D4B8027068B-Air Conditioning Systems With Refrigerant R134a - General Information

Service
Workshop Manual
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Air conditioning systems with refrigerant R134a -

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General information
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00 - 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 © 2019 Volkswagen AG, Wolfsburg D4B8027068B

Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2 ...
Air conditioning systems with refrigerant R134a - General information - Edition 08.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General information on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Basics of air conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 How air conditioning works A. G
. ..V.o.lk.sw. a. g.e.n .A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.9 General work safety olk.sw
. . . . . . . . . . . . . . . . . . .s.no. t.g.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.10 Safety measures ris when working on vehicles with air conditioning
ed nte and when working with
refrigerantauR134a
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o.r a. . . . . . . . . . . . . . . . . . . . . . . . . 12
1.11 Basics for ss working on refrigerant circuit . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . 13
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2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2.1 Components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2.2 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.3 Evacuation and charging valves for quick-release couplings of air conditioner service station
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on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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2.4 Switches and senders in refrigerant circuit and related connections . . . . . . . . . . . . . . . . . . 27
2.5 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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2.6 Pressures and temperatures in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.8 Refrigerant circuit with restrictor and reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9 Test and measurement work that can be performed using a pressure gauge . . . . . . . . . . 35
ss
2.10 Air conditioner service and recycling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o 36
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2.11 Notes to repairs on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
nform
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3 Legal texts and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3.2 Recycling and refuse law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3.3 Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them
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(retrofitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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3.4 Maintaining records on refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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4.1 Important repair notes on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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4.2 Converting refrigerant circuits from R12 refrigerant to R134a . . . . . . . . . . . . . . . . . . . . . . 45
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5 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.1 Important instructions for working with the air conditioner service station . . . . . . . . . . . . 46
5.2 Connecting a air conditioner service station for measuring and testing . . . . . . . . . . . . . . . . 47
5.3 Drain the refrigerant circuit using the air conditioner service station . . . . . . . . . . . . . . . . . 48
5.4 Evacuating refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . 48
5.5 Filling refrigerant circuit with air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6 Bringing air conditioning system into service after charging . . . . . . . . . . . . . . . . . . . . . . . . 50
5.7 Charging the container in the air conditioning service station with refrigerant . . . . . . . . . . 51
5.8 Emptying air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Detecting leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.1 Leak detection in refrigerant circuit using compressed air or nitrogen . . . . . . . . . . . . . . . . 53
6.2 Searching for leaks in refrigerant circuits using leak detector V.A.G 1796 . . . . . . . . . . . . 55
6.3 Detecting leaks in refrigerant circuit using leak detecting system VAS 6196 or leak detecting
system VAS 6201 or a later model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 Clearing refrigerant circuit of contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.1 Vehicles with high-voltage system (hybrid vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.2 Blowing through refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . 63
Contents i
7.3 Flushing refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8 Clearing refrigerant circuit of contaminants, commercial vehicles . . . . . . . . . . . . . . . . . . . . 95
8.1 Vehicles with high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.2 Flushing refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.3 Adapters for setting up flushing circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.4 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► . . . . . . . . . . . . . . 100
8.5 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► . . . . . . . . . . . . . . 105
8.6 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 . . . . . . . . . . . . . . . . 112
8.7 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter
Grand California ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.8 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ► . . . . . . . . . . 138
9 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9.2 Odours from heater and air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10 Connecting the air conditioning service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.1 For vehicles that have connections on both low-pressure and high-pressure sides of
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
11 Checking pressures on vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
11.1 Checking pressures in the refrigerant circuit (using a air conditioning service station ) . . . . 155
11.2 Checking systems with a restrictor and collector (with internally regulated air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
11.3 Checking systems with an expansion valve and reservoir (with internally regulated air
conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.4 Checking systems with an expansion
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(with externally regulated air conditioner teecompressor) . . . . . . . . . . . . . . . . . . 168
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11.6 Checking
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regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 174
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11.7 With expansion valve, receiver and electrical air conditioner compressor . . . . . . . . . . . . . . 184
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12 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

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12.2 Renew the air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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12.3 Replace receiver or reservoir and restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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13 Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

13.1 List of test equipment, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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ii Contents
00 – Technical data
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1.1 Other reference material
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♦ Technical Service Handbook with measures for rectifying lat‐
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♦ Workshop manual for service work specific to model ⇒ Heat‐
hole
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♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
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♦ Catalogue of special tools / workshop testing.
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♦ Workshop manual for air conditioning system with R12 refrig‐

erant (for vehicles that were manufactured up to model year
1993). This workshop manual is only available as a hard copy.
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1.2 Basics of air conditioning technology
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3- Liquid
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When water is heated in a vessel (heat absorption), water vapour

can be seen to rise. If the vapour is heated by further heat ab‐
sorption, the visible vapour becomes invisible gas. The process
is reversible. If heat is extracted from gaseous water, it changes
first to vapour, then to water and finally to ice.
A - Heat absorption
B - Heat dissipation
1. General information on air conditioning 1

1.2.2 Heat always flows from a warmer to a

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

The boiling point given in tables for a liquid is always referenced
to an atmospheric pressure of 1 bar. If the pressure over a fluid
changes, its boiling point changes as well.
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1.3 Vapour pressure table for refrigerant

R134a
The vapour pressure table for every refrigerant is published in
literature for refrigeration system engineers. This table makes it
possible to determine the vapour pressure acting on the column
of liquid in a vessel if the temperature of the vessel is known.
Since a characteristic vapour pressure table is known for every
refrigerant, one can determine what refrigerant is present by
measuring pressure and temperature.
2 Rep. gr.00 - Technical data

Note
Absolute pressure means that 0 bar correspondsswtoagan en Aabsolute

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45 10.54
50 12.11
55 13.83
60 15.72
65 17.79
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34
1.4 Refrigerant R134a

Air conditioners in vehicles use the evaporation and condensation
process. Use is made of a substance with a low boiling point, re‐
ferred to as refrigerant.
The refrigerant employed is tetrafluoroethane or R134a, which
boils at -26.5°C at a pressure of 1 bar.
1.4.1 Physical data of refrigerant R134a

Chemical formula CH2F–CF3 or CF3–CH2F
Chemical designation Tetrafluoroethane
Boiling point at 1 bar -26.5°C

Solidification point -101.6°C

Critical temperature 100.6°C
Critical pressure 40.56 bar (technical) pressure
equates to 39.5 bar (standard)
pressure
1.4.2 Critical point

The critical point (critical temperature and critical pressure)
means the point above which there is no longer a surface of sep‐
aration 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
contained within a pressure tank exhibit a liquid phase and a gas
phase, so that there is a gas cushion above the liquid.
As long as there is gas in the pressure vessel alongside the liquid,
the pressure depends directly on the ambient temperature
⇒ page 2 .
Note
Different types of refrigerant are never to be mixed. Only the re‐

frigerant prescribed for the respective air conditioning system
may be used.
G. Volkswagen
1.4.3 Environmental aspects
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♦ R134a is a fluorocarbon
s a and contains no chlorine.
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♦ R134a has a shorter atmospheric persistence than refrigerant

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R12.
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♦ R134a does not damage the ozone layer, the potential to re‐
ility
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♦ The Global Warming Potential (GWP) of R134a amounts to

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approx. 1430 (the GWP for carbon dioxide amounts to 1).

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♦ R134a contributes only one tenth as much to the greenhouse

effect as refrigerant R12.
1.5 Properties of refrigerant R134a

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1.5.1 Trade names and designations

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Refrigerant R134a is currently available under the following trade

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names:
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♦ H-FKW 134a
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♦ SUVA 134a
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Note
♦ Different trade names may be used in other countries.

♦ Of the wide range of refrigerants available, this is the only one
which may be used for vehicles. The names Frigen and Freon
are trade names. They also apply to refrigerants which are not
to be used in vehicles.
1.5.2 Colour
Like water, refrigerants are colourless in both vapour and liquid
form. Gas is invisible. Only the boundary layer between gas and
liquid is visible (liquid level in indicator tube of charging cylinder
or bubbles in sight glass). Liquid refrigerant R134a may have a
coloured (milky) appearance in a sight glass. This cloudiness is
caused by partially dissolved refrigerant oil and does not indicate en AG. Volkswagen AG
a fault. olks
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1.5.3 Vapour pressure ho
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In an enclosed container that is not completely full,
ss refrigerant c
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evaporates as vapour at the surface in a quantity sufficient to form

un
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an equilibrium between vapour and liquid. This state of equilibri‐
an
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vapour pressure. The vapour pressure is temperature-dependant
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⇒ page 2 .
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1.5.4 Physical properties of R134a
spec
As the vapour pressure curves of R134a and other refrigerants
t to the co
are often very similar, unequivocal identification cannot be made
simply on the basis of pressure.
rrectne
The air conditioner compressor used for R134a is lubricated with
special synthetic refrigerant oils, such as PAG oils (polyalkylene
s
glycol oils).
s o
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1.5.5 Effects on metal
nform
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In its pure state, refrigerant R134a is chemically stable and does
om
not react with iron or aluminium.
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However, impurities such as chlorine compounds in the refriger‐

t
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ages, leaks and deposits on the air conditioner compressor

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1.5.6 Critical temperature and critical pres‐
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The refrigerant R134a remains stable up to a pressure of 39.5 bar

(corresponding to a temperature of 101°C). Above this tempera‐
ture, the refrigerant decomposes (see "Combustibility").
1.5.7 Water content

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

Water destroys the air conditioner because at high pressures and

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

There must be space both for liquid and vapour in a container. As
the temperature rises, the liquid expands. The vapour-filled space
becomes smaller. At a certain point, there will only be liquid in the
vessel. Beyond this, even a slight increase in temperature causes
great pressure to build up in the vessel as the liquid attempts to
continue expanding despite the absence of the necessary space.
The resultant force is sufficient to rupture the vessel. To prevent
containers from being overcharged, regulations governing the
storage of compressed gases specify how many kilograms may
AG. Volkswagen AG d
be charged into a container for every litre of lcontainer
ksw
agen volume. oes
not
This charge factor multiplied by the internal
d by Vvolume gives the per‐
o gu
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missible charge quantity. The chargeorisfactor for refrigerant used
e nte
in vehicles is 1.15 kg/litre. au
th eo
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1.5.9 Detecting leaks
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External damage, for example, can cause a leak in the refrigerant
erm
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circuit. Because a small leak will involve only small quantities of
ility
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refrigerant, leaks should be checked for using an electronic leak
wit
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detector or by introducing a leak detection additive to the refrig‐
h re
erant circuit. Electronic leak detectors can detect leakage rates
hole
spec
of less than 5 grams loss of refrigerant per year. The leak detector
es, in part or in w
should be specific to the composition of the particular refrigerant
t to the co
in use. For example, a leak detector for R12 refrigerant is not ap‐
propriate for R134a refrigerant because R134a refrigerant has no
chlorine atoms to which the lead detector responds.
rrectness of i
1.6 Refrigerant oil
l purpos
Refrigerant oil mixes with the refrigerant (about 20 to 40%, de‐
nf
ercia
pending on air conditioner compressor type and amount of refrig‐

or
erant) and circulates constantly in the system, lubricating the
m
m
atio
moving parts.
om
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Special synthetic refrigerant machine oils such as polyalkylene

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

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

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air conditioning system could be attacked if the mixture circulated
Co
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within the refrigerant circuit under pressure and at high tempera‐
. C rig
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co Vo
down. The use of unapproved oils can lead to the failure of the air
by lksw
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Prote
conditioning system, so only approved oils must be used.
AG.
⇒ Electronic parts catalogue (ETKA)

Type of oil for R134a in cars: PAG

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

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

nl
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The most important properties are high solubility with refrigerant,

ab
ility
good lubricating quality, absence of acid and low water content.

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For this reason, only certain oils may be used. A list of approved
, is n
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refrigerant oils and quantities can be found in the vehicle-specific

hole
spec
workshop manuals in ⇒ Rep. gr. 00 or ⇒ Rep. gr. 87 .

es, in part or in w
t to the co
The PAG oils suitable for refrigerant R134a are strongly hygro‐
scopic and are immiscible with other oils. Opened containers
should therefore be closed again immediately to prevent ingress
rrectness of i
of moisture. Moisture and acids promote ageing of refrigerant oil,

causing it to become dark, viscous and aggressive towards met‐
l purpos
als.
nf
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Note
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♦ For refrigerant circuits with refrigerant R134a, use only the oil
n in
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approved for the air conditioner compressor. See ⇒ Rep. gr.

thi
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sd
a
00 or ⇒ Rep. gr. 87 in the repair manual for the specific ve‐

iv
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hicle.
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t.
♦ Disposal of used oils: Volkswagen InfoNet; Operation; Hand‐
yi Co
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books & dealer literature; Handbook Service; 15. Environmen‐
C py
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rig ht
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Prote AG.
used oils; Refrigerant oils

1.7 Comfort
A basic requirement for concentration and safe driving is a feeling
of comfort in the passenger compartment. This comfort is only
reached by using an air conditioning system, particularly when it
is hot and humid. Of course, open windows, an open sunroof or
increased air ventilation can contribute to comfort, but they all
have certain disadvantages within the vehicle interior, such as
additional noise, draughts, exhaust gases, unfiltered entry of pol‐
len (unpleasant for allergy sufferers).
A well regulated air conditioning system in conjunction with a well
thought-out heating and ventilation system can create a feeling
of well-being and comfort by regulating the interior temperature,
humidity and rate of air change, regardless of the external con‐
ditions. This must be available whether the vehicle is moving or
not.
Other important advantages of air conditioning are:
♦ The cleansing of the air directed into the passenger compart‐
ment. (Dust and pollen, for example, are washed out by the
moist fins of the evaporator and carried off with the conden‐
sation water.)
♦ Temperatures in a mid-range car (for example, after a short
period of driving, ambient temperature 30°C in the shade and
the vehicle in direct sunlight).
With air conditioning Without air condi‐
tioning
Head height 23°C 42°C
Chest 24°C 40°C
Footwell 30°C 35°C
1.7.1 Environmental aspects

As of around 1992, the air conditioning systems of newly manu‐
factured cars have been successively AG.changed
VolkswagentoAG
refrigerant
R134a. This refrigerant contains agen
ksw no chlorine and therefore not does
does
ol
no damage to the ozoneed blayer.
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Until about 1992, athe
ut air conditioning systems were equipped with or a
h e
refrigerant R12.sDue to its chlorine atoms, this CFC has a high
s c
potential for destroying ozone and, in addition, a higher potential
ce
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un
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for increasing the greenhouse effect.

an
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There are programs for exchanging old air conditioning systems

pe
ility
containing the ozone-damaging refrigerant R12.

