/C Compressor Regulator Valve - N280- .
Note

tures, high humidity), pressure on high-pressure side may
increase to max. 29 bar (421 psi). G. Volkswagen nA AG do
wage es n
♦ The control current -B- is shown in the measured
yV
olks value block. ot g
ua
b
ed ran
♦ The high pressure measured from thethoHigh
ris Pressure Sensor tee
- G65- is not shown in the measured au value block. Refer to ⇒
or
ac
Rep. Gr. 87 . ss
ce
e
nl
pt
du
♦ Low pressure settles as a function of control current for A/C
an
itte
y li
Compressor Regulator Valve - N280- within compressor out‐
erm
ab
put range in tolerance range.
ility
ot p
wit
, is n
h re
tures, high humidity), compressor output may not always be
hole
spec
sufficient to attain the specified value.
es, in part or in w
t to the co
♦ The specified operating current for the regulator valve must be
greater than 0.3 A in order to ensure reliable valve activation.
♦ In the setting “maximum cooling output” control current is
rrectness of i
regulated to approximately 0.65 A up to 0.8 A (vehicle specific,
l purpos
displayed in measured value block). Refer to ⇒ Rep. Gr. 87 .

nf
ercia
uum. Normal ambient pressure corresponds to 1 bar (14.5 psi)

absolute pressure. 0 bar/psi pressure corresponds to an ab‐ orm
m
atio
solute pressure of 1 bar (14.5 psi) on most pressure gauges

om
n in
(indicated by 1 bar (14.5 psi) below 0 bar/psi).

or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Beetle 2012 ➤ , CC 2010 ➤ , CC nte2012 ➤ , Eos 2006 ➤ , Golf 1992 ➤ , G ...
o eo
aut
h
Refrigerant
ra R134a Servicing - Edition 08.2015
ss c
ce
le
un
pt
an
from specification d tion
itte
y li
erm
ab
• High pressure ♦ Activation of A/C – Check acti‐
ility
ot p
remains con‐ Compressor Regula‐ vation of A/C
wit
is n
stant or increa‐ tor Valve - N280- is Compressor
h re
ole,
ses only slightly faulty. Regulator
spec
(above pressure Valve -

♦ Not enough refriger‐
t to the co
with engine N280- .
stopped). ant in refrigerant cir‐
cuit – Localize the
• Low pressure
rrectne
leak with
quickly drops to leak detector
value in graph or and elimi‐
s
below.
s
nate
o
cial p
f in
• Required cool‐
form
– Charge the
mer
ing output is not

refrigerant
atio
attained
m
circuit.
o
n
c
i
or
n
• High pressure
thi
te
sd
a
normal.
iv
o
pr
cum
r
fo
• Low pressure in
en
ng
t.
yi
line with value in
Co
op py
graph.
. C rig
ht ht
rig by
py
• Required cool‐
co Vo
by lksw
cted agen
ing output is not Prote AG.
attained
• High pressure • Not enough refriger‐ – Extract re‐

normal. ant in refrigerant cir‐ frigerant
cuit from the re‐
• Low pressure frigerant cir‐
too low (see cuit
graph).
• Required cool‐ • If quantity of
ing output is not refrigerant
attained extracted is
substantially
less than
specified ca‐
pacity.
– Localize leak
with leak de‐
tector and
eliminate.
– Charge the
refrigerant
circuit.
– Repeat the
test.
• If quantity of
refrigerant
extracted
roughly cor‐
responds to
specified ca‐
pacity:


from specification tion
• Expansion valve – Replace ex‐
faulty pansion
valve
– Charge the
refrigerant
circuit.
– Repeat the
test.
Note
♦ If no malfunction is found with this complaint, flush (clean) re‐

frigerant circuit with refrigerant R134a. Refer to
the refrigerant circuit with compressedgenair
AG.and
Volksremove
wagen AGmois‐
does
ture with nitrogen. Refer to Volkswa not
⇒ “7.1 Refrigerant Circuit,seFlushing
db
y
with Compressed Air and guaran
Nitrogen”, page 81 . thori tee
o
au ra
♦ Check measured values
ss from Evaporator Vent Temperature c
ce
e
Sensor - G263- or Evaporator Temperature Sensor - G308-

nl
pt
du
and activation of A/C Compressor Regulator Valve - N280- . If

an
itte
y li
the measured value of the Evaporator Vent Temperature Sen‐
erm
sor - G263- or Evaporator Temperature Sensor - G308- is not ab

ility
ot p
OK, the evaporator can ice up or the cooling output will not be wit
, is n
reached. h re
hole
spec
♦ If the function of the air conditioning system is not OK when

es, in part or in w
the test is repeated after replacing expansion valve, re-install

t to the co
old expansion valve and flush refrigerant circuit with com‐

pressed air and nitrogen. Then replace A/C compressor and
receiver/dryer.
rrectness of i

l purpos

♦ If expansion valve is malfunctioning (permanently closed or
nf
ercia
does not open sufficiently), A/C Compressor Regulator Valve

rm
- N280- is actuated to maximum output and low pressure drops

m
atio
m
to value in graph or below (compressor draws off refrigerant

o
n in
c
from low-pressure side). Because refrigerant cannot flow

or
thi
e
through the expansion valve, the correct cooling output cannot

t
sd
iva
be reached. The high pressure may not increase or may only

o
r
rp
cu
increase slightly.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
tion
by lksw
cted agen
Prote AG.
• High pressure only increases ♦ Activation of A/C Compressor Regulator – Check activation of
slightly above pressure with en‐ Valve - N280- is faulty. A/C Compressor
gine stopped. Regulator Valve -
N280- .
• Low pressure drops only slight‐
ly.
attained


tion
♦ A/C compressor faulty. – Extract refrigerant
circuit.

to
Circuit, Flushing
frigerant R134a”,
page 83 .

pressor.

ant circuit.
• High pressure increases above ♦ Activation of A/C Compressor Regulator – Check activation of
specification. Valve - N280- is faulty. A/C Compressor
Regulator Valve -
• Low pressure quickly drops to N280- .
value in graph or below.
attained
♦ Constriction or obstruction in refrigerant cir‐ – Run hand over re‐

cuit frigerant circuit to
check for differen‐
ces in temperature
• If difference in tem‐
one component:
wage
es n
yV
olks ot g
ua
pipe if kinked or
ir se
d b ran constricted.
o tee
th or
u
ss
a ac – In the event of an
obstruction, flush
ce
le
un
pt
refrigerant circuit
an
d
itte
with compressed air

y li
rm
ab
and nitrogen
pe
ility
ot
wit

, is n
h re
ant circuit.
hole
spec
es, in part or in w

t to the co
• If no malfunction
can be found:
rrectness of i

l purpos

to
nform
ercia
Circuit, Flushing
m

a
com
tio
frigerant R134a”,
n in
r
page 83 .
te o
thi
s
iva
do

r
rp
cum
fo
ant circuit.
en
ng
t.
yi Co
op
C py
t. rig
gh
tion is not OK.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


tion
♦ Expansion valve faulty – Extract refrigerant
circuit.
valve and receiver/
dryer

ant circuit.
Note

increase slightly. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
Possible deviation from specifica‐ Possible
ris cause of fault Corrective tee action
ho
tion aut or
ac
ss
• High and low pressure normal at ♦ Activation of A/C Compressor Regulator – Check activation of
ce
le
un
pt
first, after some time high pres‐ Valve - N280- is faulty. A/C Compressor
an
d
itte
sure increases above specifica‐ Regulator Valve -
y li
rm
ab
tion. N280- .
pe
ility
ot
wit
• after some time, low pressure
, is n
h re
decreases to graph value or low‐
hole
spec
er.
es, in part or in w
t to the co
• Required cooling output is no
longer attained.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


tion
• High pressure and lower pres‐ ♦ Moisture in refrigerant circuit – Extract refrigerant
sure normal first, after a long pe‐ circuit.
riod of driving, the low pressure
falls below the specified value – Flush refrigerant
(evaporator iced up). agen
AG. Volkswagen AG d
o
circuit with com‐
Vol
ksw es n
ot g pressed air and ni‐
ed by ua
ran trogen.
ris tee
tho or
au ac – Replace receiver/
ss
dryer with dryer.
ce
e
nl
pt
du
an
– Evacuate refriger‐
itte
y li
erm
ant circuit for at
ab
ility
least 3 hours.
ot p
wit
, is n
h re
hole
spec
ant circuit.
es, in part or in w
t to the co
– Repeat test, if func‐
tion is not OK.
rrectness of i
l purpos
to
Circuit, Flushing
nform
ercia

m
at
frigerant R134a”,
om
ion
page 83 .
c
in t
or
his
te

a
do
riv
ant circuit.
p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ If this complaint occurs after a long operating time or only

sporadically (the low pressure falls under the specified value
and the evaporator ices up), replacing the dryer (installed in
the receiver/dryer) is sufficient. The quantity of refrigerant oil
should be adjusted. Refrigerant circuit is then to be evacuated
for at least 3 hours.
♦ First, it is not necessary to flush the refrigerant circuit with
compressed air and nitrogen in case of this complaint because
generally only a small amount of moisture is in the system and
this can be removed by a long evacuation.

tion
• High pressure normal, low pres‐ ♦ Activation of A/C Compressor Regulator – Check activation of
sure too low (see graph), the Valve - N280- is faulty. A/C Compressor
necessary cooling output is not Regulator Valve -
reached. N280- .


tion
♦ Expansion valve faulty – Extract refrigerant
circuit.

to
Circuit, Flushing
en AG. Volkswagen AG (Cleaning) with Re‐
ag does
Volksw not frigerant R134a”,
apage 83 .
by gu
ed ra nte
ris
ho eo
aut – Replace
r a expansion
ss c
valve and receiver/
ce
le
dryer
un
pt
an
d
itte
y li
rm
ab
pe
ility
ant circuit.
ot
wit
, is n
h re
hole
tion is not OK.
spec
es, in part or in w
t to the co
– Replace the A/C
compressor.
♦ A/C compressor faulty. – Extract refrigerant
rrectness of i
circuit.
l purpos

nform
ercia
to
m
a
com
Circuit, Flushing
tion in
r
te o
thi
frigerant R134a”,
s
iva
page 83 .
do
r
rp
cum
fo
en
g
– Replace the A/C

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

Note
♦ For the malfunction “high pressure normal, low pressure too

low”, note the following: faulty, the evaporator can ice up or
the cooling output is not reached.
♦ Check measured values from Evaporator Vent Temperature
Sensor - G263- or Evaporator Temperature Sensor - G308-
and activation of A/C Compressor Regulator Valve - N280- . If
the measured value of the High Pressure Sensor - G65- is
faulty, the evaporator can ice up or the cooling output is not
reached.
♦ If the problem is with the A/C Compressor Regulator Valve -
N280- (regulating valve is not actuated but compressor oper‐
ates nevertheless), refrigerant circuit does not have to be
flushed. With this malfunction, replacing the A/C compressor
is sufficient (adjust refrigerant oil quantity in new A/C com‐
pressor). agen
AG. Volkswagen AG d
o w es n
olks o
♦ If expansion valve
ed
bis
y Vmalfunctioning (permanently closed
t gu
ara or
does not open ho
rsufficiently),
is A/C Compressor Regulator Valve
nte
eo
- N280- is actuated
aut to maximum output and low pressure drops ra
to value ins graph or below (compressor draws off refrigerant
s c
ce
le

un
pt
an
d
itte
y li
rm
ab
increase slightly.
pe
ility
ot
wit
, is n
h re

hole
spec
es, in part or in w

t to the co
cation
• High pressure normal or too ♦ Activation of A/C Compressor Regulator – Check activation of
rrectness of i
high. Valve - N280- is faulty. A/C Compressor

Regulator Valve -
• Low pressure too high (see ♦ Too much refrigerant in the circuit.
l purpos
N280- .
graph).
– Extract refrigerant
nform
ercia
• A/C compressor noise (partic‐

ularly after switch-on). from the refrigerant
circuit
m
a
com
tio

n in
r
attained
te o
thi
ant extracted roughly

s
iva
do
corresponds to
r
rp
cum
specified capacity:
fo
en
ng
t.
yi Co
– Replace the A/C
Cop py
. rig
compressor.
ht ht
rig by
copy Vo
by lksw
cted
agen
Prote AG.
stantially greater
pacity:
ant circuit.


cation
♦ To much refrigerant oil in the circuit. – Discharge the refrig‐
erant circuit.
AG. Volkswant
agen AG
extracted roughly
agen does
ksw
y Vol
corresponds not
to
gu
db specified capacity:
ara
rise nte
ho eo
ut
ss a – Flush (clean) refrig‐ ra
c
ce
le
un
pt
an
d
Circuit, Flushing
itte
y li
erm
ab
ility
frigerant R134a”,
ot p
wit
is n page 83 .
h re
ole,
spec
ant circuit.
t to the co
♦ Expansion valve faulty – Discharge the refrig‐
rrectne
erant circuit.
ss
o
cial p
f
valve and receiver/
inform
dryer
mer
atio
m

o
n
c
ant circuit.
i
or
n thi
te
sd
va

i
o
pr
cum
r
tion is not OK.

fo
en
ng
t.
yi Co
op
– Replace the A/C
C py
t. rig
compressor.
gh ht
pyri by
Vo
o
by c
♦ A/C compressor faulty. – Discharge the refrig‐
lksw
cted agen
Prote
erant circuit.
AG.