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To protect the environment, no refrigerant should be released into

hole
the atmosphere ⇒ page 38 (statutory texts and instructions).

spec
es, in part or in w
t to the co
1.8 How air conditioning works

The temperature in the passenger compartment depends on the
rrectness of i
amount of heat radiated through the windows and conducted by

the metal parts of the body. In order to maintain comfortable tem‐
l purpos
peratures for the occupants on very warm days, part of the

prevailing heat must be pumped away.
nform
ercia
Since heat spreads towards cooler bodies, a unit that can create
low temperatures is fitted in the vehicle interior Within this, refrig‐
m
a
com
erant is continually evaporated. The heat required to do this is

ion in
extracted from the air flowing through the evaporator.

r
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The refrigerant carries the heat with it as it is pumped away by the

do
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air conditioner compressor. The work performed by the air con‐

um
fo
ditioner compressor on the refrigerant increases its heat content

en
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Rep. gr.00 - Technical data
AG.
Amarok 2011 ➤ , Amarok 2017 n AG➤
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AG do ➤ , Arteon 2018 ➤ , Atlas 2 ...
wage
Air conditioning systems withVrefrigerant
olks R134a - Generalesinformation
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y ua
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and its temperature. Its temperature ut is now
ho substantially higher or
than that of the surrounding air. ss a ac
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The hot refrigerant flows with its heat content to the condenser.
un
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where the refrigerant dissipates its heat to the surrounding air via
itte
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the condenser due to the temperature gradient between the re‐
rm
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frigerant and the surrounding air.
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h re
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re-used, the refrigerant is returned to the evaporator.
spec
es, in part or in w
For this reason all air conditioning systems are based on the re‐
t to the co
frigerant circulation principle. There are however differences in
the composition of the units.
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1.9 General work safety
l purpos
♦ In accordance with VBG 20, the Federation of Employers Li‐

ability Insurance Associations.
nform
ercia
♦ Observe instructions specific to the workplace; ⇒ Volkswagen

m
ServiceNet; Handbooks; Service handbook; Environmental
a
com
tio
protection . Refrigerant from air conditioning systems / refrig‐
n in
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erant oils - to be displayed at refrigerant designated working

te o
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area.
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1.9.1 Product characteristics
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Refrigerants used in car air conditioning systems belong to the
C py
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new generation of refrigerants, the chlorine-free, partially-fluori‐
ht
pyri by
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dated hydrocarbons (H-CFC, R134a).
c by lksw
cted agen
Prote AG.
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.
Compliance with specific conditions is required to ensure safe and
proper use.
1.9.2 Handling refrigerants
Note
♦ Risk of freezing injuries.

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

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

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

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

into contact with the skin. Degreased skin is however sensitive to

the cold and germs.
1.9.5 Do not allow liquid refrigerant to come in

contact with the
swa
gskin
en AG. V
olkswagen AG
does
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The refrigerant draws heat d b for evaporation from the surrounding
y ua
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area - even if this is tthe
ho skin. This may give rise to extremely low e o
ri te
temperatures. Thes aresult
u is local freezing (boiling point of R134a: r ac
-26.5°C at atmospheric
s
pressure).
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1.9.6 Do not breath in refrigerant vapour
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In high concentrations, emerging refrigerant vapours can mix with
es, in part or in w
the air and displace the oxygen necessary for breathing.
t to the co
1.9.7 Absolutely NO SMOKING
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A burning cigarette can cause refrigerant to decompose. The re‐
l purpos
sultant substances are toxic and must not be inhaled.
1.9.8 Welding and soldering on refrigeration
nform
ercia
systems
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at
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Before welding and brazing on vehicles (in the vicinity of the air in t
or
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conditioning system components), extract the refrigerant and

at
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then purge the system by blowing through with compressed air

p
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and using nitrogen.

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The products of decomposition of refrigerants under heat are not Cop py
only poisonous but are strongly corrosive, so that pipework and
t. rig
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system parts could be attacked. This refers primarily to hydrogen
p by
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fluoride. Prote
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agen
1.9.9 Pungent smell

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

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

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

If they should fall, the containers may become severely deformed

and break open. The refrigerant evaporates immediately, liberat‐
ing considerable force. Flying fragments of cylinders can cause
severe injuries.
Valves may break off if cylinderseare AGnot
. Volkproperly
swagen Gtransported. To
protect cylinder valves, cylindersag nare only to be Atransported
does with
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by Von. gu
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• Do not placeanear
ut
ho radiators! eo
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High temperatures can occur near radiators. High temperatures
ce
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nl
are also associated with high pressures and the maximum per‐
pt
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1.9.12 Do not heat up above 50°C
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To prevent danger, the pressure vessel regulations provide that
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vessels shall not be heated to more than 50°C.
es, in part or in w
t to the co
1.9.13 Do not expose to uncontrolled heat
Do not heat with a naked flame under any circumstances. The
rrectness of i
local overheating that will result can change the structure of the
container's materials, thereby reducing the safe maximum pres‐
l purpos
sure limit of the container. There is also a danger of the refrigerant

decomposing due to localised overheating.
nf
ercia
o
1.9.14 Seal empty tanks/containers
rm
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atio
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Empty refrigerant tanks/containers must always be closed to pre‐

o
n in
or c
vent the ingress of moisture. Moisture causes steel tanks/con‐ thi

e
tainers to rust. Rust weakens the tank/container walls. In addition,

t
sd
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rust particles which ingress into refrigeration systems from con‐

r
rp
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tainers cause malfunctions.

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1.9.15 Safety instructions for using extraction
C py
ht. rig
rig ht
and charging equipment
py by
co Vo
by lksw
cted agen
Prote AG.
• Before connecting the charging system to the air conditioner,
make sure that all existing shut-off valves are closed.
• Before the charging equipment is decoupled from the air con‐
ditioning system, ensure that the process has finished. The
reason for this is to ensure that no refrigerant oil escapes into
the atmosphere.
• Once the purified refrigerant from the charging system has
been filled into 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.
• Before performing service work on the charging system, dis‐
connect the power supply.
• To reduce the risk of fire, avoid using an extension cable. If
the use of an extension cable is unavoidable, use an extension
cable with a cross-section of at least 2.5 mm2.
• In case of fire, remove external cylinder.
• If entrained oil from the air conditioning system suction accu‐
mulator is trapped in the measuring beaker supplied, be sure
subsequently to pour the oil into a container that can be
sealed, since the oil contains a small amount of refrigerant.
Refrigerant must not be released into the environment.
• When the air conditioner service station is switched off, it must
be secured against rolling away.

1.10 Safety measures when working on ve‐

hicles with air conditioning and when
working with refrigerant R134a
Air conditioner service station
⇒ Workshop equipment
Risk of freezing injury from refrigerant

olksw
When working on the air conditioning asystem,
gen AG there isnaAG
.V age
risk
doeof
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highly pressurised refrigerant escaping
by Vol from the system. There ist gu
a risk of injury to the skin and
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– Wear protective gloves.
sa
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– Wear protective goggles.

nl
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– Extract refrigerant and open the refrigerant circuit immediately
erm
ab
afterwards.
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– If more than 10 minutes have passed since the refrigerant was
, is n
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extracted, repeat the extraction process before opening the
hole
spec
refrigerant circuit. Pressure could build up in the refrigerant
es, in part or in w
circuit from continued evaporation.
t to the co
rrectness of i
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Risk of damage to refrigerant lines

There is a risk of damage to the refrigerant lines due to rupture of
nf
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the inner foil.

orm
m
– Never bend refrigerant lines to a radius less than 100 mm.

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• Do not weld, braze or soft-solder any parts of the charged air

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

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

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

service station ) must never be subjected to excessive heat or
exposed to direct sunlight.
Remedy:
– Containers must never be completely filled with liquid refrig‐
erant. Without sufficient expansion space (gas cushion), the
container will burst should the temperature rise with devastat‐
ing consequences ⇒ page 4 .
Under no circumstances may refrigerant be charged into systems
or vessels containing air.
Remedy:
– Evacuate systems and containers before charging with refrig‐
erant.
1.11 Basics for working on refrigerant

agen
AGcircuit
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• Observe instructions specific to the workplace;
db
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ran
ServiceNet; Handbooks; Service handbook; rise Environmental tee
ho
protection . Refrigerant from air conditioning
au
t systems / refrig‐ or
ac
erant oils - to be displayed at refrigerant
ss designated working
ce
e
area.
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• Observe the utmost cleanliness when working.
erm
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• When handling refrigerants and nitrogen, wear protective
wit
clothing, protective glasses and protective gloves.
, is n
h re
hole
• Switch on exhaust gas fume extractor (if there is one).
spec
es, in part or in w
• Drain the refrigerant circuit using only the air conditioner serv‐
t to the co
ice station , and only then undo the screwed joints and renew
the defective components.
rrectness of i
• Protect units and hoses against moisture and dirt using sealing
caps.
l purpos
• Make exclusive use of tools and materials intended for refrig‐

erant R134a.
nf
ercia
• Protect refrigerant oil by sealing container to prevent ingress orm

m
atio
m
of moisture.
o
n in
or c
thi
– Blow through refrigerant circuit with compressed air and nitro‐

te
sd
a
gen ⇒ page 63 .
iv
o
r
rp
cu
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– Flush refrigerant circuit with refrigerant R134a ⇒ page 65 .

f
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op
In vehicles that have an air conditioner compressor without a
C py
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gh
magnetic clutch:
ht
pyri by
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cted agen
Prote AG.

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

properly assembled. If, for example, the refrigerant lines are
not connected to the air conditioner compressor and the en‐
gine is running, the compressor may heat up so much through
internal warming that it will be destroyed.
♦ The air conditioner compressor regulating
wage
n AGvalve
. Volks-wN280-
agen AGis not
doe
activated when the refrigerant ycircuit
Vol
ks is empty and the air con‐
s no
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ditioner compressor idles with
ise the engine.
d b ara
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♦ If it is necessary to start
sa
u engine with an empty refrigerant cir‐ or
ac
cuit: s
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pt
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♦ The refrigerant circuit must be fully assembled.
an
itte
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erm
ab
♦ At least ¼ of the quantity of refrigerant oil specified for this
ility
ot p
refrigerant circuit must be in the air conditioner compressor.
wit
, is n
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♦ The engine speed must not exceed 2000 rpm.
hole
spec
♦ The engine should run for less than 10 minutes.
es, in part or in w
t to the co
1.11.1 O-ring
rrectness of i
♦ Use only O-rings that are resistant to refrigerant R134a and
related refrigerant oils. O-rings are no longer colour-coded.
l purpos
Coloured and black O-rings are used.

♦ Check that the O-rings used have the correct internal diame‐
nf
ercia
o
ters.
rm
m
atio
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⇒ Rep. gr. 87
o
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thi

te
sd
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♦ Never reuse O-rings.

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

t.
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op
(PAG oil).
C py
t. rig
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pyri by
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by c lksw
cted agen
Note
Prote AG.
♦ When purging components with compressed air and nitrogen,

always collect the gas mixture exiting the component with suit‐
able exhaust gas extraction equipment (workshop fume ex‐
tractor).
♦ After completion of repair work screw sealing caps (with seals)
onto valve and service connections.
Before operating the air conditioning system. Check the vehicle-

specific charge quantities ⇒ Rep. gr. 87 .
Do not top up refrigerant in circuit; discharge existing refrigerant
and re-charge system.
1.11.2 Before operating the air conditioning

system after recharging with refrigerant
– After installing a new air conditioner compressor or filling with
fresh refrigerant oil (e.g. after blowing out refrigerant circuit),
turn compressor pulley 10 revolutions by hand before starting
engine. This will prevent damage to the air conditioner com‐
pressor.
– On 5 or 10-cylinder diesel engine, turn air conditioner com‐
pressor at overload protection 10 times by hand. Then install

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or
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compressor. This will prevent damage to the air conditioner
pt
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an
compressor. itte
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ab
– Start the engine with the air conditioning system switched off
ility
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(the air conditioning system magnetic clutch - N25- and the air
wit
, is n
conditioner compressor regulating valve - N280- are not acti‐
h re
hole
vated).
spec
es, in part or in w
– After the engine has stabilised at its idling speed, switch on
t to the co
the air conditioner compressor and allow the engine to idle for
at least 10 minutes at maximum cooling power.
rrectness of i
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Cop py
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by
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Prote AG.

2 General information on refrigerant

circuit
2.1 Components of refrigerant circuit

• All components of the refrigerant circuit that were submitted
for quality monitoring must always be sealed (use the original
sealing caps from the genuine part).
• Renew damaged or leaky components of the refrigerant circuit
⇒ page 185 .
• The genuine parts (air conditioner compressor, reservoir, re‐
ceiver, evaporator and condenser) are charged with nitrogen
before shipment. This charge is being gradually discontinued.
Therefore, when the sealing plugs are unscrewed from the
genuine part little or no pressure equalisation is noticeable.
2.1.1 Distribution of the refrigerant circuit

components and their influence on the
high-pressure and low-pressure sides
On the high-pressure side, there are the condenser, the receiver
and the restrictor or expansion valve that acts as the separation
between the high-pressure fluid and low-pressure fluid sides.
High pressure is created because the restrictor or expansion
valve forms a restriction and holds back the refrigerant, leading
to increased pressure and temperature.
Excessive pressure results if the circuit is filled with too much re‐
frigerant or refrigerant oil, or the condenser is dirty, the radiator
fan is defective, there is a blockage in the system or there is
moisture in the refrigerant circuit (causing the restrictor or expan‐
sion valve to ice up). AG. Volkswagen AG d
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On the low-pressure side, there are the evaporator, the reservoir,d b ara
ise nte
the temperature sensor for the evaporator and the air conditioner
thor eo
compressor that acts as the separation between the high-pres‐
ss au ra
c
sure and low-pressure gas sides. ce
le
un
pt
an
A loss of pressure in the system can be due to loss of refrigerant,
d
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restrictor or expansion valve failure (not creating a restriction),
rm
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defective air conditioner compressor or an iced-up evaporator.

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Cop py
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Air conditioning systems with refrigerant R134a b-yGeneral
Vol information - Edition n08.2019
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2.1.2 Air conditioning system compressor with th or
au ac
ss
magnetic clutch:
ce
le
un
pt
an
d
itte
The air conditioner compressor is driven by a V-belt from the en‐
y li
erm
ab
gine.
ility
ot p
wit
An electromagnetic clutch is fitted to the air conditioner compres‐
is n
h re
sor. When the air conditioning system is switched on, it transmits
ole,
the mechanical drive between the V-belt pulley and the air con‐
spec
ditioner compressor drive shaft.
t to the co
A fusible link is incorporated in the air conditioner compressor V-
belt pulley. In the event of stiffness in the air conditioner com‐
pressor, it trips the electromagnetic clutch and protects the V-belt
rrectne
drive from overload.
s
The air conditioner compressor draws refrigerant gas from the
s o
evaporator, compresses it and sends it to the condenser. cial p
f inform
mer
atio
m
Note
o
n
c
i
or
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e
♦ The air conditioner compressor contains refrigerant oil, which

t
sd
va
can be mixed with R134a refrigerant at any temperature.

i
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pr
cum
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en
ng
♦ The identification plate states the refrigerant for which the air
t.
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conditioner compressor is suitable. A valve regulates the pres‐ Cop py
t. rig
sure on the low-pressure side within the specified range (con‐ yri
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trol characteristic).
op Vo
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♦ So that the air conditioner compressor suffers no damage
AG.
when the refrigerant circuit is empty, the magnetic clutch is

disconnected and the regulating valve for the air conditioner
compressor - N280- is no longer activated (the air conditioner
compressor idles with the engine).
2. General information on refrigerant circuit 17

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Air conditioning systems
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2.1.3 Air conditioner compressor without
ce
le
un
pt
magnetic clutch
an
d
itte
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erm
ab
The air conditioner compressor is driven by a V-belt from the en‐
ility
ot p
gine.
wit
is n
h re
ole,
A shear link is incorporated in the air conditioner compressor V-
spec
belt pulley. In the event of stiffness in the air conditioner com‐

pressor, it shears off and protects the V-belt drive from overload.
t to the co
evaporator, compresses it and sends it to the condenser.
rrectnes
Note
s o
cial p
f inform
mer
is miscible with R134a refrigerant at all temperatures.
atio
om
n
c
i
or
n thi
conditioner compressor is suitable. A valve regulates the pres‐
te
sd
a
sure on the low-pressure side within the specified range (con‐

iv
o
pr
c
um
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fo
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ng
t.
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♦ The regulating valve for this air conditioner compressor is ex‐
Co
op py
ternally activated. t. C rig
gh ht
pyri by
♦ The engine should be started only when the refrigerant circuit
o Vo
by c lksw
cted agen
has been fully assembled ⇒ page 13 . Prote AG.
♦ The air conditioner compressor has an internal oil circuit to

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

2.1.4 Air conditioner compressor without

magnetic clutch, with elasticn Adrive cou‐
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The air conditioner compressor ishodriven
ris directly by the power nte
e
steering vane pump. s aut or
ac
s
There is an overload protection on the drive shaft of the air con‐
ce
le
un
pt
ditioner compressor, which shears in the event of the air condi‐
an
d
itte
y li
tioner compressor seizing, thus permitting the power steering
erm
ab
vane pump to remain operational.
ility
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wit
is n
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ole,
spec
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Note
rrectne
s
s o
conditioner compressor is suitable. A valve regulates the pres‐
cial p
f in
sure on the low-pressure side within the specified range (con‐
form
mer
atio
om
♦ The regulating valve for this air conditioner compressor is ex‐
n
c
i
or
n
ternally activated.
thi
te
sd
va

i
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pr
cum
r
has been fully assembled ⇒ page 13 .

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♦ The air conditioner compressor has an internal oil circuit to Cop py
t. rig
ensure that the air conditioner compressor is not damaged yri
gh by
ht
when the refrigerant circuit is empty. This means that approx. cop Vo
by lksw
cted agen
Prote AG.
compressor.
2.1.5 Electrical air conditioner compressor for

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

Note
♦ The electrical air conditioner compressor requires a different

refrigerant oil!
♦ For capacities, see workshop manual for specific vehicle.
♦ Do not touch air conditioner compressor when drive units are
starting. Danger of short circuit! agen
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Electrical air conditioner compressor orise nte
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h
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The air conditioner compressor draws refrigerant gas
ss a
from the c
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
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spec
es, in part or in w
t to the co
conditioner compressor is suitable. The flow rate is controlled
via the engine speed.
rrectness of i
has been fully assembled ⇒ page 13 .
l purpos
♦ The air conditioner compressor has an internal oil circuit to

ensure that the air conditioner compressor is not damaged
nform
ercia
when the refrigerant circuit is empty. This means that approx.

m
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com
tio
compressor.
n in
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♦ The air conditioner has a pressure relief valve.
s
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2.1.6 Condenser
yi Co
Cop py
t. rig
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The condenser transfers heat from the compressed refrigerant pyri by
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gas to the surrounding air.
lksw
cted agen
Prote AG.
When this happens, the refrigerant gas condenses to liquid.

2.1.7 Evaporator
The liquid refrigerant evaporates in the tubes of the evaporator.
The required heat is extracted from the air flowing past the evap‐
orator ribs. The air cools down. The refrigerant evaporates and is
drawn into the air conditioning system compressor carrying with
it the heat it has absorbed.
A restrictor or an expansion valve supplies a defined quantity of
refrigerant to the evaporator. In systems with an expansion valve
the flow rate is regulated such that only gaseous refrigerant
emerges at the evaporator outlet.
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2.1.8 Reservoir
ed
ris nte
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aut ra
The sreservoir collects the vaporised and gaseous mixturec coming
s
ce
le
from the evaporator to ensure the air conditioner compressor re‐

un
pt
ceives only gaseous refrigerant. The vapour becomes gaseous
an
d
itte
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refrigerant.
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ility
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Refrigerant oil flowing in the circuit does not remain in the reser‐
wit
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voir because an oil extraction hole has been provided.

h re
ole,
Any moisture which has entered the refrigerant circuit during as‐ spec
sembly will be trapped by a filter (drying bag) in the reservoir. t to the co
Gaseous refrigerant with oil is drawn in by the air conditioner

compressor.
rrectne
Note
ss o
cial p
f i
♦ Renew the reservoir if the refrigerant circuit has stood open

nform
for any length of time (more than the normal repair time) and
mer
atio
moisture has entered the system, or if it is required because

om
of a specific complaint ⇒ page 185 .

n
c
i
or
n thi
e
♦ Do not remove sealing plugs -A- and -B- until just before in‐
t
sd
va
stallation.
i
o
pr
cum
r
fo
en
ng
♦ The desiccant bag in an unsealed reservoir will become satu‐

t.
yi Co
rated with moisture within a short time and is then unusable.
Cop py
t. rig
gh ht
yri
♦ When installing, observe arrow indicating direction of flow if
p by
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applicable.
Prote
cted AG.
agen

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

♦ Renew it every time the refrigerant circuit is opened.
♦ Observe different versions.
⇒ Rep. gr. 87
2.1.10 Receiver
The receiver collects the liquid droplets and directs them in a
continuous stream to the expansion valve. Moisture which has
entered the refrigerant circuit during assembly is collected by the
desiccant bag in the receiver. AG. Volkswagen
agen AG do
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ed ran
Note oris tee
th or
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ss
♦ Renew the reservoir if the refrigerant circuit has stood open
ce
le
for any length of time (more than the normal repair time) and
un
pt
an
d
moisture has entered the system, or if it is required because

itte
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of a specific complaint ⇒ page 185 .

erm
ab
ility
ot p
♦ Do not remove sealing plugs until just before installation.

wit
is n
h re
ole,
♦ The desiccant bag in an unsealed receiver will become satu‐

spec
rated with moisture within a short time and is then unusable.

t to the co
♦ When installing, observe arrow indicating direction of flow if

applicable.
rrectnes
The new generation of receivers is mounted directly on the con‐

s o
denser and contains a desiccant cartridge.

cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
e
♦ Renew the desiccant cartridge if the refrigerant circuit was

t
sd
va
open for a longer period of time (more than the normal repair
i
o
pr
cum
time) and moisture has entered the system, or if it is required

r
fo
en
ng
because of a specific complaint ⇒ page 185 .

t.
yi Co
Cop py
♦ Remove the dryer cartridge from its packaging only immedi‐
t. rig
gh ht
yri
ately before installing it.
p by
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♦ A dryer cartridge in unsealed packaging will become saturated
Prote AG.
with moisture within a short time and is then unusable.

Amarok 2011 ➤AG, .Amarok
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Air conditioningolsystems oR134a
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2.1.11 Expansion valve aut
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The expansion valve atomises incoming refrigerant and regulates
ce
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nl
the flow so that, depending on the heat transport, the vapour does
pt
du
an
itte
not become a gas until it reaches the outlet of the evaporator.
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erm
ab
ility
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
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2.1.12 O-ring
nform
ercia
These O-rings seal the joints between the individual components

m
at
of the refrigerant circuit.
om
ion
c
in t
r
Use only seals that are resistant to refrigerant R134a and its as‐
o
his
te
sociated refrigerant oils. This is assured by using genuine re‐

a
do
riv
placement parts.
p
cum
for
en
g

n
t.
yi Co
Cop py
.
O-ring
t rig
gh ht
pyri by
Vo
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• Strictly use only once:
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cted agen
Prote AG.
• Check that diameters -a- and -b- are correct.
• Moisten with refrigerant oil before fitting
2.1.13 Pipes and hoses of refrigerant circuit

The mixture of refrigerant oil and refrigerant R134a attacks certain
metals (e.g. copper) and alloys and dissolves certain hose mate‐
rials. Therefore, always use genuine spare parts.
The pipes and hoses are joined with bolted connections or special
connectors.
Note
Observe specified torques for bolted connections and use the

envisaged release tools for connectors.
2.1.14 High-pressure safety valve

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

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

may be attached to the high pressure safety valve -A- which
breaks off as soon as the valve is actuated.
♦ Depending on the version of high pressure safety valve -A-, a
cover -C- may also be pushed onto the high pressure safety
valve -A-. Should the pressure in the refrigerant circuit actually
rise above the opening pressure of the high pressure safety
valve -A- and cause the valve to open, refrigerant will not es‐
cape in one direction but scatter through the openings -D- n AG. Volkswagen AG do
beneath the cover -C- instead. olkswage es n
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♦ If a high-pressure safety valve -A- needs to be renewed,
ris
ed the nte
specified torque for the new valve (depending on ut the manu‐
ho eo
ra
facturer and the version of the air conditioner compressor)
a c
ss
must be observed when installing. Air conditioner compres‐
ce
e
nl
pt
du
sors manufactured by “Denso”, “Sanden” and “Valeo” are
an
itte
equipped with an O-ring seal (currently valid torque settings
y li
erm
ab
are: 10 Nm for “Denso” and “Zexel/Valeo” air conditioner com‐
ility
ot p
pressors, and 15 Nm for “Sanden” air conditioner compres‐
wit
, is n
sors). Air conditioner compressors manufactured by “Delphi”
h re
are fitted with an oil seal (currently valid torque setting: 15 Nm).
hole
spec
es, in part or in w
♦ Renewing seals (oil seals or O-rings) ⇒ Electronic parts cata‐
t to the co
logue .
♦ If a seal (oil seal or O-ring) fitted to the high-pressure safety
rrectness of i
valve is not available as a replacement part, the removed old
part can be reused (as an exception to the general rule of using
l purpos
new seals only). The old seal, however, must always be

checked for damage prior to installation. If any damage or de‐
formation is detected on the old seal, it must be renewed with
nf
ercia
o
a commercially available new part ⇒ Electronic parts cata‐
rm
m
logue .
atio
om
n in
c
♦ After filling the refrigerant circuit, check the installed high-

or
thi
pressure safety valve for leaks using e.g. an electronic leak
te
sd
iva
detector.
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f
en
ng
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op
2.2 Design of refrigerant circuit
C py
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pyri by
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2.2.1 Refrigerant circuit with expansion valve
c by lksw
cted agen
Prote AG.
and evaporator
1- Evaporator
2- Expansion valve
3- Valve for extracting, charging and measuring
4- Receiver with desiccant bag or cartridge
5- Condenser
6- Air conditioner compressor
Note
Arrows show direction of refrigerant flow

. Volkswagen AG
gen AG does
swa
Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo y V 2017 ➤ , Arteon 2018 ➤ , Atlas
olk not
gu 2 ...
b ara
Air conditioning systems with refrigerant R134arised
- General information - Edition 08.2019 nte
ho eo
aut ra
2.2.2 Refrigerant circuit with restrictor and ss c
ce
le
un
pt
reservoir
an
d
itte
y li
rm
ab
1- Air conditioner compressor
pe
ility
ot
wit
2- Condenser
, is n
h re
hole
3- Restrictor
spec
es, in part or in w
4- Evaporator
t to the co
5- Reservoir with desiccant cartridge
rrectness of i
Note
Arrows show direction of refrigerant flow l purpos
nform
mercia
a
com
ti
2.3 Evacuation and charging valves for
on in
r
te o
quick-release couplings of air condition‐
thi
s
iva
do
er service station on refrigerant circuit
r
rp
cum
fo
en
ng
t.
Special tools and workshop equipment required
yi Co
Cop py
ht. rig
♦ Torque wrench - V.A.G 1783- (2…10 Nm) with 1/4" ratchet rig ht
py by
adapter - VAS 6234-
co Vo
by lksw
cted agen
Prote AG.
CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
freezing.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.
• Only valves and connections resistant to R134a refrigerant

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

2.3.1 Evacuation and charging valve with

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

6234-
♦ Appropriate insert - T10364- to remove Schrader valve core
⇒ page 199
A - Service port (soldered in)

B - Valve core (2.4 ± 0.2 Nm)
C - O-ring (for the valve)
D - Sealing cap with seal
2.3.2 Extraction and charging valve, high-

pressure side
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS
a
♦ ss c
6234-
ce
le
un
pt
an
d
♦ Appropriate insert - T10364- to remove valve core

itte
y li
rm
ab
⇒ page 199
pe
ility
ot
wit
, is n
1- Base with external or internal thread

h re
hole
spec
2- Seal designation: black or colour-coded

es, in part or in w
t to the co
3- Valve with external thread and groove for seal (7 Nm)

rrectness of i
5- Cap
l purpos
2.3.3 Extraction and charging valve, low-pres‐

nform
ercia
sure side
m
a
com
tion in
r
Note
te o
thi
s
iva
do
r
♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS

rp
cum
fo
6234-
en
ng
t.
yi Co
op
♦ Appropriate insert - T10364- to remove valve core
C py
t. rig
gh
⇒ page 199
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1- Connection with external thread and groove for O-ring
3- Valve with external thread and groove for seal (7 Nm)
5- Cap

2.4 Switches and senders in refrigerant cir‐

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

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

system - F23- AG. Volkswagen A
agen G do
es n
Function: ksw
y Vol ot g
ua
b
ed ran
Switches radiator fan to next higher speed twhen ris pressure increa‐ tee
ho or
ses in refrigerant circuit (approx. 16 bar).au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.4.2 High-pressure switch for magnetic
rrectness of i
clutch - F118-
l purpos
Function:
nf
ercia
o
In the event of excess pressure in the refrigerant circuit, switches
rm
the air conditioner compressor off (at approx. 32 bar).
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.
2.4.3 Low-pressure switch for air conditioning

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

2.4.4 Connections with valve for switches in

refrigerant circuit
CAUTION
erant.
freezing.
– Wear protective gloves. n AG. Volkswagen AG do
wage es n
– Wear protective goggles. yV
olks ot g
d b ua
– Extract refrigerant and open the refrigerant circuit immedi‐ orise ran
tee
ately afterwards. auth or
ac
s
– If more than 10 minutes have passed since the refrigerant s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
• The switches on the high pressure and low pressure sides
h re
ole,
have different threads.
spec
• Only valves and O-rings resistant to R134a refrigerant and the
t to the co
related refrigerant oils may be used.
A - Connection (brazed)
rrectne
B - O-ring
s
C - Valve (with O-ring)
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
2.4.5 Air conditioning system pressure switch

t
sd
iva
o
pr
c
- F129-
um
r
fo
en
ng
t.
yi Co
This pressure switch has 3 functions: t. Cop py
rig
gh ht
1. Switches radiator fan to next higher speed when pressure in‐ pyri by
Vo
co
creases in refrigerant circuit (approx. 16 bar).
by lksw
cted agen
Prote AG.
2. Switches the air conditioning system off in the event of excess
pressure (approx. 32 bar) (e.g. because of lack of engine cooling).
3. Switches the air conditioning system off in the event of insuffi‐
cient pressure (approx. 2 bar) (e.g. because of loss of refrigerant).
Note
The air conditioning system pressure switch - F129- replaces the

high-pressure switch for air conditioning system - F23- , the low-
pressure switch for air conditioning system - F73- and the high-
pressure switch for magnetic clutch - F118- .