Circuit, Flushing
frigerant R134a”,
page 83 .
– Replace the A/C

compressor.
stantially greater
pacity:
ant circuit.

Note
♦ If the problem is with the A/C Compressor Regulator Valve -

N280- (regulating valve is not actuated but compressor oper‐
ates nevertheless), refrigerant circuit does not have to be
flushed. With this malfunction, replacing the A/C compressor
is sufficient (adjust refrigerant oil quantity in new A/C com‐
pressor). AG. Volkswagen A gen G do
swa es n
♦ Overfilling with refrigerant oil can occur
by
Vif,
olk for example, the ot g
ua
compressor has been replaced without
ris
ed adjusting the quantity ran
tee
of refrigerant oil. ut
ho
or
sa ac
♦ If the A/C compressor is not replaced,
s
the refrigerant oil should
ce
le

un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
increase slightly.
ss o
cial p
f inform
mer
atio
cation
om
n
c
i
or
n
• High and low pressure nor‐ ♦ Activation of A/C Compressor Regulator – Check activation of
thi
te
mal. Valve - N280- is faulty. A/C Compressor
sd
iva
o
Regulator Valve -
pr
cum
r
• Required cooling output is not ♦ To much refrigerant oil in the circuit.

fo
N280- .
en
ng
attained
t.
yi Co
op py
t. C rig
gh ht
yri
p by
o Vo
c by lksw
cted agen
Circuit, Flushing
Prote AG.

frigerant R134a”,
page 83 .
• High and low pressure nor‐ ♦ To much refrigerant oil in the circuit. – Discharge the refrig‐
mal. erant circuit.
• A/C compressor noise (partic‐ – Flush (clean) refrig‐
ularly after switch-on). erant circuit. Refer to
• The required cooling perform‐ ⇒ “7.2 Refrigerant
ance is obtained Circuit, Flushing
frigerant R134a”,
page 83 .

ant circuit.

♦ Expansion valve faulty – Replace expansion
valve

Note
♦ Overfilling with refrigerant oil can occur if, for example, the
compressor has been replaced without adjusting the quantity
of refrigerant oil.
♦ If expansion valve is malfunctioning (permanently open),
evaporator temperature is no longer regulated such that only
refrigerant in gaseous state exits from the evaporator. Under
certain usage conditions, liquid droplets may then be drawn in
by the compressor and cause noise (liquid cannot be com‐
pressed).
10.7 With Expansion Valve, Receiver/Dryer

and Electrically-Driven A/C Compressor
Note
The electrically-driven A/C compressor does not have an A/C

Compressor Regulator Valve - N280- . The A/C compressor RPM
does the regulating. The A/C compressor contains the control
electronics and a G-charger, which moves the refrigerant.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
186
op Vo
by c lksw
Rep. Gr.00 - General, Technical Data Prote
cted AG.
agen
11 Components, Replacing
⇒ “11.1 General Information”, page 187
⇒ “11.2 Leaking or Damaged Components except A/C Compres‐
sor, Reservoir or Receiver/Dryer”, page 188
⇒ “11.3 A/C Compressor, Replacing”, page 189
⇒ “11.4 Receiver/Dryer or Reservoir and Restrictor, Replacing”,
page 191
11.1 General Information

of original part).
gen gas. This charging stops gradually or the charging pres‐
sure is so low that gas does not escape noticeably when
opening.
• On vehicles installed with a compressor with no A/C clutch,
the engine is only to be started following complete assembly
of the refrigerant circuit (compressor always in operation as
well). Refer to
• So that the compressor with A/C Compressor Regulator Valve
- N280- (without A/C clutch) is not damaged when the refrig‐
erant circuit is empty, it is equipped with a secured oil supply.
This means that approximately 40 to 50 cm3 of refrigerant oil
remains in the A/C compressor. Refer to
⇒ “1.12 Refrigerant Circuit, General Precautions”, page agen
15
AG.. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris
Note tho
tee
or
au ac
ss
♦ As original parts are sometimes stored for lengthy periods and
ce
le
un
pt
at different locations within the spare parts organization, it is
an
d
itte
entirely possible that gas will escape from some parts and not
y li
rm
ab
from others on initial opening (even in the case of identical

pe
ility
original part numbers). Sealing caps at original part connec‐

ot
wit
, is n
tions are therefore to be removed carefully and the nitrogen

h re
gas allowed to escape slowly.

hole
spec
es, in part or in w
♦ The refrigerant circuit is equipped either with a restrictor and

t to the co
accumulator or with an expansion valve and receiver/dryer.

♦ Seal open connections and pipes (to prevent absorption of
rrectness of i
moisture).
l purpos
♦ Always replace the restrictor.
The reservoir/receiver/dryer or dryer bag/cartridge should not be

nform
ercia
replaced under the following conditions.

m
a
com
ti
• After an accident when there is no damage on the reservoir/

on in
receiver/dryer.
r
te o
thi
s
iva
• The repair was done quickly (not beyond the normal repair
do
r
rp
time) and no moisture has entered. The vehicle is not older

um
fo
en
than 5 years.
ng
t.
yi Co
op py
The reservoir/receiver/dryer or dryer cartridge should be replaced t. C rig
gh ht
under the following conditions. pyri by
Vo
co lksw
by
cted agen
• The refrigerant circuit was opened and the vehicle is older than Prote AG.
5 years.
11. Components, Replacing 187

• The refrigerant circuit has been opened for an indefinite period

of time (slow leak).
• The repair exceeded the normal repair time and moisture has
entered.
• Always replace the receiver/dryer or dryer cartridge after flush‐
ing with compressed air, nitrogen or refrigerant R134a. Leave
original parts in their packaging as long as possible to mini‐
mize the amount of moisture they absorb.
• The A/C compressor has locked up.
• The reservoir/receiver/dryer is damaged (accident).
11.2 Leaking or Damaged Components ex‐

cept A/C Compressor, Reservoir or Re‐
ceiver/Dryer
⇒ “11.2.1 Empty Refrigerant Circuit”, page 188
⇒ “11.2.2 Refrigerant Still in Circuit”, page 188
11.2.1 Empty Refrigerant Circuit

– Remove malfunctioning component.
– Remove the A/C compressor.
– Drain the coolant from the A/C compressor via the block con‐
nections. en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed
Note tho
ris nte
eo
au ra
c
ss
♦ To speed up refrigerant oil drainage, turn A/C compressor by
ce
le
un
hand via ribbed belt or magnetic clutch plate.

pt
an
d
itte
y li
♦ Pour the used refrigerator oil out of the A/C compressor.

rm
ab
pe
ility
♦ Then fill the A/C compressor with quantity of fresh refrigerant

ot
wit
, is n
oil corresponding to quantity of refrigerant oil in original part

h re
compressor. Refer to ⇒ Rep. Gr. 87 .

hole
spec
es, in part or in w
♦ Use different refrigerant oils and quantities for the various

t to the co
compressors. Refer to ⇒ Rep. Gr. 87 .