2.4.6 High-pressure sender - G65-

This high-pressure sender - G65- is fitted in placegof the
en AG. Vair
olkscon‐
wagen AG
does
ditioning system pressure switch - F129- . Volkswa not
g y ua
db ran
When voltage is applied to the high-pressure
ris
e
sender, it generates tee
a square wave signal, or data telegram.
utho This signal changes with or
a ac
the pressure in the system. ss
ce
le
un
pt
Using this signal, the control units that are connected in-line (ra‐
an
d
itte
diator fan control unit, engine control unit, operating and display
y li
rm
ab
unit for Climatronic air conditioning system - E87- or Climatronic
pe
ility
control unit - J255- etc.) calculate the pressure in the refrigerant
ot
wit
, is n
circuit and actuate the radiator fan, the engine, the air conditioning
h re
system magnetic coupling - N25- accordingly and/or alter actua‐
hole
spec
tion from the air conditioning system compressor regulating valve
es, in part or in w
- N280- .
t to the co
2.4.7 Refrigerant pressure and temperature
rrectness of i
sender - G395-
l purpos
CAUTION
nform
ercia

erant.
m
a
com
tio
n in
r
te o
freezing.
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Extract refrigerant and open the refrigerant circuit immedi‐ . Cop py
ately afterwards.
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
was extracted, repeat the extraction process before opening Prote AG.
This refrigerant pressure and temperature sender - G395- is fitted

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

2.4.8 Air conditioner compressor regulating

valve - N280-
The regulating valve is fitted to the air conditioner compressor. It
is activated by the operating and display unit for Climatronic air
conditioning system - E87- or the Climatronic AG. Vocontrol
lkswagenunit
A do
- J255-
The regulating valve influences the agen
pressure on the lowGpressure
es n
o lksw ot g
side and thus the temperature d b at the evaporator.
yV ua
r e an
ris tee
tho or
au ac
Note ss
ce
le
un
pt
an
d
The air conditioner compressor regulating valve - N280- is an in‐

itte
y li
erm
tegral part of the air conditioner compressor and cannot be re‐
ab
ility
newed individually on all air conditioner compressors ⇒
ot p
wit
Electronic parts catalogue .
is n
h re
ole,
spec
2.5 Electrical components not installed in
t to the co
refrigerant circuit
rrectne
2.5.1 Control and regulating unit for air condi‐
tioning system - J127-
ss o
cial p
f
The control and regulating unit switches off the flow of refrigerant
inform
via the 2nd evaporator if the temperature at the cooling ribs of the
mer
2nd evaporator drops to the freezing point for water (anti-freeze
atio
m
protection).
o
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.
2.5.2 Radiator fan control unit - J293-
Note
Available in various designs, sometimes separately.
This control unit switches the magnetic clutch and thus the air
conditioner compressor on and off. It controls the radiator fan, and
for vehicles with high-pressure sender - G65- or refrigerant pres‐
sure and temperature sender - G395- , it calculates the pressure
in the refrigerant circuit.

2.5.3 Radiator fan control unit - J293-
Note AG. Volkswagen AG d

agen oes
olksw not
Available in various ed designs,
by
V
sometimes fitted to the radiator
gu
ara fan
-arrows-. thoris nte
e or
au ac
ss
This control unit switches the magnetic clutch and thus the air
ce
e
nl
pt
conditioner compressor on and off. It controls the radiator fan, and
du
an
itte
for vehicles with high-pressure sender - G65- or refrigerant pres‐
y li
erm
ab
sure and temperature sender - G395- , it calculates the pressure
ility
ot p
in the refrigerant circuit.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.5.4 Temperature switch for evaporator -
nf
ercia
o
E33-
rm
m
atio
m
Function:
o
n in
or c
thi
e
The temperature switch for evaporator - E33- senses the tem‐

t
sd
iva
perature between the cooling fins of the evaporator. It prevents

o
r
rp
cu
the possibility of ice forming between the evaporator cooling fins

o
m
f
en
ng
by interrupting the current to the air conditioner compressor mag‐

t.
yi Co
op
netic clutch if the temperature at the fins falls to the freezing point C py
t. rig
of moisture in the air.
gh ht
pyri by
Vo
o
by c lksw
The insertion depth of the sensor tube is marked on the device or cted agen
Prote AG.
is given in the repair manual ⇒ Rep. gr. 87 .
2.5.5 Evaporator output temperature sender -

G263- or evaporator temperature sen‐
sor - G308-
Function:
The evaporator output temperature sender - G263- or evaporator
temperature sensor - G308- reads the temperature downstream
from the evaporator. This value is transmitted to the air condi‐
tioning system control unit and serves as a reference signal for
regulating the air conditioner compressor. This prevents icing of
the evaporator.
2.6 Pressures and temperatures in refriger‐

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

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

(e.g. ambient temperature, humidity, required cooling output).
In vehicles with air conditioner compressor regulating valve -
N280- , the pressure on the low-pressure side is varied by acti‐
vating the valve.
Therefore, the values given in the following tables may only be
considered as guidelines. They occur at an engine speed of 1,500
to 2,000 rpm and an ambient temperature of 20°C after about
20 minutes.
The locations of connections provided for pressure measure‐
ments are vehicle-specific.
⇒ Rep. gr. 87
At 20°C and with the engine stopped, the refrigerant circuit will
adjust itself to a pressure of 4.7 bar positive pressure ⇒ page 2 .
2.7 Refrigerant circuit with expansion valve

A- low-pressure side of the refrigerant circuit.
B- high-pressure side of the refrigerant circuit.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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.

Component Refrigerant Pressure (bar) Temperature in degrees

state Centigrade
-1- evaporator, from inlet to Vapour approx. 1.2 bar1) approx. -7°C2)
outlet
(approx. 1.8 bar)3) (approx. -1°C)3)
-2- Air conditioning system Gas approx. 1.2 bar1) approx. -1°C
compressor A-side
(approx. 1.8 bar)3) (approx. +1°C)3)
-3- Air conditioning system Gas approx. 14 bar approx. +65°C
compressor B-side
-4- Condenser Gas, vapour, approx. 14 bar at outlet approx. + 55°C
liquid
-5- Receiver Liquid approx. 14 bar approx. +55°C
-6- Extraction and charging Liquid approx. 14 bar approx. +55°C
valve, B side
-7- Expansion valve Liquid expan‐ approx. 14 bar approx. +55°C, reduced to
ded to vapour -7°C
-8- Extraction and charging Gas approx. 1.2 bar1) approx. -7°C2)
valve, A side
(approx. 1.8 bar)3) (approx. -1°C)3)
1) The pressure in refrigerant circuits with regulating air conditioner compressor is held to approx. 2 bar despite changing heat transport
and differing engine speeds. This applies however only within the rated range of the air conditioner compressor; if the rated range of the
air conditioner compressor is exceeded, the pressure will increase ⇒ page 155 .
2) The temperature in refrigerant circuits with regulating air conditioner compressor is held within the regulation range of the air conditioner
compressor despite changing heat transport and differing engine speeds. This applies however only within the rated range of the air
conditioner compressor; if the rated range of the air conditioner compressor is exceeded, the temperature will increase ⇒ page 155 .
3) Measured values for air conditioning systems with two evaporators
Note
. Volkswagen AG
gen AG
♦ Air conditioning system compressors thatVodo not self-regulate
a does
lksw not
their load are switched off by the respective
edb
y control unit via the gu
ara
air conditioner compressor regulating horis
valve - N280- when an nte
eo
evaporator temperature less than s aut 0°C is sensed. ra
c
s
♦ In vehicles with air conditioner compressor regulating valve -
ce
le
un
pt
N280- , the pressure on the low-pressure side is varied by

an
d
itte
y li
activating the valve.

erm
ab
ility
ot p
wit
2.8 Refrigerant circuit with restrictor and reservoir

is n
h re
ole,
spec
Arrows show direction of refrigerant flow

t to the co
A- low-pressure side of the refrigerant circuit.

B- high-pressure side of the refrigerant circuit.
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
33
by c lksw
cted
2. General information on refrigerant circuit
agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Component Refrigerant Pressure (bar) Temperature in degrees

state Centigrade
-1- Air conditioning system com‐ Gas up to 20 bar to +70°C
pressor B-side
-2- Condenser From gas to va‐ up to 20 bar to +70°C
pour to liquid
-3- Restrictor From liquid to B-side up to 20 bar, A-side B-side up to +60°C, A-
vapour greater than 1.5 bar side warmer than -4°C
-4- Evaporator From vapour to Greater than 1.5 bar Warmer than -4°C
gas
-5- Reservoir Gas
-6- Air conditioning system com‐ Gas
pressor A-side
The pressures on the A-side are held at approx. 2 bar by the
“regulating” air conditioner compressor even at differing engine
speeds. This applies however only within the rated range of the
air conditioner compressor; if the rated range of the air conditioner
compressor is exceeded, the pressure will increase
⇒ page 155 .

Note
In vehicles with air conditioner compressor regulating

wage
valve
n AG . Volks-wagen AG
does
N280- , the pressure on the low-pressure sidey Volksis varied by acti‐ not
gu
vating the valve. ise
d b ara
nt
r ee
ho
aut or
ac
ss
ce
le
un
pt
2.9 Test and measurement work that can be
an
d
itte
y li
rm
performed using a pressure gauge
ab
pe
ility
ot
wit
, is n
Indicated on pressure gauge
h re
hole
1- Temperature scale for refrigerant R134a CF3–CH2F or
spec
es, in part or in w
CH2F–CF3.
t to the co
2- Pressure scale
In addition to the pressure scale, the pressure gauges can have
rrectness of i
one or more temperature scales. The scale values for R134a are
assigned according to the vapour pressure table. Because differ‐
l purpos
ent refrigerants have different vapour pressures at the same

temperature, each temperature scale is labelled for the respective
nform
ercia
refrigerant.
m
a
com
tion in
r
te o
thi
2.9.1 Pressure gauges enable the following
s
iva
do
test and measurement work
r
rp
cum
fo
en
ng
t.
yi
a – Pressure and temperature measurement in the refrigerant cir‐
Co
op py
cuit t. C rig
gh ht
pyri by
♦ The high-pressure gauge allows the pressure and tempera‐
co Vo
by lksw
cted agen
ture to be measured with the air conditioning system switched Prote AG.
on irrespective of whether this is at the outlet of the air condi‐
tioner compressor through the condenser up to the restriction
(restrictor or expansion valve).
♦ The low-pressure gauge allows the pressure and temperature
to be measured with the air conditioning system switched on
irrespective of whether this is at the restriction (restrictor or
expansion valve) through the evaporator up to the inlet to the
air conditioner compressor.
Note
The relationship between pressure and temperature shown on

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

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

Note
The dependency between pressure and temperature described

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

equipment
AG. Volkswagen AG d
At present, various manufacturers offer air conditioner serviceksw
agen oes
not
stations on the market for evacuating, cleaning and charging
y Vol re‐ gu
db ara
frigerant in vehicle air conditioning systems. or
ise nte
th eo
au ra
2.10.1 Classification of extraction and charging ss c
ce
e
devices in groups
nl
pt
du
an
itte
y li
Group 3:
erm
ab
ility
ot p
Portable extraction and charging devices linking the air condi‐
wit
, is n
tioning system to a fixed compressed gas container.
h re
hole
spec
The fixed gas pressure vessel is charged with refrigerant or re‐
es, in part or in w
frigerant/oil mixture. The portable extraction and charging device
t to the co
is then permanently attached to the pressure vessel. In accord‐
ance with § 3 section 5 no. 3 of the Regulations for Pressure
Tanks, in this case the terms "compressed gas container" and
rrectness of i
"pressure tank" are equivalent.
l purpos
Charging devices require:

♦ no approval and testing by officially recognised experts, be‐
nform
ercia
cause the gas is filled into compressed gas vessels which are
m
equivalent to pressure vessels. (Devices for filling refrigerant
at
om
i
from these pressure tanks into compressed gas containers
on
c
in t
that are intended for third-party use, in turn, require licensing
or
his
e
and they are subject to checking by an authorised official.)

at
do
priv
cum
for
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
The air conditioner service and recycling devices used in vehicle p by
o Vo
by c
workshops are Group 3 extraction and charging devices which do
lksw
cted agen
Prote
not require a permit, but which can be operated only by skilled
AG.
staff. Instructions for the operation and service of the devices may
be found in the respective manufacturer's documentation.
2.10.2 Charging devices that do not require a

permit
Charging devices that do not require a permit are mobile charging
devices into which pressurised gases are charged into com‐
pressed gas containers for exclusive use of one company.
Note:
Some air conditioner service devices are charging devices that
do not require a permit. When working with such equipment, the
refrigerant is not transferred to mobile compressed-gas vessels,
but rather into a permanently installed charging cylinder with visi‐
ble level gauge and float switch.
Recommendation:
When surplus refrigerant is transferred for one's own require‐
ments, it is recommended that a portable charging cylinder with
visible level gauge and pressure relief valve be used.

Make sure to observe the corresponding technical rules (e.g.

TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRBS 3145/
TRGS 725) when handling compressed gases and, in particular,
when filling compressed gases from one compressed gas con‐
tainer into another one.
2.11 Notes to repairs on refrigerant circuit

Special tools and accessories
The performance of proper workmanlike repairs on an air condi‐
tioning system
• Special tools and materials are required; these are listed on
⇒ page 193 .
• The essential information on the leak detector should be re‐
ferred to ⇒ page 55 .
• Expert knowledge is necessary.
Note
Releasing refrigerant into the environment is not permitted

⇒ page 38 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

3 Legal texts and regulations
3.1 Laws and regulations
Note
♦ The laws and regulations listed below are valid in Germany.

Other or additional laws and regulations may apply in other
countries.
♦ Sources in other countries may be obtained from the respon‐
sible authorities.
The effects concerning the changingwaclimate

gen AG can be seen
. Volkswagen AG world-
does
wide. Protection of the climate yisVotherefore one of the most im‐
lks not
gu
portant roles of the human irace.
ed b
This role is a huge challenge for aran
rs
all concerned. ut
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The so called Kyoto Protocol
s defines, among other things, world-
ce
le
wide targets to protect the climate. This protocol defines apart

un
pt
an
d
from the reduction targets for carbon dioxide, the reduction tar‐
itte
y li
gets for fluoride containing greenhouse gases e.g. for refrigerant
rm
ab
pe
ility
R134a due to the high greenhouse potential.
ot
wit
, is n
Within Europe a large number of respective statutes exist for the
h re
hole
motor industry. In Germany, for example, the Climate Protection
spec
Regulation Concerning Chemicals (Chemikalien-Klimaschutz‐
es, in part or in w
verordnung) came into force from the 1st of August 2008 in

addition to European legislation. t to the co
♦ Regulation (EC) No. 1005/2009

rrectness of i

l purpos
♦ Regulation (EU) No. 517/2014

nform
ercia

m

com
tion in
♦ Directive 2006/40/EC
r
te o
thi
s
iva
do
♦ Climate Protection Regulation Concerning Chemicals (Chem‐

r
rp
cum
ikalien-Klimaschutzverordnung), Closed Substance Cycle

fo
en
g
Waste Management Law (Kreislaufwirtschaftsgesetz, KrWG)

n
t.
yi Co
Cop py
Maintenance and repairs to refrigerant circuits for air conditioning
t. rig
gh ht
yri
systems p by
co Vo
by lksw
cted agen
All personnel performing maintenance and repairs on air condi‐ Prote AG.
tioning systems for motorized vehicles must have attended the

respective training programme and have the appropriate knowl‐
edge (certified). Other legislation may apply outside the European
Union.
In general the following applies:
Operation, maintenance, decommissioning, duty to accept re‐
turned material
♦ It is prohibited to allow the release into the atmosphere of ma‐
terials contained in products containing refrigerants during the
operation, maintenance or removal from service of such prod‐
ucts.
♦ The quantities used during operation and maintenance work
should be documented (see Refrigerant Logbook, ⇒ Volks‐
wagen InfoNet, Service handbook; Environmental protection;
Environmental protection in the dealership and in the work‐
shop; Emission protection; Air contaminating substances, re‐

frigerant for vehicle air conditioning systems ) so that a proof

of use document is available for presentationgto the
AG. Vresponsi‐
olkswagen AG
ble authorities upon request. A record sheet a en does
olksw need no longer not
V
be kept within the EU due to respective d b European parliament
y gu
ara
rise
legislation from 2005. Other legislation may apply in countries nte
ho eo
not belonging to the EU. sa
ut ra
c
s
♦ Companies that sell materials and preparations listed in the
ce
le
un
pt
above mentioned legislation have a duty to accept returned
an
d
itte
y li
materials and preparations after they have been used, or to erm
ab
ensure that a specified third party will accept them.
ility
ot p
wit
is n
♦ Maintenance work and decommissioning of products that con‐
h re
tain refrigerant referred to in the above mentioned legislation.
ole,
spec
as well as the acceptance of returned substances and prepa‐
rations referred to in this legislation may only be carried out by
t to the co
persons who have the necessary specialist knowledge and
technical equipment.
rrectne
Offences and breaches of the regulations
♦ A person is in breach of the regulations and laws referred to if
ss
that person performs acts of wilful misconduct or negligence
o
cial p
f
when operating, performing maintenance work on or decom‐
inform
missioning products that contain the refrigerants referred to,
mer
contrary to the norms of technical practice, allows the sub‐
atio
m
stances contained in them to escape into the atmosphere or

o
n
c
wilfully or negligently breaches the applicable regulations and
i
or
n thi
e
laws mentioned above.

t
sd
iva
o
pr
c
um
r
fo
en
ng
TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS yi
t.
Co
3145) when handling compressed gases and, in particular, when t. Cop py
filling compressed gases from one compressed gas container into
rig
gh ht
yri by
another one. cop Vo
by lksw
cted agen
Prote AG.
Note
The following paragraphs are only extracts from the Technical

Rules for Hazardous Substances (TRGS) (relevant for automo‐
tive manufacturers and workshops).
♦ TRGS 400 (Risk assessment for activities involving hazardous

substances).
♦ TRGS 402 (Identification and assessment of the risks from
activities involving hazardous substances: inhalation expo‐
sure).
♦ TRGS 407 (Risk assessment for activities involving gaseous
substances).
♦ TRGS 510 (Storage of hazardous substances in non-station‐
ary containers).
♦ TRBS 3145/TRGS 725 (Non-stationary compressed gas con‐
tainers – charging, storage, in-house transportation, empty‐
ing).
3. Legal texts and regulations 39

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

nical Rules for Hazardous Substances (TRGS) and the Tech‐
nical Rules for Operational Safety (TRBS) reflect the state of
technology, occupational safety and health, occupational hy‐
giene as well as other definite knowledge relating to provision
and use of work equipment, operation of facilities requiring
supervision and activities involving hazardous substances.
♦ The technical rules stated here are valid in the Federal Re‐
public of Germany and do not necessarily reflect the rules and
regulations valid in other countries.

TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS
3145) when handling compressed gases and, in particular, when
filling compressed gases from one compressed gas container into
another one.
♦ Filling stations – general provisions.
♦ Terms and definitions.
♦ Filling stations – set-up and operation.
Filling stations
♦ This does not apply to vehicle manufacturers and workshops.
♦ Filling stations are systems for charging non-stationary
AG. Volkcom‐
swagen AG
agen does
pressed gas containers. A filling station comprises
Volksw its corre‐ not
sponding premises and equipment. ed by gu
ara
is nte
or eo
♦ Charging systems that require authorisation
au
th are charging sys‐ ra
tems which are filled with compressed
ss gases in mobile com‐ c
ce
pressed gas containers for transfer to other containers.

le
un
pt
an
d
itte
♦ Charging devices that do not require a permit are mobile

y li
rm
ab
charging devices into which pressurised gases are charged

pe
ility
into compressed gas containers for exclusive use of one com‐

ot
wit
, is n
pany.
h re
hole
Employees and instructing employees

spec
es, in part or in w
t to the co
Employees are to be instructed in the following points before be‐

ginning work as well as at regular, appropriate intervals, but at
least annually:
rrectness of i
• The particular hazards arising when handling compressed

gases;
l purpos
• The safety regulations, particularly the existing Technical

Rules for Hazardous Substances (TRGS) and the Technical
nform
ercia
Rules for Operational Safety (TRBS);

m
a
com
ti
• The actions to be taken in the event of defects, damage or

on in
accidents;
r
te o
thi
s
iva
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• The handing of fire extinguishers and protective equipment;

r
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cum
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• The operation and maintenance of filling stations, with partic‐

en
ng
t.
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ular reference to the user's manual.
Co
Cop py
ht. rig
Filling stations may be operated and maintained only by persons
rig ht
py by
o Vo
who by c lksw
cted agen
Prote AG.
• are at least 18 years of age;
• Possessing the necessary technical knowledge
• can be expected to fulfil their duties reliably.

Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo . V2017
olkswa➤
gen, AArteon 2018 ➤ , Atlas 2 ...
gen AG G do
Air conditioning systems with refrigerant
VolkR134a
swa - General information
es n - Edition 08.2019
ot
y gu
db ara
ise nte
Charging pressure tanks (for tanks from other tho countries,
r
other eo
technical rules that are not mentioned here
s au may apply). ra
c
s
ce
le
♦ A compressed gas container may be charged only with the
un
pt
an
d
compressed gas that is listed on its label, and only up to the
itte
y li
quantity indicated on the container in terms of pressure, weight
erm
ab
and volume (see Regulations for Pressure Tanks).
ility
ot p
wit
is n
♦ A container that can be used for different types of compressed
h re
ole,
gas must have a label on it listing the compressed gases with
spec
which it may be charged. If the compressed gas concerned
has a tc ≥ -10°C (tc = critical temperature), the max. permis‐
t to the co
sible charging weight in accordance with TRGS must also be
indicated on the container before it is connected for charging.
rrectne
♦ Gas pressure vessels for which the highest permissible
charge positive pressure at 15°C is given in bar must be
s
charged by pressure gauge. If during charging the tempera‐
s o
ture is different from 15°C, the pressure corresponding to the
cial p
f in
different temperature should be determined by the charging
form
mer
equipment; it must be ensured that the permissible overpres‐
atio
sure for charging at 15°C in the gas pressure vessel is not
om
n
exceeded. To determine possible overfilling, the charged ves‐
c
i
or
n
sels must be checked by way of random pressure measure‐
thi
te
sd
a
ments.
iv
o
pr
cum
r
fo
♦ Compressed gas containers on which the maximum permis‐
en
ng
t.
yi
sible charging quantity is indicated by the net weight (charged
Co
op py
weight, permissible weight of the contents) in kilograms must t. C rig
gh ht
be charged according to weight (gravimetrically). The vessels yri
p by
o Vo
are to be weighed during filling and subsequently subjected to
by c lksw
cted agen
a weight check on special scales to establish possible over‐
Prote AG.
filling. Scales used for this purpose must be calibrated.

♦ Under particular conditions, gases with tc ≥ +70°C from gas
pressure vessels of no more than 150 l volumetric contents
may be charged into a gas pressure vessel of no more than
1000 cc volumetric contents. The conditions of the TRGS ap‐
ply to charging mechanic's bottles with liquid gas.
♦ For vehicle containers, different TRGS apply:
– For gases with tc ≥ +70°C.
– For technical gas mixtures with tc ≥ +70°C.
– Liquid, deep-cooled compressed gases in variance to those
stated under item 4 may be charged by volume (volumetrical‐
ly), if the charging device and/or the container with equipment
is equipped with devices for measuring or limiting the volume
of the charge and (except vehicle containers as specified un‐
der item 3) for measuring the temperature of the charge. When
charging by volume it must be ensured that the permitted
charge weight shown on the container is not exceeded. To
determine possible overcharging, the charged containers are
to be checked gravimetrically on a calibrated scale or – provi‐
ded that the pressurised gases are not highly toxic – volumet‐
rically. Volumetric checking presupposes that the appropriate
equipment is in place; charging and checking equipment must
be independent of each other.
♦ The fill and check measurements must not be performed by
the same person. Check measurements must be performed
immediately upon conclusion of the filling process.
♦ Overfilled vessels must be discharged immediately and in a
safe manner down to the permissible fill quantity. Following
this, the quantity of compressed gas charged must be deter‐
mined once again.
♦ Some regulations of the TRGS 407 do not (fully) apply to con‐
tainers for liquid, deep-cooled compressed gases which are

neither flammable nor toxic; regulations for traffic law remain

unaffected.
♦ When gas pressure vessels are to be charged with gases in
the liquid state at charging temperatures ≤ -20°C, the gas
pressure vessel (if the vessel material is not tested for tem‐
peratures ≤ -20°C) must be released from the charging system en AG. Volkswagen AG
for transportation only when the vessel wall has achieved ksa
wag does
not
Vol
temperature ≥ +20°C. ed by gu
ara
ris nte
Converting R12 refrigerant circuits to R134a refrigerant
au
tho circuits eo
ra
and repairing them (retrofitting) ss c
ce
e
nl
pt
du
an
itte
y li
Note erm
ab
ility
ot p
♦ Due to the environmental situation and the consequent legis‐
wit
, is n
lation, refrigerant R12 is currently neither in production nor
h re
hole
available. Refrigerant R134a has been developed as a re‐
spec
placement for R12.
es, in part or in w
t to the co
♦ However, air conditioning systems developed and designed
for refrigerant R12 cannot simply be charged with refrigerant
R134a. To ensure trouble-free operation of the air conditioning
rrectness of i
system even after a retrofit, various components of the refrig‐
l purpos
erant circuit must be replaced.

♦ An exact description of the procedure for conversion and in‐
nform
ercia
structions for repair of converted refrigerant circuits can be

found in the ⇒ Repair manual for air conditioning systems with
m
at
refrigerant R12 parts 2 and 3 . This workshop manual is only
om
ion
available as a hard copy.
c
in t
or
his
ate
do
riv
Maintaining records on refrigerant

p
cum
for
en
g
According to the environmental statistics law, a record concerning

n
t.
yi Co
the use of refrigerants must be kept. t. Cop py
rig
gh ht
yri
Car manufacture and repair businesses must be prepared to fur‐ p by
co Vo
nish information concerning use of refrigerants to the statistical
by lksw
cted agen
Prote
office for the country in which the work is being performed. It is
AG.
therefore recommended to keep records of the amounts of refrig‐

erant handled during operation and maintenance (Refrigerant
Logbook) ⇒ Volkswagen ServiceNet, Environmental Protection;
Service handbook; Emission protection; Air contaminating sub‐
stances, refrigerant for vehicle air conditioning systems ) which
must be available for presentation to the responsible authorities
upon request.
Note
A record sheet need no longer be kept within the EU due to re‐

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

countries.
sible authorities.

Statutes and regulations concerning the use and disposal of re‐

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

machine oil
Refrigerant
Refrigerants intended for disposal are to be transferred to marked
recycling containers, observing the permissible filling quantity.
Observe, for example in the Federal Republic of Germany, the
Climate Protection Regulation Concerning Chemicals (Chemika‐
lien-Klimaschutzverordnung) and the Closed Substance Cycle
Waste Management Law (Kreislaufwirtschaftsgesetz, KrWG) (in
other countries other statutes and regulations may apply).
Refrigerant oil
Disposal of used oils: Volkswagen InfoNet; Operation; Hand‐
books & dealer literature; Handbook Service; 15. Environmental
protection; under general instructions follow the link “Environ‐
mental protection in the dealership and in the workshop”; 4.
Waste disposal; 6. Disposal channels; Disposal of used oils; Re‐
frigerant oils
Used refrigerant oils from systems with halogenated hydrocar‐
bons (at least one hydrogen atom has been replaced by e.g the
halogens fluorine, chlorine, bromine or iodine) must be disposed
of as waste requiring particular care. They are not to be mixed
with other oils or substances. Proper storage and disposal mustgen AG. Volkswagen AG d
a
be ensured in line with local regulations. Observe, for example Vol in
ksw
oes
not
gu
the Federal Republic of Germany, the Climate Protection ed by Regu‐ ara
nte
lation Concerning Chemicals (Chemikalien-Klimaschutzverord‐
horis
eo
aut
nung) and the Closed Substance Cycle Waste Management Law ra
s c
(Kreislaufwirtschaftsgesetz, KrWG) (in other countries
s
other stat‐
ce
e
nl
utes and regulations may apply).
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Reference sources for technical rules and safety at work/accident

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

R134a refrigerant circuits and repairing
them (retrofitting)
Note

countries. gen AG
. Volkswagen AG
d a oes
lksw not
♦ Sources in other countries may be obtained from the
db
respon‐
yV
o gu
ara
sible authorities. ris
e nte
tho eo
♦ Due to the environmental situation and the sconsequent
s legis‐ au ra
c
lation, refrigerant R12 is currently neither in production nor
ce
le
un
pt
available. Refrigerant R134a has been developed as a re‐
an
d
itte
placement for R12.
y li
erm
ab
ility
♦ However, air conditioning systems developed and designed
ot p
for refrigerant R12 cannot simply be charged with refrigerant
wit
is n
h re
R134a. To ensure trouble-free operation of the air conditioning
ole,
system even after a retrofit, various components of the refrig‐
spec
erant circuit must be replaced.
t to the co
♦ An exact description of the procedure for conversion and in‐
structions for repair of converted refrigerant circuits can be
found in the ⇒ Repair manual for air conditioning systems with
rrectne
refrigerant R12 parts 2 and 3 . This workshop manual is only
available as a hard copy.
ss o
cial p
f in
3.4 Maintaining records on refrigerant
form
mer
atio
om
n
c
i
Note
or
n thi
te
sd
iva

pr
cum
r
fo

en
ng
t.
countries.
yi Co
Cop py
t. rig
gh ht
pyri by
sible authorities.
o Vo
by c lksw
cted agen
Prote AG.
The quantities used during operation and maintenance work

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

4 Refrigerant circuit
wage es n
4.1 Important repair notes on air condition‐ olks ot g
byV ua
d ran
ing utho
ir se tee
or
s a ac
• Air conditioning systems designed for refrigerant R12 must not
s
ce
e
be charged with refrigerant R134a until specific conversion
nl
pt
du
an
measures have been performed ⇒ page 44 .
itte
y li
erm
ab
• The refrigerant oils specifically developed for R134a refriger‐
ility
ot p
ant circuits must never be mixed with the refrigerant oils spe‐
wit
cifically developed for R12 refrigerant circuits. , is n
h re
hole
spec
• Air conditioner service stations which come in contact with the
es, in part or in w
refrigerant must be used only for the intended refrigerant.
t to the co
• Components for R134a refrigerant circuits are identified by
lettering or a green label, or are so designed (e.g. with different
rrectness of i
threads), that they cannot be confused with components for
R12 refrigerant circuits.
l purpos
• Within the engine compartment, on the bonnet catch striker

plate or in the plenum chamber there is an information plate
nf
ercia
which states what refrigerant is used.
orm
m
atio
• Different refrigerants must never be mixed.
om
n in
or c
4.2 Converting refrigerant circuits from R12
thi
te
sd
iva
refrigerant to R134a
o
r
rp
cu
o
m
f
en
ng
Chlorofluorocarbon (CFC) is no longer used as a refrigerant in the

t.
yi Co
op
automotive sector.
C py
t. rig
gh ht
yri by
R12Converting refrigerant circuits from refrigerant R12 to refrig‐ cop Vo
by lksw
erant R134a and repairing the converted circuits.
cted agen
Prote AG.
⇒ Repair manual for air conditioning systems with refrigerant R12

parts 2 and 3 . This workshop manual is only available as a hard
copy.
4. Refrigerant circuit 45
5 Working with the air conditioner serv‐

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

stances (leak inhibitor additives) for purposes of sealing leaks
in refrigerant circuits. There are currently no permanent, ef‐
fective or material compatible tests that guarantee
. Volnever
kswagecaus‐
gen AG
ing damage or malfunctions in an airlkconditioning
n Gd
systemAor
swa oes
not
air conditioner service station. d by Vo gu
ar
e an
ris tee
♦ The leak inhibitor additivesuthcurrently
o available on the market or
have differing physical and
ss chemical characteristics that may
a ac
subsequently affect the function of the air conditioning system
ce
le
un
pt
and air conditioner service station or even cause a total failure.
an
d
itte
y li
♦ Volkswagen rejects the use of chemical substances for pur‐
erm
ab
ility
poses of sealing leaks in refrigerant circuits.
ot p
wit
is n
♦ Chemical substances used for sealing leaks in refrigerant cir‐
h re
ole,
cuits often react with the surrounding air and the humidity
spec
contained within. They cause deposits to build up in the re‐
t to the co
frigerant circuit (and your air conditioner service station),
valves to malfunction and defects in other components with
which they come into contact. These deposits cannot be com‐
pletely removed from the components.
rrectne
♦ It is often not possible to detect from the outside whether
s
chemical substances have been used to seal leaks in the re‐
s o
frigerant circuit. The adhesive label that serves to identify its
cial p
f in
use can usually not be found. Therefore, exercise caution on
form
mer
vehicles for which you have no service or repair record. atio

om
♦ Containers or tanks are offered as accessories on the open

n
c
i
or
market that are designed to separate these chemical substan‐

thi
te
ces (to seal leaks). Since Volkswagen rejects the use of these
sd
iva
o
r
substances, no statement can be made at this point regarding

p
cum
r
fo
the effectiveness and separation rate of these filters.

en
ng
t.
yi Co
Cop py
ht. rig
5.1 Important instructions for working with rig ht
py by
co Vo
the air conditioner service station
by lksw
cted agen
Prote AG.
• The fitted filter and dryer must be renewed at the latest when
the operational time specified in the related operating instruc‐
tions has been reached.
• Fill only with refrigerant oils which have been approved for the
vehicle-specific refrigerant circuit.
Refrigerant that has been extracted may not be reused, even after
cleaning within the station, in any of the following circumstances:
• If there is damage to the air conditioner compressor, such that
decomposition of the refrigerant due to overheating might
have occurred.
• If there are dark sticky deposits in the refrigerant circuit (these
can be detected only by opening up the system).
• If there is any doubt about the composition of the refrigerant
extracted from the refrigerant circuit.
In all of these circumstances the air conditioner service station
must be drained ⇒ page 48 , the system must be cleaned and
the filter, dryer and any filled refrigerant oil must be renewed.