♦ To ensure the compressor is lubricated at start-up, at least 80
rrectness of i
cm3 of refrigerant oil must be poured into the compressor. The

remainder can be added to the new reservoir or receiver/dryer.
l purpos

♦ If dirt has penetrated into the compressor with the refrigerant
nform
ercia
circuit open (for example after an accident), compressor is to

m
be replaced.
a
com
tion in
♦ Flush the refrigerant circuit with compressed air and remove

r
te o
thi
moisture with nitrogen. Refer to

s
iva
do

r
rp
cum
Nitrogen”, page 81 .
fo
en
ng
t.
yi Co
op py
– Replace receiver/dryer or accumulator and restrictor. . C rig
ht ht
rig by
py
– Assemble, evacuate and recharge refrigerant circuit.
co Vo
by lksw
cted agen
Prote AG.
11.2.2 Refrigerant Still in Circuit
– Discharge the refrigerant circuit.
– Remove malfunctioning component, flush with compressed
air, collect escaping refrigerant oil.

– The new component is to be filled with the amount of refriger‐

ant oil flushed out (plus 20 cm3 for evaporator, plus 10 cm3 for
condenser, refrigerant pipes and refrigerant hoses) as fresh
refrigerant oil fill.
– Replace the restrictor depending on the vehicle.
– Assemble, evacuate and charge the refrigerant circuit.
11.3 A/C Compressor, Replacing

. Volkswagen AG
gen AG d
⇒ “11.3.1 FlushingVoNot
lksw Necessary”, page 189es not
a o
y gu
db ar
⇒ “11.3.2 Leaks
ris or Internal Damage, for Example Noises
e an
tee or No
utho 190
Output”, page or
a a c
ss
11.3.1 Flushing Not Necessary
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
For vehicles with an electrically-driven A/C compressor, de-en‐
hole
spec
ergize the high voltage system before removing the A/C com‐
es, in part or in w
pressor. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ;
t to the co
Electric Drive; De-Energize the High Voltage System .
rrectness of i
l purpos
nform
ercia
Note
m
a
com
ti
If a different A/C compressor is installed with a different refrigerant

on in
oil, the refrigerant circuit is to be flushed with refrigerant R134a.

r
te o
thi
Refer to
s
iva
do

r
rp
cum
R134a”, page 83 .
fo
en
ng
t.
yi Co
op py
Electrically-driven A/C compressor:
t. C rig
gh ht
pyri by
Vo
o
If an electrically-driven A/C compressor is being replaced that
c by lksw
cted agen
does not have a mechanical fault (for example, a faulty circuit
Prote AG.
board), then determine how much refrigerant is in this A/C com‐
pressor.
Note
♦ This A/C compressor must be flushed to get all the refrigerant

oil out.
♦ The A/C compressor is flushed in the flow direction (from the
low pressure side input to the high pressure side output)
♦ So that as much refrigerant oil as possible is flushed out of the
A/C compressor, the A/C compressor must be positioned so
that the high pressure side output is as low as possible.
♦ If an A/C service station without a flushing program is used,
the procedure must be performed manually (evacuate, flush 3
times with at least 2 kg refrigerant each and extract refrigerant
again, evacuate).
Quantity: for example 50 cm³

Pour so much refrigerant oil out of the new A/C compressor so
that only the amount remains (plus 10 cm 3) that had been flushed
out of the old A/C compressor beforehand. If the new original A/

C compressor has for example, 200 cm3, then only pour out 140
cm3.
frigerant oil.
Note
In not enough refrigerant oil can be poured out from the A/C com‐
pressor to be installed, flush the new A/C compressor. After
flushing, fill the A/C compressor to be installed with as much new
refrigerant oil as was flushed from the replaced A/C compressor.
Mechanically driven A/C compressor, draining the coolant via the

block connections.
– To accelerate drainage of refrigerant oil, rotate compressor
e.g. by way of ribbed belt pulley/clutch plate of A/C clutch for
example. Does not apply to the electrically-driven A/C com‐
pressor.
frigerant oil.
– Only refill the quantity of coolant that corresponds to the
amount poured out (of the faulty A/C compressor).
Note
♦ If, for example, 70 cm3 of refrigerant oil has been poured out
of the malfunctioning A/C compressor and 220 cm3 out of the swa
gen AG
. Volkswagen AG
does
original part A/C compressor (a small quantity of refrigerant oil by Volk not
gu
remains in the A/C compressor). Fill the compressor to be in‐rise d ara
nte
3
stalled with 70 cm of refrigerant oil (use can be made ofauoiltho eo
ra
poured out of original part compressor). ss c
ce
le
un
♦ Use different refrigerant oils and quantities for the various
pt
an
d
compressors. Refer to ⇒ Rep. Gr. 87 .

itte
y li
erm
ab
♦ If a greater quantity of refrigerant oil (more than approximately
ility
ot p
80 cm3) has been poured out of the malfunctioning compres‐
wit
is n
h re
sor, the remaining refrigerant oil can also be added to the
ole,
evaporator or reservoir/receiver/dryer. Refer to ⇒ Rep. Gr.
spec
87 .
t to the co
rrectne
11.3.2 Leaks or Internal Damage, for Example

ss o
Noises or No Output
cial p
f inform
mer

atio
om

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

Note
♦ In the case of internal damage or leaks (on A/C compressor),

flush refrigerant circuit with refrigerant R134a. Refer to
R134a”, page 83 . swa
gen AG
. Volkswagen AG
does
k not
Vol
♦ If a different A/C compressor is installed with
ed a different re‐
by gu
ara
frigerant oil, the refrigerant circuit is tothbe
or flushed with refrig‐
is nte
eo
erant R134a. Refer to s au ra
c
⇒ “7.2 Refrigerant Circuit, Flushing s(Cleaning) with Refrigerant
ce
e
R134a”, page 83 .
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
11.4 Receiver/Dryer or Reservoir and Re‐
, is n
h re
hole
strictor, Replacing
spec
es, in part or in w
t to the co
⇒ “11.4.1 Contaminants Removed from Refrigerant Circuit”, page
191
⇒ “11.4.2 Replacing Reservoir, No Contaminants, No Loss of Re‐
rrectness of i
frigerant”, page 192
l purpos
11.4.1 Contaminants Removed from Refriger‐

ant Circuit
nform
mercia
The reservoir/receiver/dryer or dryer bag/cartridge should not be
at
om
io
replaced under the following conditions.
n
c
in t
or
his
e
• After an accident when there is no damage on the reservoir/

at
do
riv
receiver/dryer.
p
cum
for
• The repair was done quickly (not beyond the normal repair
en
ng
t.
yi Co
time) and no moisture has entered. The vehicle is not older Cop py
than 5 years.
t. rig
gh ht
pyri by
Vo
o
by c
The reservoir/receiver/dryer or dryer cartridge should be replaced
lksw
cted agen
under the following conditions.
Prote AG.
• The refrigerant circuit was opened and the vehicle is older than
5 years.
• The refrigerant circuit has been opened for an indefinite period
of time (slow leak).
• The repair exceeded the normal repair time and moisture has
entered.
• Always replace the receiver/dryer or dryer cartridge after flush‐
ing with compressed air, nitrogen or refrigerant R134a. Leave
original parts in their packaging as long as possible to mini‐
mize the amount of moisture they absorb.
• The A/C compressor has locked up.
• The reservoir/receiver/dryer is damaged (accident).
– Rectify cause of trouble.
– Examine expansion valve for dirt or corrosion; replace if nec‐
essary.
– Drain the coolant from the A/C compressor via the block con‐
nections.

– To accelerate drainage of refrigerant oil, rotate compressor

e.g. by way of ribbed belt pulley/clutch plate of A/C clutch for
example.
frigerant oil.
– Then fill compressor with quantity of fresh refrigerant oil cor‐
responding to quantity of refrigerant oil in original part com‐
pressor. Refer to ⇒ Rep. Gr. 87 .
Note
♦ Which refrigerant oils and quantities

agen
AG. Voare used
lkswa for
gen AG
dothe various
compressors. Refer toy V⇒
olksRep. Gr. 87 .
w es n
ot g
d b ua
ran
♦ To ensure the compressor
horis
e
is lubricated at start-up, at least 80
tee
cm3 of refrigerant
t
s au oil must be poured into the compressor. The or
ac
remainder can be added to the new reservoir or receiver/dryer.
s
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♦ If dirt has penetrated into the compressor with the refrigerant
erm
ab
circuit open (for example after an accident), compressor is to
ility
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be replaced.
wit
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– Replace receiver/dryer or accumulator and restrictor.
es, in part or in w
t to the co
11.4.2 Replacing Reservoir, No Contaminants, rrectness of i

No Loss of Refrigerant
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– Remove receiver or accumulator.

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– Remove dirt from receiver or reservoir.

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or
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– Weigh removed receiver/dryer or reservoir.

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♦ Install new receiver/dryer or reservoir.

. Volkswagen AG
gen AG Refrigerant dR134a Servicing - Edition 08.2015
swa k
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12 Tools and Testing Equipment autho eo
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⇒ “12.1 Testing Equipment, Tools and Materials”, page 193
ce
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12.1 Testing Equipment, Tools and Materials
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⇒ “12.1.1 Commercially Available Tools and Materials”,
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page 193
h re
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page 196
t to the co
⇒ “12.1.3 Improvised Tools”, page 197
rrectness of i
page 197
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page 201
nform
ercia
⇒ “12.1.6 Improvised Tools”, page 203

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12.1.1 Commercially Available Tools and Ma‐
on in
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terials
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Overview Page
fo
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t.
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A/C Service Station - VAS6007A- . For ad‐ Refer to
Co
Cop py
ditional A/C service stations. Refer to VAG‐ ⇒ Fig. ““ A/C
t. rig
gh ht
yri
Workshop Equipment Catalog. Service Station -
p by
co Vo
by lksw
VAS6007A- (and Prote
cted AG.
agen
further or current
A/C service sta‐
tion)”“ ,
page 197
Electronic Leak Detector - VAG1796- Refer to
⇒ Fig. ““ Electron‐
ic Leak Detector -
VAG1796- ”“ ,
page 198
Leak Detection System - VAS6196- Refer to
⇒ Fig. ““ Leak De‐
tection System -
VAS6196- ”“ ,
page 198
Leak Detection System - R-134a/PAG single Not illustrated
dose Tracer-Stick® capsules - VAS6196/1-
Leak Detection System - VAS6201- or suc‐ Refer to
ceeding model ⇒ Fig. ““Leak De‐
tection
KitVAS6201A or
succeeding mod‐
el”“ , page 199
A/C Service Station - VAS6380- with flushing Not illustrated
device or Air Conditioning Flush Tool -
VAS6337- other A/C service station. Refer to
VAGWorkshop Equipment Catalog.
♦ With installed program to flush refrigerant
circuit with refrigerant R134a.
12. Tools and Testing Equipment 193

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Refrigerant R134a sServicing
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Overview Page
an
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Air Conditioning Flush Tool - VAS6337/1A- . Refer to
rm
ab
pe
ility
For flushing tools that are currently available. ⇒ Fig. ““ Air Con‐
Refer to the VAGWorkshop Equipment Cat‐ ot ditioning Flush
wit
, is n
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alog. Tool -
hole
♦ For flushing refrigerant circuit with refrig‐ VAS6337/1A-
spec
erant R134a. To be used also with older from the compa‐
es, in part or in w
t to the co
A/C service stations (flushing procedure ny Behr or suc‐
must then be performed manually) with a ceeding model”“ ,
reservoir volume of at least 10 kg of re‐ page 198
rrectness of i
frigerant R134a.
l purpos
Air Conditioning Flush Tool - VAS6336/1- . Refer to

For flushing tools that are currently available. ⇒ Fig. ““ Air Con‐
nform
Refer to the VAGWorkshop Equipment Cat‐ ditioning Flush
ercia
alog. Tool -
m
a
♦ For flushing refrigerant circuit with refrig‐ VAS6336/1- from
com
tio
erant R134a. To be used also with older the company
n in
r
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A/C service stations (flushing procedure Waeco or suc‐
thi
s
iva
must then be performed manually) with a ceeding model”“ ,
do
r
reservoir volume of at least 10 kg of re‐ page 198

rp
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frigerant R134a.
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VW/Audi Passenger Vehicle Set Adapter Not illustrated
t. rig
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Chest - VAS631- for refrigerant circuits with
p by
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refrigerant R134a. Prote
cted AG.
agen
♦ For connecting the A/C service station to
the refrigerant circuit and bridging certain
components when flushing with refriger‐
ant R134 or compressed air and nitrogen.
Refrigerant Circuits Adapter Set 2 - Not illustrated