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

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

. Volkswagen AG
tion for measuringolkand
swa testing
gen AG does
not
V gu
by ara
• Depending on the type of equipment
ris
ed chosen, there may be nte
variations in the required
aut procedure; therefore always follow
ho eo
ra
the user's manual forssthe equipment being used. c
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
Always follow the procedure described in the user's manual for
wit
is n
your air conditioning service station .
h re
ole,
spec
The charging hoses must only be connected according to the fol‐
t to the co
lowing work procedure to prevent air or moisture from entering
the refrigerant circuit:
rrectne
– Switch off ignition.
– Connect the air conditioner service station to the power sup‐
ss
ply.
o
cial p
f in
– Unscrew sealing caps from service station connections or
form
mer
from connections with valve (see vehicle-specific refrigerant

atio
m
circuit).
o
n
c
i
or
⇒ Rep. gr. 87
thi
te
sd
va
– Evacuate charging hose.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
o
by c
Connect the charging hose to the service connections of the re‐
lksw
cted agen
Prote
frigerant circuit using quick-release couplings.
AG.
NOTICE
Risk of damage to the air conditioner compressor or air condi‐
tioner service station.
Opening the valves with the air conditioning system switched
on can cause a short circuit between the high pressure and low
pressure side.
– Never open valves on the high pressure or low pressure side
with the air conditioning system switched on.
– Turn hand wheel into quick-release coupling adapter until the

valve in the service connection is definitely open (observe
pressure gauge; do not over-tighten valve).
– Start the engine and perform the planned tests and measure‐
ments.
5. Working with the air conditioner service station 47

– Compare determined values with specifications ⇒ page 155 .

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

conditioner service station .
• Depending on the type of equipment chosen, there may be
variations in the required procedure (always follow user's man‐
ual for the equipment being used).
• The refrigerant circuit must be discharged if parts of the re‐
frigerant circuit are to be removed, if there is any doubt about
the quantity of refrigerant in the circuit or if required by the
safety precautions.
• All operational instructions important for working with the air
conditioning service station for refrigerants can be found in the
air conditioning service station user's manual.
AG. Volkswagen AG d
Draining agen oes
olksw not
byV gu
ara
d
– Switch off ignition. orise nte
h eo
ut ra
– Connect the air conditioning service station to the service
ss a con‐ c
nections as described in the user's manual for the vehicle ⇒
ce
e
nl
pt
Rep. gr. 87 and start the service station.
du
an
itte
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erm
ab
ility
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Note
wit
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h re
hole
♦ Sometimes, refrigerant oil is extracted from the refrigerant cir‐
spec
cuit along with the refrigerant and there is no way of stopping
es, in part or in w
t to the co
this. To ensure lubrication of the air conditioner compressor,
the refrigerant oil quantity should be topped up with fresh oil
⇒ Rep. gr. 87 .
rrectness of i
♦ On vehicles with air conditioner compressor and no magnetic
coupling (with air conditioner compressor regulating valve -
l purpos
N280- ) the engine should only run for less than 10 minutes
with empty refrigerant circuit and closed refrigerant circuit (the
nform
ercia
air conditioner compressor runs with it continually). The en‐

gine speed must not exceed 2000 rpm.
m
at
om
io
♦ On vehicles with air conditioner compressor and magnetic
n
c
in t
r
coupling, the engine may be started as the air conditioning

o
his
te
system pressure switch - F129- or high-pressure sender -

a
do
riv
G65- (checks whether refrigerant is in the circuit) switches off

p
cum
or
the magnetic coupling as soon as there is no refrigerant in the

f
en
ng
t.
yi
refrigerant circuit.
Co
Cop py
ht. rig
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5.4 Evacuating refrigerant circuit using air
co Vo
by lksw
cted agen
Prote
conditioner service station
AG.
• Always follow the procedure described in the user's manual

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

Evacuating
NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty. AG. Volkswagen AG d
agen
– Never start theVoengine
lksw if the refrigerant circuit
oes
not is empty.
g
by ua
ed ran
oris tee
– Switchauoff
th ignition. or
ac
ss
– If necessary, check the refrigerant oil quantity in the refrigerant
ce
e
nl
pt
circuit; see vehicle-specific repair manual ⇒ Rep. gr. 87 .
du
an
itte
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erm
ab
ility
ply.
ot p
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– Check the refrigerant quantity in the air conditioning service
h re
hole
station .
spec
es, in part or in w
– Connect the charging hose of the air conditioning service sta‐
t to the co
tion to the vehicle refrigerant circuit using quick-release con‐
nector adapters (see vehicle-specific refrigerant circuit).
rrectness of i
⇒ Rep. gr. 87
l purpos
– Turn the handwheel of the quick-release coupling adapter far

enough inwards to ensure that the valves on the service con‐
nections are open (do not overstress the valve).
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
Where a vehicle has a service connection on only one side of the

do
riv
refrigerant circuit, if the system pressure has to be measured after

p
cum
for
charging, use the valve adapter and charging hose with valve
en
ng
t.
yi
opener.
Co
Cop py
ht. rig
rig ht
py by
– Check the vacuum phase in the air conditioning service sta‐
co Vo
by lksw
cted
tion . The refrigerant circuit will be evacuated automatically
agen
Prote AG.
(observe preset evacuation period).
When the vacuum phase has been completed, the leakage test
of the refrigerant circuit will start. The displays show the vacuum
in bar and the time in seconds.
If the vacuum is not maintained, proceed as follows:
– Check the vacuum phase in the air conditioning service station
again. The refrigerant circuit will be evacuated automatically
(observe preset evacuation period). Observe vacuum gauge
for a longer period. Only when a vacuum is maintained can
charging commence.
♦ If there is a leak so major that it causes air to escape to such
a degree during evacuation that the air conditioner service
station is incapable of generating a sufficient vacuum or the
vacuum gauge indicates immediately after switching off the air
conditioner service station that air has entered the system and
negative pressure is lost.
– Search for the leak in the refrigerant circuit as follows:
⇒ page 52
5.5 Filling refrigerant circuit with air condi‐

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

olkswagen AG
en AG. V
• The entire refrigerant charging quantity can
ksw
ag be introduced ei‐does
not
Vol
ther into the high-pressure or the
ed
blow-pressure side.
y gu
ara
ris nte
Charging refrigerant circuit aut
ho eo
ra
ss c
ce
e
nl
pt
du
an
– Evacuate the refrigerant circuit with the air conditioner service
itte
y li
station ⇒ page 48 .
erm
ab
ility
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– Unscrew handwheel on quick-release coupling adapter (to
wit
, is n
close).
h re
hole
spec
– Allow refrigerant to flow into charging hose.
es, in part or in w
t to the co
– Screw handwheel of quick-release coupling adapter inwards
(do not overstress the valve) and charge system with prescri‐
bed quantity of refrigerant.
rrectness of i
– Switch off air conditioning service station .
l purpos
Note
nf
ercia
orm
m
atio
If the air conditioner compressor was removed, the V-belt pulley /
om
freewheel must be turned by hand approx. 10 times prior to initial
n in
or c
operation. This does not apply for the electrical air conditioner
thi
te
compressor. This prevents any damage occurring from a fluid
sd
iva
o
r
hammer in the air conditioner compressor when the air condition‐

rp
cu
o
m
ing system is switched on for the first time. If there is oil in the
f
en
ng
t.
yi
cylinder of the air conditioner compressor, it will be forced out by
Co
op py
the rotation. t. C rig
gh ht
pyri by
Vo
o
by c lksw
– Start engine with air conditioner compressor switched off (ver‐
cted agen
Prote AG.
sion with magnetic clutch).
– Set air conditioner compressor to lowest possible setting; se‐
lect “ECON” mode or “A/C Off” (if version without magnetic
clutch but with regulating valve).
– Wait until idling speed has stabilised:
– Switch air conditioner compressor on and let system run for at
least 2 minutes with engine idling.
– If necessary, check the pressures in the refrigerant circuit, us‐
ing the air conditioning service station .
– Switch off engine.
– Turn out handwheel on quick-release coupling adapter.
– Detach the charging hose from the refrigerant circuit.
– Screw protective caps back on.
5.6 Bringing air conditioning system into

service after charging
Note
If the air conditioner compressor was removed, the V-belt pulley /

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

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

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

G. Volkswagen AG d
tioning
yV
service
olkswagen
station with refrigerant
oes
not
g
b ua
ed ra
• Always follow
ho
ris the procedure described in the user's manual
nte
eo
for your aair conditioning service station .
ut ra
c
ss
• A certain quantity of refrigerant is specified as charge for each
ce
e
nl
pt
du
air conditioning system. To ensure that the system is neither

an
itte
y li
overcharged nor undercharged with refrigerant (both circum‐

erm
ab
stances will impair the function of the air conditioning system),

ility
ot p
the refrigerant container is on a weighing machine.

wit
, is n
h re
5.8 Emptying air conditioner service station

hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ If it becomes necessary to drain the air conditioning service

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

the filters and dryers out of their airtight packaging until im‐
mediately prior to installation in order to keep moisture ab‐
nf
ercia
sorption (hygroscopic property) as low as possible.

rm
m
atio
m
♦ Refrigerant bottles filled with contaminated, used refrigerant

o
n in
c
are known as “recycling bottles”.

or
thi
te
sd
a
♦ Recycling bottles must be evacuated as a rule before being

iv
o
r
rp
cu
filled for the first time with refrigerant. Refrigerant bottles that
o
m
f
en
ng
have air in them must not be filled with refrigerant.

t.
yi Co
op py
♦ Different types of refrigerants must not be mixed with each
t. C rig
gh ht
yri
other. Mixed refrigerants cannot be processed for reuse. They
p by
co Vo
have to be disposed of. If there is any doubt about the com‐
by lksw
cted agen
Prote
position of the contents of the container, the refrigerant recy‐
AG.
cler is to be informed accordingly.

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

leak detection in the refrigerant circuit. These processes have
been tested and lead to a positive result under the different
conditions of use if the application is carried out correctly and
in accordance with the complaint.
♦ When leak detection using compressed air/nitrogen or vac‐
uum does not produce results, use electronic leak detector or
UV leak detector additive.
♦ Small leaks can be detected with, for example, an electronic
leak detector or a UV leak detector lamp.
♦ A wide range of processes are offered on the open market for
finding leaks in refrigerant circuits. These processes do not
always produce conclusive results. If they are not used pre‐
cisely according to the specifications, they may even cause
components of the refrigerant circuit to develop leaks where
there were none before. Furthermore, certain processes can
cause preliminary or permanent damage to the components
of the refrigerant circuit
♦ Components that are found to be leaking must not be repaired.
They have to be replaced with genuine parts.
♦ A leaking refrigerant circuit must not be charged with refriger‐
ant, therefore evacuate an empty refrigerant circuit and check
for leaks before charging the system with refrigerant
⇒ page 48 .
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV ua
♦ Volkswagen rejectsristhe
ed use of chemical substances for pur‐
b ran
tee
poses of sealinguthleaks in refrigerant circuits.
o
or
a ac
ss
ce
e
nl
pt
du
an

itte
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erm
ab
ility

ot p

wit
, is n
h re
pletely removed from the components (not even by flushing).

hole
spec

es, in part or in w
t to the co

vehicles for which you have no service or repair record.
rrectness of i
♦ Containers or tanks are offered as accessories on the open

l purpos
market that are designed to separate these chemical substan‐

ces (to seal leaks). Since Volkswagen rejects the use of these
nform
ercia
substances, no statement can be made at this point regarding

the effectiveness and separation rate of these filters.
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.

6.1 Leak detection in refrigerant circuit us‐

ing compressed air or nitrogen
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.
6. Detecting leaks in refrigerant circuit 53

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

by pressurising the circuit to a maximum of 15 bar using
cleaned and dried compressed air or nitrogen ⇒ page 63 . If
the leak is large, the leakage point can be detected by sound
as the air or gas escapes.
♦ Introduce the compressed air or the nitrogen through the serv‐
ice connection.
♦ The quick-release coupling adapter for service connection can
be fitted with a modified charging hose -A- (e.g. with a 5/8"-18
UNF thread, depending on the thread of the quick-release
coupling adapter) and a suitable adapter -B- to connect to the
workshop compressed air system ⇒ page 201 . To ensure that
no moisture, oil or dirt from the workshop compressed air sys‐
tem enters the refrigerant circuit of the air conditioning system,
use e.g. a combination fine filter unit for compressed air sys‐
tems with an oil, dirt and water separator, which is commonly
used in paint spraying facilities. Install this between the com‐ AG. Volkswagen AG d
pressed air system and the charge hose -A- ⇒ Workshop lksw
agen oes
not
equipment catalogue . db
y Vo gu
ar
e an
ris tee
♦ Using the manifold gauge with pressure reducer forutnitrogen
ho or
(maximum reduced pressure: 15 bar) -1- you canssconnecta a ac
gas cylinder -3- filled with nitrogen via a charging hose -2- (e.g.
ce
e
nl
pt
with 5/8"-18 UNF threaded connection) to the service connec‐
du
an
itte
tion (to which a quick-release coupling adapter is connected)
y li
erm
ab
of the closed refrigerant circuit. ⇒ page 201
ility
ot p
wit
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– Slowly increase pressure in refrigerant circuit to a maximum
h re
hole
of 15 bar.
spec
es, in part or in w
t to the co
CAUTION
Risk of injury from nitrogen escaping under high pressure.
rrectness of i
– Use pressure limiter for nitrogen tank.
l purpos
– Search for leak by sound, which is created by the escaping

gas. Use Ultrasonic tester - V.A.G 1842- to ease localisation
nform
ercia
of sounds.
m
at
om
– Press nitrogen out of refrigerant circuit using cleaned and ion

c
dried compressed air. Nitrogen must not enter the service cyl‐
in t
or
inder. This prevents the service cylinder from being filled with
his
ate
condensible gases.
do
priv
cum
or
– Rectify leak.
f
en
ng
t.
yi Co
op
– Evacuate again and observe the vacuum display over a period
C py
t. rig
gh
of hours. Only when a vacuum is maintained can charging
ht
pyri by
Vo
commence.
co lksw
by
cted agen
Prote AG.
♦ If a leak is present of a size where no or very little air is drawn
in and the air conditioning service station can create sufficient
vacuum. The vacuum gauge does not increase or increases
very slowly after switching the air conditioner service station
off. This indicates that there may be a very small ingress of air
and the vacuum is lost.
– Charge circuit with 100 g of refrigerant and search for the pos‐
sible leak using an electronic leak tester and rectify fault as
necessary ⇒ page 55 or add an approved UV contrast sub‐
stance to the refrigerant and search for the possible leak in the
circuit using leak detector system VAS 6201 or later model and
rectify fault as necessary ⇒ page 55 .
– Evacuating refrigerant circuit if necessary ⇒ page 48

– Evacuate refrigerant circuit and observe the vacuum gauge

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

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

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

⇒ page 48 .
wage
Note yV
olks es n
ot g
d b ua
ran
ir se tee
♦ If a larger leakuthis detected during the evacuation process, de‐
o
or
termine causess and rectify as described ⇒ page 48 .
a ac
ce
e
nl
♦ If during the evacuation process no leak is detected or a very
pt
du
an
small leak is detected that but cannot be located, proceed as
itte
y li
erm
follows ⇒ page 53 .
ab
ility
ot p
♦ Refrigerant gas is quickly dispersed by movement of air.
wit
, is n
Draughts must therefore be avoided during leak detection.

h re
hole
spec
♦ If the refrigerant circuit is completely empty, charge with about
es, in part or in w
10% of refrigerant capacity (sticker R134a or vehicle-specific t to the co

workshop manual). rrectness of i
Leak search:
l purpos
– Start the leak detector according to the operating instructions.