VAS6338/50- for refrigerant circuits with re‐
frigerant R134a.
♦ For connecting the A/C service station to
the refrigerant circuit and for bridging cer‐
tain components when flushing.
Ultrasound A/C Cleaner - VAS6189B- Not illustrated

♦ For eliminating unpleasant odors caused
by A/C system.
Suction Feed Spray Gun - VAG1538- Not illustrated

♦ Suction Feed Spray Gun - Probe for
Evaporator (Straight) - VAG1538/5-
♦ Spray Nozzle (Long) - VAG1538/6-
♦ Suction Feed Spray Gun - Probe -
VAG1538/7-
♦ Cleaning solution D 600 100 A1
♦ Cleaning solution for evaporator D 600
100 A2
♦ To remove unpleasant odors from the
evaporator

Overview Page
Release Tool - VAS6127- case Refer to
♦ For opening refrigerant pipes. ⇒ Fig. ““ Spring
Lock Release
Tools -
VAS6127A- case
consists of the
Release Tool -
VAS6127/1A-
Release Tool -
VAS6127/2A-
and Release Tool
-VAS6127/3- ”“ ,
page 199
Release Tools - VAS6127/1-3- Refer to
♦ For opening refrigerant pipes. ⇒ Fig. ““ Release
Tool -
VAS6127/1- Re‐
lease Tool -
VAS6127/2- ”“ ,
page 199
Magnetic Coupling Tool - VAG1616- Refer to
♦ For clutch plate (A/C compressor manu‐ ⇒ Fig. ““ Magnetic
factured by “Sanden”). Coupling Tool -
VAG1616- for
clutch plate (for
Sanden A/C com‐
pressors)”“ , page
200
Magnetic Coupling Tool Puller - VAG1616/1- Refer to
for the magnetic coupling (Sanden A/C com‐ ⇒ Fig. ““ Magnetic
pressor). Coupling Tool
Puller -
VAG1616/1- (for
Sanden A/C com‐
n AG. Volkswagen AG d
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A/C Clutch Set - VAG1719- (Zexel A/C com‐ orised
Refer to nte
pressor). aut
h ⇒ Fig. ““ A/C eo
ra
ss Clutch Set - c
VAG1719- (for
ce
le
un
pt
Zexel A/C com‐

an
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itte
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rm
ab
200
pe
ility
ot
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A/C Adapter Set - VAG1785/1-10- R134a. Refer to

, is n
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⇒ Fig. ““ A/C
hole
Adapter Set -
spec
es, in part or in w
VAG1785/1-10-
t to the co
”“ , page 200
Combined fine filter unit for compressed-air Not illustrated
system (oil, dirt and water separator as used
rrectness of i
for painting facilities). Refer to VAGWork‐

l purpos
shop Equipment Catalog.

O-ring. Refer to the Parts Catalog. Not illustrated
nform
ercia
Refrigerant oil. Refer to the Parts Catalog. Not illustrated

m
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tion in
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Overview Page
Refrigerant Sockets - T10364- for high pres‐ Refer to
sure/low pressure side service connection ⇒ Fig. ““ Refriger‐
valves on refrigerant circuit. ant Sockets -
T10364- for the
high pressure/low
pressure side
service connec‐
tion valves in the
refrigerant cir‐
cuit”“ , page 201

terials
Caution
Non-approved tools or materials (such as leak stop additives)

The warranty is void if non-approved tools or materials are
used.
Overview Page
Fin comb Refer to
⇒ Fig. ““Fin Comb”“ ,
n AG. Volkswagen AG do page 201
lkswage es n
5/8" - 18 UNF charging hoses with valvebyopener.
Vo ot gu
ara Refer to
ris
ed nte ⇒ Fig. ““Fill Hoses”“ ,
o
au
th eo
ra page 202
ss c
Connection piece for refrigerant cylinder and seal with quick-release coupling Refer to
ce
e
nl
connection or threaded connection 5/8" - 18 UNF. ⇒ Fig. ““Connection Piece for

pt
du
an
Refrigerant Cylinder and Seal

itte
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with Quick-Release Coupling

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Connection or Threaded Con‐

ot p
nection 5/8" - 18 UNF”“ , page

wit
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202
hole
spec
Valve caps 5/8"-18 UNF. Refer to

es, in part or in w
⇒ Fig. ““Valve Caps with

t to the co
Spare Seals (for 5/8"-18 UNF

Thread)”“ , page 202
rrectness of i
Pressure gauge set with pressure reducer for nitrogen. Refer to

⇒ Fig. ““Pressure Gauge Set
l purpos
with Pressure Reducer for Ni‐

trogen (Maximum Reducing
Pressure: 15 bar (218 psi))”“ ,
nform
ercia
page 202
m
at
om
Quick-release coupling adapter for service connections (quantity: 2) included Refer to

ion
c
in scope of delivery of A/C service station. ⇒ Fig. ““Quick-Release Cou‐

in t
or
pling Adapter for Service Con‐

his
ate
nections”“ , page 203

do
priv
cum
or
The wrench size depends on the threaded connections on the refrigerant lines. Not illustrated
f
en
ng
t.
yi Co
Valve opener for charging hoses. Not illustrated
t. Cop py
rig
gh
Connecting nipple for conical seal 5/8"-18 UNF. Not illustrated
ht
pyri by
Vo
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by
Compressed-air gun with rubber mouthpiece. Not illustrated Prote
cted AG.
agen
Hand shut-off valve 5/8"-18 UNF. Not illustrated

Recycling container for refrigerant R134a. Not illustrated
Digital thermometer Not illustrated

Overview Page
Protective gloves Not illustrated
Protective glasses Not illustrated
Refrigerant R134a with cylinder (capacity as required). Not illustrated
Nitrogen with compressed gas cylinder. Not illustrated
Band wrench (oil filter) as counterhold for ribbed belt
en AG. V
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wagen AG Not illustrated
ag does
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12.1.3 Improvised Tools
t
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Overview Page
du
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itte
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Charging hose with connection for workshop Refer to
erm
ab
compressed-air system ⇒ Fig. ““Charging
ility
ot p
Hose with Con‐
wit
, is n
nection for Work‐
h re
hole
shop Com‐
spec
pressed-Air Sys‐
es, in part or in w
t to the co
tem”“ , page 203
rrectness of i
terials
l purpos
Caution
nform
ercia
Non-approved tools or materials (such as leak stop additives)

m
at
om
i
on
c
in t
or
his
ate
do
riv
The warranty is void if non-approved tools or materials are

p
cum
or
used.
f
en
ng
t.
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Cop py
t. rig
gh ht
yri by
A/C Service Station - VAS6007A- (and further or current A/C cop Vo
by lksw
service station) cted agen
Prote AG.

♦ Procedure: the operations "testing, extraction (recycling),
evacuation and charging" are to be performed in line with the
relevant operating instructions.
♦ The filters and dryers installed are to be replaced at the latest
at the end of the period of use specified in the operating in‐
structions and whenever the station has been drained (keep
replacement filter to hand. available from equipment manu‐
facturer. Refer to the operating instructions.
♦ Other A/C service stations or flushing equipment that is ap‐
proved by VW but not illustrated here may also be used.
Note
♦ This A/C service station has the following known units: charg‐
ing cylinder, pressure gauge set, vacuum pump, shutoff valves
and charging hoses.
♦ One quick-release coupling each (for service connections on
high and low-pressure side) is included in the scope of delivery
of this A/C service station.

Air Conditioning Flush Tool - VAS6337/1A- from the company

“Behr” or succeeding model
Note
♦ With a filter -1- and two large cylindrical viewing glasses.

circuit, it should be changed after 2 flushing cycles at the latest.
If a heavily contaminated refrigerant circuit is flushed (the re‐
frigerant oil from the refrigerant circuit is black and viscous, or
there are many shavings in the refrigerant circuit), the filter
should be replaced after flushing the refrigerant circuit.
Air Conditioning Flush Tool - VAS6336/1- from the company

“Waeco” or succeeding model
Note
♦ With a filter -1- and one viewing glass.

circuit, it should be changed after 2 flushing cycles at the latest.
If a heavily contaminated refrigerant circuit is flushed (the re‐
frigerant oil from the refrigerant circuit is black and viscous, or
there are many shavings in the refrigerant circuit), the filter
should be replaced after flushing the refrigerant circuit.
Electronic Leak Detector - VAG1796- n AG. Volkswagen AG do

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hole
spec
es, in part or in w
t to the co
Leak Detection System - VAS6196-

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

Leak Detection KitVAS6201A or succeeding model

AG. Volkswagen AG d
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olksw not
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pt
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Spring Lock Release Tools - VAS6127A- case consists of the
Release Tool - VAS6127/1A- Release Tool - VAS6127/2A- and
Release Tool - VAS6127/3-
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
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f
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ng
Release Tool - VAS6127/1- Release Tool - VAS6127/2-

t.
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Cop py
t. rig
♦ Blue 1/2 inch opyri
gh by
Vo
ht
c
♦ Black 5/8 inch
by lksw
cted agen
Prote AG.
♦ Red 3/8 inch
♦ White 3/4 inch
Release Tool - VAS6127/3-

♦ Green NW 8 for the high pressure line
♦ Black NW 13 for the low pressure line

Magnetic Coupling Tool - VAG1616- for clutch plate (for “Sanden”

A/C compressors)
Magnetic Coupling Tool Puller - VAG1616/1- (for “Sanden” A/C

compressors)
A/C Clutch Set - VAG1719- (for “Zexel” A/C compressors)
AG. Volkswagen AG d
agen oes
olksw not
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pt
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ility
A/C Adapter Set - VAG1785/1-10-

ot p
wit
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♦ Adapter for cleaning refrigerant circuit (flush with refrigerant

h re
hole
R134a. Refer to
spec

es, in part or in w
t to the co
R134a”, page 83 ) or blow through with compressed air and

nitrogen. Refer to
Nitrogen”, page 81 ).
rrectness of i
A - 5/8" 18 UNF thread for conical seal

l purpos
B - Union nut (for connection with O-ring) with thread

nform
ercia
♦ M 18x1.5 VAG1785/1
m
at
om
♦ M 20x1.5 VAG1785/2
ion
c
in t
or
♦ M 24x1.5 VAG1785/3
his
ate
do
riv
♦ M 28x1.5 VAG1785/4
p
cum
for
en
g
A - 5/8"-18 UNF thread for conical seal

n
t.
yi Co
Cop py
B - Threaded connection for O-ring ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ M 18x1.5 VAG1785/5
♦ M 20x1.5 VAG1785/6 olkswage es n
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♦ M 24x1.5 VAG1785/7 ir se
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♦ M 28x1.5 VAG1785/8 ss
au ac
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pt
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ab
ility
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spec
es, in part or in w
t to the co
Valve Adapter
A - 5/8"-18 UNF thread for conical seal
rrectness of i
B - Internal threads with valve opener M 10x1.25 VAG1785/9 (for
connections with valve on high pressure side) M 12x1.5
l purpos
VAG1785/10 (for connections on low pressure side)
nform
ercia
Note
m
at
om
ion
c
♦ A Schrader valve is screwed into connection -A-.
in t
or
his
ate
♦ A valve opener must be installed in the charging hose con‐
do
priv
c
nection.
um
for
en
ng
t.
yi Co
Cop py
. rig
Refrigerant Sockets - T10364- for the high pressure/low pressure
t
gh ht
yri by
side service connection valves in the refrigerant circuit cop Vo
by lksw
cted agen
Prote AG.

terials
Fin Comb

Fill Hoses
5/8"-18 UNF thread
Note
♦ Use differently colored charging hoses (1800 mm long).

♦ Have valve opener and spare seals to hand.
Connection Piece for Refrigerant Cylinder and Seal with Quick-

Release Coupling Connection or Threaded Connection 5/8" - 18
UNF
Valve Caps with Spare Seals (for 5/8"-18 UNF Thread)