– Always hold probe tip under location of suspected leak.
nf
ercia
If clicking rate increases or a warning tone sounds (depends on

rm
m
model), this indicates that the leak has been located (refer to op‐
atio
om
erating instructions for leak detector).

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.
6.3 Detecting leaks in refrigerant circuit us‐

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

tector additive.

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

⇒ page 48 .
Note
♦ If a larger leak is detected during the evacuation process, de‐

termine cause and rectify as described ⇒ page 48 .
♦ If during the evacuation process no. Vleak
gen AG
olkswis
agedetected
n AG d or a very
small leak is detected thatolks but cannot be located, proceed
wa oes
not as
follows ⇒ page 53 e. d by V gu
ara
is nte
or
♦ Refrigerant gas
au is quickly dispersed by movement of air.
th eo
ra
Draughts must
ss therefore be avoided during leak detection. c
ce
le
un
pt
♦ If the refrigerant circuit is completely empty, charge with about
an
d
itte
10% of refrigerant capacity (sticker R134a or vehicle-specific
y li
erm
ab
workshop manual).
ility
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wit
is n
Leak detecting system - VAS 6196-
h re
ole,
spec
or
t to the co
Leak detecting system - VAS 6201- or later model
1- Hand pump with low-pressure service hose, service cou‐
rrectne
pling and non-return valve - VAS 6201/1-
s
2- Cartridge - VAS 6201/2-
s o
cial p
f
3- Cleaning agent - VAS 6201/3-
inform
mer
4- UV leak detector lamp - VAS 6201/4-

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

c
i
or
n thi
te
6- Stickers - VAS 6201/7-

sd
iva
o
pr
cum
r
7- Tube
fo
en
ng
VAS 6201 8
t.
yi Co
Cop py
t.
8- Safety gloves - VAS 6201/9-
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pouring in leak detection additive with refrigerant circuit empty

The cartridge -A- contains 15.4 ml of leak detecting additive (one
unit -B- equates to 2.5 ml).

– Assemble hand pump - VAS 6201- item -1- and cartridge item
-2- -VAS 6201/2- .
– Connect filler hose - VAS 6201/8- ( ⇒ page 56 item -7-) to hand
pump.
– Open service valve of hand pump.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

When the refrigerant circuit is empty, the leak detection additive

can best be poured in via an open connection.
– Open the refrigerant circuit at a readily accessible connection.
– Cover the surrounding area with sheeting or absorbent paper.
– Hold tube upwards.
– Turn T-bar of hand pump until the leak detecting additive flows
out of the tube.
– Inject 2.5 ± 0.5 ml (millilitre = cm3) of leak detecting additive
into the refrigerant circuit.
Note
Note the following, if a leak detecting additive has been injected

during a previous repair of the refrigerant circuit, only inject new
leak detecting additive if the refrigerant machine oil has been re‐
placed. If only some of the refrigerant machine oil was replaced
then only the respective amount of leak detecting additive should
be injected. If for example 100 ml of machine oil was replaced on
a vehicle with 250 ml of refrigerant machine oil, inject only 1 ml
(cm3) of leak detecting additive.
– Renew O-rings at opened connection.

– Assemble refrigerant circuit.
– Attach a label, close to the service connection, which has in‐
formation showing that the refrigerant circuit has been injected
with a leak detecting additive.
– Evacuate and fill the refrigerant circuit as per specifications
⇒ page 48 and ⇒ page 49 .
– Start air conditioning system.
lkswage es n
o ot g
yV
Note ir se
d b ua
ran
o tee
th or
u
The air conditioning system
ss
a
must be operated for at least 60 mi‐ ac
nutes to ensure that the injected leak detecting additive is distrib‐
ce
le
un
pt
uted throughout the entire refrigerant circuit (air conditioner

an
d
itte
compressor must run). The leak may become visible after a short
y li
erm
ab
period, but this depends on the size of the leak.

ility
ot p
wit
is n
– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
h re
ole,
erant circuit ⇒ page 60 .

spec
t to the co
Note
rrectne
Using cleaning solution - VAS 6201/3- , clean the engine com‐

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

Pouring in leak detection additive with refrigerant circuit charged
Note
wage es n
♦ Note the following, if a leak detecting additive has been injec‐ yV
olks ot g
ted during a previous repair of the refrigerant circuit, only
ir se inject
d b ua
ran
new leak detecting additive if the refrigerant machine th oil has
o tee
or
been replaced. If only some of the refrigerant machine
ss
au
oil was ac
replaced then only the respective amount of leak detecting
ce
e
nl
additive should be injected. If for example 100 ml of machine
pt
du
an
oil was replaced on a vehicle with 250 ml of refrigerant ma‐
itte
y li
erm
ab
chine oil, inject only 1 ml (cm3) of leak detecting additive.
ility
ot p
wit
♦ A small amount of leak detecting additive remains in the serv‐
, is n
h re
ice connection. This is to be carefully removed so as to avoid
subsequent erroneous leak detection. hole
spec
es, in part or in w
t to the co
The cartridge -A- contains 15.4 ml of leak detecting additive (one
unit -B- equates to 2.5 ml).
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Switch off ignition. t. C rig
gh ht
pyri by
– Remove sealing cap from service connection on low-pressure
co Vo
by lksw
cted
side of refrigerant circuit.
agen
Prote AG.
– Assemble hand pump - VAS 6201- item -1- and cartridge item
-2- -VAS 6201/2- .
Note
Ensure the hose of the hand pump is completely filled with leak
detecting additive.
– Fit the quick release coupling to the service connection of the

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

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

wage es n
– Close the service coupling and remove it from the service y Volks ot g
ua
connection. ris
ed
b ran
tee
tho or
– Remove the remains of the leak detecting additive from
au the ac
ss
service connection, with for example, absorbent paper.
ce
e
nl
pt
du
– Seal service connection using sealing cap.
an
itte
y li
erm
ab
– If necessary, use cleaning agent to clean area around service
ility
ot p
connection.
wit
, is n
h re
– Attach a label, close to the service connection, which has in‐
hole
spec
formation showing that the refrigerant circuit has been injected
es, in part or in w
with a leak detecting additive.
t to the co
– Start air conditioning system.
rrectness of i
Note
l purpos
The air conditioning system must be operated for at least 60 mi‐
nf
ercia
nutes to ensure that the injected leak detecting additive is distrib‐
o
uted throughout the entire refrigerant circuit (air conditioner
rm
m
atio
compressor must run). The leak may become visible after a short
om
period, but this depends on the size of the leak.
n in
or c
thi
te
sd
iva
– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
Note
gh ht
pyri by
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co lksw
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cted agen
Using cleaning solution - VAS 6201/3- , clean the engine com‐
Prote AG.

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

6196/4
CAUTION
Risk of eyes being dazzled by UV light.
– Never glare into the UV lamp.
– Never point a UV lamp at another person.

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

60 minutes to ensure that the injected leak detecting additive
is distributed throughout the entire refrigerant circuit (air con‐
ditioner compressor must run). The leak may become visible
after a short period, but this depends on the size of the leak.
♦ In the event of leaks at the evaporator, the additive may be
washed out with the condensate and emerge via the conden‐
sate drain. As the evaporator is not accessible on the majority
of models without a great amount of pre-preparation, a check
of the condensed water drain point can indicate a leaking
evaporator. The additive must have been in the refrigerant cir‐
cuit for a long time to make this possible.
♦ The protective goggles are not only designed to provide eye
protection. They also make the additive more readily visible
under UV light.
♦ Independent of the accessibility to the various components of agen AG. Volkswagen AG do
the refrigerant circuit, it may become necessary to remove Vol
ksw es n
ot g
certain components from the vehicle (e.g. bumper orisair
ed byfilter). ua
ran
r tee
ho
aut or
ac
ss
– Move vehicle to a poorly lit area of the workshop (daylight or
ce
le
un
pt
bright artificial lighting diminishes the effect of the UV light).
an
d
itte
y li
– Check the accessibility to the various components of the re‐
rm
ab
pe
ility
frigerant circuit and remove components in the vicinity of the
ot
refrigerant circuit that obstruct the view of the respective circuit
wit
, is n
h re
components (e.g. sound insulation and bumper).
hole
spec
– Protect eyes with protective glasses.
es, in part or in w
t to the co
– Connect UV lamp to a 12 V battery (vehicle battery). Take care
to ensure correct polarity.
rrectness of i
– Switch on UV lamp and illuminate components of refrigerant
circuit. Positions at which refrigerant - along with refrigerant oil
l purpos
and leak detection additive - can leak out fluoresce (light-up)

under UV light.
nform
mercia
a
Note
com
tion in
r
te o
thi
♦ The leak detection additive can be allowed to remain in the
s
iva
do
r
rp
cum
fo
♦ Using cleaning solution - VAS 6201/3- , clean the engine com‐

en
ng
t.
yi
Co
op py
circuit, to remove leak detection additive residue left from the t. C rig
gh ht
repair work. pyri by
Vo
co lksw
by
cted agen
Prote AG.

7 Clearing refrigerant circuit of contam‐

inants
⇒ “7.1 Vehicles with high-voltage system (hybrid vehicles)”, page
62
⇒ “7.2 Blowing through refrigerant circuit with compressed air and
nitrogen”, page 63
⇒ “7.3 Flushing refrigerant circuit with refrigerant R134a”,
page 65
7.1 Vehicles with high-voltage system (hybrid vehicles)

Danger to life from high voltage
The high-voltage system is under high voltage. Damage to high-
voltage components can result in severe or fatal injury from
electric shock.
– Perform visual check of high-voltage components and high-
voltage cables.
– Never use cutting or forming tools, or any other sharp-edged
tools.
– Never use heat sources such as welding, brazing, soldering,
hot air or thermal bonding equipment.
If repair work in the vicinity of high-voltage components and ca‐

bles is necessary, carry out a visual check for damage on high-
voltage components and cables ⇒ Electrical system; Rep. gr.
93 ; General warning instructions for work on the high-voltage
system .
If repair work on high-voltage components is necessary, de-en‐
AG. Volkswagen
ergise the high-voltage system ⇒ Electrical system; kswagenRep. gr. 93 ; AG does
not
De-energising high-voltage system , and b“observe
yV
ol the general gu
ara
warning instructions for work on the high-voltage
rise
d
system” ⇒ Elec‐ nte
trical system; Rep. gr. 93 ; General autwarning instructions for work
ho eo
ra
on the high-voltage system . ss c
ce
le
un
pt
an
d
itte
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Note
erm
ab
ility
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wit
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poses of sealing leaks in refrigerant circuits.

h re
ole,
spec

t to the co

rrectne

s
The refrigerant circuit can only be repaired by replacing all

s o
cial p
components that have come into contact with this substance.

inform
mer

atio

om

c
i
or

thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
• In order to remove dirt (e.g. abraded matter from a defective

t.
yi Co
op
air-conditioning compressor) as well as old refrigerant oil as C py
t. rig
gh ht
pyri by
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co lksw
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cted agen
62
Prote AG.
cleanly as possible and with as little work as possible, rinse

the refrigerant circuit with R134a refrigerant.
On vehicles with electrical air conditioner compressor, observe
the notes on renewing the electrical air conditioner compressor -
V470-. If the electronics of the air conditioner compressor are
damaged, the refrigerant circuit must not always be cleaned
⇒ page 188 .
7.2 Blowing through refrigerant lcircuit

ksw
agen with
AG. Volkswagen AG d
oes
not
compressed air and nitrogen Vo gu
d by ara
se n i
or tee
• Use compressed air to force moisture au and other contaminants
th or
ac
out of the refrigerant circuit and use
s nitrogen to force moisture
s
ce
le
out of the refrigerant circuit.
un
pt
an
d
itte
• The method of blowing through the refrigerant circuit with
y li
rm
ab
compressed air and nitrogen often requires a lot more work
pe
ility
than purging with refrigerant R134a. When purging with re‐
ot
wit
, is n
frigerant R134a, cleaning of the components is considerably
h re
better. It is therefore always best to purge the system in the
hole
spec
event of complaints (the method of blowing through should
es, in part or in w
only be selected for certain complaints and for individual com‐
t to the co
ponents).
Only individual components are to be blown through if:
rrectness of i
♦ There is no way of purging the refrigerant circuit with refriger‐
l purpos
ant R134a.
♦ If there is dirt or contamination in individual components of the
nform
ercia
m
a
♦ If during evacuation of a leak-tight refrigerant circuit the vac‐
com
tio
uum display is not constant on gauge (moisture in the refrig‐
n in
r
te o
erant circuit, which generates vapour pressure).
thi
s
iva
do
♦ If the refrigerant circuit has been left open for longer than nor‐
r
rp
cum
fo
mally required for repairs (e.g. following an accident).

en
ng
t.
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op
♦ Pressure and temperature measurements in the circuit indi‐ C py
t. rig
cate that there is moisture in the refrigerant circuit.
gh ht
pyri by
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o
by c lksw
♦ The vehicle-specific repair manual ⇒ Heating, air conditioning Prote
cted AG.
agen
deems it necessary after replacement of certain components.
Note
♦ Blowing through the refrigerant circuit with compressed air and

nitrogen will not achieve the same degree of cleanliness as
purging with refrigerant R134a. When purging with refrigerant
R134a, the refrigerant oil is shifted and cleaning of the com‐
ponents is better ⇒ page 65 .
♦ When blowing through, a maximum working pressure of 15 bar
must not be exceeded (if necessary, use pressure limiter for
compressed air as well).
CAUTION
Risk of injury from nitrogen escaping under high pressure.
– Use pressure limiter for nitrogen tank.
– Always flush components in direction opposite to refrigerant

flow.
Compressed air and nitrogen cannot be blown through the re‐
strictor, expansion valve, air conditioner compressor, receiver or
reservoir.
7. Clearing refrigerant circuit of contaminants 63

– In cases where condensers have a drying agent cartridge in

the integrated receiver, this drying agent cartridge must be re‐
moved.
– First blow out soiling using compressed air and then dry com‐
ponents with nitrogen.
– Fit adapter for connection of pressure hose to refrigerant cir‐
cuit ⇒ page 82 and ⇒ Heating, air conditioning .
To prevent oil and moisture from the compressed air system
making its way into the refrigerant circuit, the following points must
be observed.
♦ The compressed air must be fed through a compressed air gen AG
. Volkswagen AG
does
swa
cleaning unit to clean and dry it. Therefore, use compressed yV
olk not
gu
air filter and dryer (included in items supplied with risedtools for
b ara
nte
painting work) ⇒ Workshop equipment and Special ut
ho tools cata‐ eo
ra
logue . ss a c
ce
le
♦ If refrigerant pipes have threads or union nuts at connections,

un
pt
an
d
use adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- to

itte
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connect to 5/8" - 18 UNF charging hose. These adapters can
erm
ab
ility
be found in the adapter case for VW/Audi passenger vehicle
ot p
wit
set - VAS 6338/1- and adapter case for commercial vehicle
is n
h re
set - VAS 6338/50- .
ole,
spec
♦ On refrigerant pipes with no thread or union nut on the con‐
t to the co
nection, use adapter from adapter case for VW/Audi passen‐
ger vehicle set - VAS 6338/1- or adapter case for commercial
vehicle set - VAS 6338/50- or commercially available air blow
gun with rubber nozzle.
rrectness
Note
o
cial p
f inform
♦ Always extract any escaping air and/or nitrogen from the com‐
mer
atio
ponents using appropriate local exhaust ventilation LEV (e.g.
om
workshop extraction system).
n
c
i
or
n thi
e
♦ Certain contaminants and old refrigerant oil cannot be shifted

t
sd
va
from the refrigerant circuit at all with compressed air or if the

i
o
pr
cum
r
compressed air is insufficient. These contaminants can only

fo
en
ng
be removed by purging with refrigerant R134a ⇒ page 65 .

t.
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Cop py
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rig ht
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cted agen
Prote AG.