Seals can also be used for charging hoses. AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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un
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an
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
Pressure Gauge Set with Pressure Reducer for Nitrogen (Maxi‐ t to the co
mum Reducing Pressure: 15 bar (218 psi))
1- Manometer battery with pressure reducer
rrectness of i
2- Pressure hose (inner diameter 5 mm, length 2 m) with hose

fittings
l purpos
3- Nitrogen cylinder
nform
ercia
4- Hose fitting
m
a
com
tion in
r
Note
te o
thi
s
iva
do
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rp
Hose fittings for connecting on A/C Adapter Set - VAG1785- with

um
fo
threads 5/8" 18 UNF for service connection quick-release cou‐

en
ng
t.
yi
pling adapter to refrigerant circuit.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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ir se
d Beetle 2012 ➤ , CC 2010 ➤ ra,n CC 2012 ➤ , Eos 2006 ➤ , Golf 1992
tee ➤ , G ...
o
auth Refrigerant
or
ac R134a Servicing - Edition 08.2015
ss
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e
Quick-Release Coupling Adapter for Service Connections
nl
pt
du
an
itte
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♦ High-pressure side, nominal size 16 mm
erm
ab
ility
ot p
♦ Low-pressure side, nominal size 13 mm
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
These quick-release couplings are supplied with the A/C service
station.
rrectness of i
l purpos
12.1.6 Improvised Tools
nf
ercia
orm
m
Charging Hose with Connection for Workshop Compressed-Air
atio
m
System
o
n in
or c
thi
e
A - Charging hose 5/8" - 18 UNF** (version with large inner di‐

t
sd
iva
ameter)
o
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m
f
B - Compressed air system connection** (operate only with filter

en
ng
t.
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and dryer for compressed air) t. Cop py
rig
gh ht
** Commercially available tools and materials.
yri
p by
co Vo
by lksw
cted agen
Prote AG.

13 Revision History
DRUCK NUMBER: 00053300021
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
tion ck
08.2 08/2 Fac‐ Tom

015 015 tory Perry
Up‐
date
04.2 06/1 Lo‐ 11 Metadata correction. Tom
015 6/20 cal 05 Changed/added model co‐ Perry
15 Feed 11 des that did not allow book
back 0 to correctly appear in ElsaP‐
ro
04.2 06/0 Cor‐ MIssing metadata for Mexi‐ Tom
015 9/20 rec‐ can factory 163, AU1 and Perry
15 tion BX5
04.2 05/2 Fac‐ Factory updates applied. No Tom
015 5/20 tory updates applied to North Perry
15 Up‐ American vehicles n AG. Volkswagen AG
date olks
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02/1 Lo‐ 10 Spelling ederror
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09/2 Lo‐ Adapter for Assembling Tom 10

6/20 cal Flushing Circuit - Changed Perry 46
14 Up‐ Golf MY 2013 to Golf MY 57
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in advance to factory re‐
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07/3 Fac‐ 10 Tom

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13 80,
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93

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= AG. Volkswagen AG d supported on stands designed for the purpose. Do not support
Never work under a lifted vehicle agenunless it is solidly oes
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a vehicle on cinder blocks,
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vehicle that is supported
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te vehicle while the engine is running.
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•= For vehicles s
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with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
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become inoperable, even if the correct code is used in a later attempt.

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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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starting the vehicle while you are under it.

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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•=
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Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
or
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
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•=
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Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
or
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
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injury could result.

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Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used Co
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only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
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washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
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new parts where indicated, and any other time it is deemed necessary by inspection.
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Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
AG. Volkswagen AG d
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•= Friction materials such V brake pads and clutch discs omay
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o gu contain asbestos fibers. Do not create dust by
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grinding, sanding,o or by cleaning with compressed air. Avoid nbreathing
ris tee asbestos fibers and asbestos dust.
uth or
Breathing asbestos
s a can cause serious diseases such as asbestosis ac or cancer, and may result in death.
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•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
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crushed by heavy parts.
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•=
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Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
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instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
ole,
spec
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
t to the co
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
rrectne
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
ss
•=
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Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
cial p
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
form
mer
listed.
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c
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is i
or
n thi
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
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The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
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serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at leastlkswage times before breaking
four es n the bead from the rim. Completely remove the
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tire from the rim before attempting b y ua
ed any repair. ra nte
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•= When driving or riding in vehicle, never hold test ana
ss airbag-equipped
in your hands or lap while the equipment c
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vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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I have read and I understand these Cautions and Warnings.
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Page 3 of 3
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Service

Golf Variant 2007ss a ➤ ,

Golf Variant 2010 ➤ ,

New Beetle 1999 ➤ ,

Passat (NMS - US) 2016 ➤ ,

Passat Variant 2011 ➤ , Phaeton 2003 ➤ , thi

The Beetle Cabriolet 2012 ➤ ,

Tiguan 2008 ➤ , Touareg 2003 ➤ ,

Touareg 2010 ➤ , Touareg 2015 ➤ ,

Transporter 1996 ➤ , e-Golf 2014 ➤

Refrigerant R134a Servicing

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E8012ED6C

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 A/C System Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.2 Refrigerant Circuit, Converting R12 to R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5 A/C Service Station, Working with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.2 A/C Service Station, Connecting for Measuring and Testing . . . . . . . . . . . . . . . . . . . . . . . . 57

5.3 Discharge Refrigerant Circuit with A/C Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.4 Refrigerant Circuit with A/C Service Station, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.7 Refrigerant in A/C Service station Container, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6 Refrigerant Circuit, Detecting Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Kit VAS6201A or Succeeding Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7 Refrigerant Circuit, Removing Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.1 Refrigerant Circuit, Flushing with Compressed Air and Nitrogen . . . . . . . . . . . . . . . . . . . . 81

8.1 Possible Refrigerant Circuit Concerns . . . . . n. A. G. ..V.o.lk.sw. a.g.en. A. G ....................... 147

11 Components, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

11.2 Leaking or Damaged Components except A/C Compressor, Reservoir or Receiver/Dryer

11.4 Receiver/Dryer or Reservoir and Restrictor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

12 Tools and Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

12.1 Testing Equipment, Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

00 – General, Technical Data

ing trained experts.

Non-approved tools or materials such as leak sealing additives

can cause damage or malfunctions in the system.

Only use tools and materials approved by the manufacturer.

The warranty is voided if non-approved tools or materials are

♦ Technical Service Handbook outlining action to be taken to

1. A/C System, General Information 1

1.3 A/C Technology Basic Principles

⇒ “1.3.1 Physical Principles”, page 2

⇒ “1.3.3 Pressure and Boiling Point”, page 3

When water is heated in a vessel (heat absorption), water vapor

1.3.2 Heat Transfer

2 Rep. Gr.00 - General, Technical Data

C - Vapor pressure curve of water

Vapor pressure curve of refrigerant R134a

1.4 Refrigerant R134a Vapor Pressure Ta‐

At absolute pressure, 0 bar/psi corresponds to absolute vacuum.

1. A/C System, General Information 3

Temperature in °C (°F) Pressure in bar (psi) of R134a

90 (194) 31.34 (454.54)

1.5 Refrigerant R134a ab

⇒ “1.5.1 Refrigerant R134a Physical Data”, page 4 h re

⇒ “1.5.2 Critical Point”, page 5

⇒ “1.5.3 Refrigerant R134a Environmental Information”,

1.5.1 Refrigerant R134a Physical Data