7.2.1 Flushing refrigerant circuit
Note
♦ On vehicles where no adapters fit the refrigerant pipes, blow

through individual components using, for example, an air blow
gun with rubber nozzle. When doing this, be particularly care‐
ful not to damage the connections (do not crush or scratch
them).
♦ The evaporator should be blown through from the connection
to the low pressure side (large diameter), with the expansion
valve or restrictor removed.
♦ Always flush components in direction opposite to refrigerant
flow.
♦ Examine the expansion valve; renew if dirty or corroded.
♦ Replace any components on which dark, sticky deposits can‐
not be removed with compressed air.
♦ Thin, light grey deposits on the insides of refrigerant pipes do
not impair the function of the components.
♦ After blowing out the system, always renew the receiver or
reservoir and the restrictor. If the condenser has a dryer, re‐
new the dryer cartridge or adryer.
gen AG
. Volkswagen AG
do w es n
olks ot g
byV ua
7.3 Flushing refrigerant circuit with refriger‐
ed ran
ris tee
tho or
ant R134a
ss
au ac
ce
le
un
pt
⇒ “7.3.1 Principle circuit diagrams for various purging circuits”,

an
d
itte
page 73
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rm
ab
pe
ility
⇒ “7.3.2 Purging electrical air conditioner compressor”,

ot
page 78
wit
, is n
h re
hole
⇒ “7.3.3 Adapters for setting up flushing circuits”, page 82

spec
es, in part or in w
The refrigerant circuit must be flushed with refrigerant R134a if

t to the co
♦ Dirt or other contaminants are in the refrigerant circuit.

♦ If during evacuation of a leak-tight refrigerant circuit the vac‐
rrectness of i
uum display is not constant on gauge (moisture in the refrig‐

l purpos

nform
ercia

m
♦ Pressure and temperature measurements in the refrigerant

com
tio
circuit indicate that there is moisture in the refrigerant circuit.

n in
r
te o
thi
♦ There is doubt about the amount of refrigerant oil in the refrig‐

s
iva
do
erant circuit. If the air conditioner compressor is to be reinstal‐

r
rp
cum
led, drain refrigerant oil out of air conditioner compressor via

fo
en
ng
the block connections. To facilitate this process, turn the air

t.
yi Co
op
conditioner compressor over by hand at the poly V-belt pulley
C py
t. rig
gh
or coupling disc of the magnetic coupling. After purging, fill
ht
pyri by
Vo
refrigerant circuit with total amount of refrigerant oil (50 g direct
co lksw
by
cted agen
into air conditioner compressor) according to ⇒ vehicle-spe‐ Prote AG.
cific workshop manual . Take account of oil volume for
2nd evaporator system.
♦ The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
♦ If it is required by the workshop manual for the specific vehicle
following the renewal of certain components.

. Volkswage
AG n AG d
agen oes
olksw no
♦ a different air conditioner compressor
d by V with other refrigerant oil t guar
is to be fitted. ris
e an
tee
utho or
Tools required ss
a ac
ce
le
♦ Air conditioner service station with purging device or air con‐ un
pt
an
d
ditioner service station with purging device - VAS 6337- .
itte
y li
erm
These air conditioner service stations feature an additional
ab
ility
function for “purging the refrigerant circuit with R134a” and the
ot p
wit
purging device for refrigerant circuits necessary for this pro‐
is n
h re
cedure ⇒ Workshop equipment and special tools catalogue .
ole,
spec
♦ Adapter case VW/Audi passenger vehicle set - VAS 6338/1-
t to the co
⇒ page 82 and ⇒ Workshop equipment and special tools
catalogue .
♦ Adapter case commercial vehicle set - VAS 6338/50-
rrectne
⇒ page 82 and ⇒ Workshop equipment and special tools
catalogue .
ss o
cial p
f inform
Note
mer
atio
m
♦ If you do not have either of the two air conditioner service sta‐
o
n
c
i
tions indicated above, you can also rinse the refrigerant circuit
or
n thi
e
with the air conditioner service station you do have if the sta‐
t
sd
iva
o
tion is of the right type (at least 7 kg of R134a refrigerant in the
pr
cum
r
fo
refrigerant bottle) by using the flushing device for refrigerant
en
ng
t.
circuits - VAS 6336/1- or flushing device for refrigerant circuits
yi Co
op
- VAS 6337/1- . The purging process must then be carried out
C py
t. rig
gh
manually ⇒ page 71 .
ht
pyri by
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co lksw
by
♦ On vehicles with threaded connections on the refrigerant cir‐
cted agen
Prote AG.
cuit, adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- from
adapter case VW/Audi passenger vehicle set - VAS 6338/1-
or adapter case commercial vehicle set - VAS 6338/50- can
be used. On vehicles with threaded connections on the air
conditioner compressor and on the reservoir, the adapter -
V.A.G 1785/8- is required two-fold.
♦ In the adapter case there is also a charging hose - VAS
6338/31- with 5/8 - 18 UNF connections and large internal di‐
ameter to bridge components (commercially available type).
Preparations
– Drain refrigerant circuit ⇒ page 48 .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing .
On vehicles with restrictor and reservoir.
– Remove restrictor (vehicle-specific) and join the refrigerant
lines together again ⇒ Heating, air conditioning .
– Remove reservoir (vehicle-specific) ⇒ Heating, air condition‐
ing and join refrigerant pipes together again (to do this, use
adapter and charging hose - VAS 6338/31- from adapter case
VW/Audi passenger vehicle set - VAS 6338/1- )
⇒ page 82 .
Note
The collector could be purged but due to its large inner volume it
would require too much refrigerant. During extraction, the refrig‐
erant ices up the reservoir heavily and the extraction procedure
takes much longer as a result.

On vehicles with expansion valve and receiver

– Remove the receiver ⇒ Heating, air conditioning (vehicle-
specific, not necessary on all vehicles) and join the refrigerant
lines together (use the adapter and the charging hose - VAS
6338/31- to do this) ⇒ page 82 .
– Remove the expansion valve ⇒ Heating, air conditioning (ve‐
hicle-specific) and insert an adapter in its place ⇒ page 82 .
Note
G. Volkswagen AG d
If there is not a suitable adapter for the expansion valve inlksthe
wage
nA oes
not
adapter case VW/Audi passenger vehicle set - VAS d6338/1- by
Vo
or gu
ara
adapter case commercial vehicle set - VAS 6338/50- oris , the re‐
e nte
moved expansion valve can also be drilled out (theau old expansion
th eo
ra
valve must be subsequently renewed). ss c
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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wit
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♦ Disregard item -3-.
h re
hole
spec
♦ When drilling out, ensure that the flow holes -2- and -4- in the
es, in part or in w
expansion valve -1- are located offset to each other.
t to the co
♦ Failure to observe this measure can result in the sealing sur‐
face on the expansion valve -1- becoming damaged when
rrectness of i
drilling, thereby rendering the expansion valve useless for set‐
ting up the flushing circuit.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

expansion valve.
♦ There are two types of expansion valve. For type -A-, parts
-B-, -C- and -D- must be removed. Now separate part -E- from
control element -D-. Then drill out the expansion valve in area
-F- using a suitably sized drill bit (6 mm in diameter).
♦ On version -G-, parts -H-, -I- and -K- must be removed and
then area -L- drilled out with a suitably sized drill bit (6 mm in
diameter).
♦ Clean away any swarf from the drilled out expansion valve.
♦ Reinstall parts -B-, -C- and -D- on type -A- or part -H- on type
-G-.
Note
On vehicles with two evaporators, the circuit to the second evap‐

orator must be isolated from the circuit to the first evaporator and
purged in a separate procedure ⇒ Heating, air conditioning and
⇒ page 82 .
AG. Volkswagen AG d
agen oes
lksw not
Drill open shut-off valve. by Vo gu
ara
d
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
Vo ot g
Amarok d 2011 ➤ , Amarok 2017 ➤ , Ameo 2017
by ua
ran ➤ , Arteon 2018 ➤ , Atlas 2 ...
ir se
Air conditioning
tho systems with refrigerant R134a - General tee
orinformation - Edition 08.2019
au ac
ss
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Two shut-off valves are required for purging the refrigerant
ot
wit
circuit. A shut-off valve must be drilled open, if no shut-off tap
, is n
h re
- VAS 6338/42- is available, for example.
hole
spec
♦ Remove the solenoid -A- and the solenoid valve -B- before
es, in part or in w
t to the co
drilling open the shut-off valve.
♦ Drill open the shut-off valve -C- using a suitable drill bit (e.g.
5 mm in diameter).
rrectness of i
♦ Remove any metal shavings resulting from drilling hole -D-
l purpos
from shut-off valve -C-.

♦ Reinstall the solenoid valve -B- with the respective seal -E- to
nform
ercia
the shut-off valve -C- which has been drilled open.

m
a
com
tion in
Flush
r
te o
thi
– Check the refrigerant volume in the air conditioning bottle.
s
iva
do
r
There must be at least 7 kg of R134a refrigerant.

rp
cum
fo
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
co lksw
by
If necessary, switch on the heater fitted to your refrigerant bottle cted agen
Prote AG.
for 30 minutes before you start rinsing. In this way, pressure in
the refrigerant bottle is increased and charging of the purging cir‐
cuit is accelerated.
– Drain the waste oil container of the air conditioner service sta‐
tion .
– Connect the supply hose (high-pressure side) of the air con‐
ditioner service station with an adapter ⇒ page 82 to the low-
pressure line leading to the air conditioner compressor (line
with larger diameter).
– Connect the return hose (low-pressure or suction side) of the
air conditioner service station to the outlet of the purging de‐
vice for refrigerant circuits.
– Connect the inlet of the purging device for refrigerant circuits
with an adapter ⇒ page 82 to the high-pressure line leading
to the air conditioner compressor (line with smaller diameter).

lkswage R134a - General
Air conditioning systems with refrigerant einformation
s no - Edition 08.2019
o t gu
yV
db ara
ir se nte
ho eo
ut ra
Note ss
a c
ce
le
un
pt
♦ The components must always be purged against the direction
an
d
itte
y li
of refrigerant flow when the air conditioning system is in oper‐
rm
ab
ation (not applicable for electrical air conditioner compressor)
pe
ility
ot
⇒ page 73 .
wit
, is n
h re
♦ When flushing, contaminants from the refrigerant circuit enter
hole
spec
the flushing device for refrigerant circuits and the air condi‐
es, in part or in w
tioner service station and are retained in the filters and dryers
t to the co
installed within. Depending on the impurity, these components
are to be replaced at shorter intervals in accordance with the
operating instructions for the air conditioner service station or
rrectness of i
the rinsing device for refrigerant circuits.
l purpos
♦ The filter in the rinsing device for refrigerant circuits is to be

replaced after 2 rinsing cycles at the latest (rinsed vehicle),
depending on the type and degree of contamination of the
nform
ercia
rinsed refrigerant circuit. If a heavily contaminated refrigerant

m
a
circuit is purged (the refrigerant oil from the refrigerant circuit
com
tio
is black and viscous or there are large amounts of shavings in
n in
r
the refrigerant circuit) renew filter after purging refrigerant cir‐

te o
thi
cuit. After such heavy contamination of the refrigerant circuit,
s
iva
do
r
we suggest purging the system again after changing the filter.

rp
cum
fo
en
ng
♦ Depending on the type of contamination, deposits (old refrig‐

t.
yi Co
op
erant oil and friction dust from the air conditioner compressor)
C py
t. rig
gh
will gather in the sight glass of the rinsing device for refrigerant
ht
pyri by
circuits. Clean the sight glass(es) after purging and purge the
co Vo
by lksw
cted agen
refrigerant circuit once more as a precautionary measure after Prote AG.
purging.
♦ Fluid refrigerant cannot flow at the necessary speed through
the expansion valve, the restrictor and the desiccant cartridge
of certain receivers. These components must therefore be re‐
moved and an adapter installed in their place ⇒ Heating, air
conditioning .
♦ Adapter for connecting the air conditioning service station and
for bridging certain components in the refrigerant circuit
⇒ page 82 .
– Switch on the air conditioner service station and flush the re‐
frigerant circuit (duration approx. 1 to 1.5 hours for one flushing
cycle with three flushes using approx. 4 kg of refrigerant
R134a for each flush).

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

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

ically by the program of the air conditioning service station )
♦ After switching on, the purging cycle (refrigerant circuit with
connection hoses and purging device for refrigerant circuits)
is first evacuated and the refrigerant circuit thereby checked
for leaks. It may be necessary to start the next steps manually,
depending on the type of air conditioning service station .
♦ A predetermined amount of refrigerant (e.g. 4 kg) is pumped
into the evacuated rinsing circuit via the high-pressure side of
the air conditioning service station ag(opposite
en AG. V
olksto
wathe
gen Adirection
G do
es n
of
flow that is normal during operation
Volksw of the air-conditioning sys‐
ot g
tem and, therefore, at ithe by
ed low-pressure end of the vehicle's ran
ua
rs
refrigerant circuit). Depending
ho on the type of air conditioning tee
ut or
service station , refrigerant
ss
a is pumped in until the rinsing circuit ac
has been completely filled with liquid refrigerant. This is indi‐
ce
e
nl
cated by the fact that refrigerant stops flowing into the circuit
pt
du
an
for a certain amount of time, for example.

itte
y li
erm
ab
♦ After the specified amount of refrigerant has been pumped in,

ility
ot p
the heater of the rinsing device for refrigerant circuits is switch‐

wit
, is n
ed on, for example, depending on the type of air conditioning

h re
hole
service station and rinsing device for refrigerant circuits (only

spec
if the refrigerant is extracted from the rinsing device for refrig‐

es, in part or in w
t to the co
erant circuits in gaseous form).

♦ Once the refrigerant has been extracted, the heater (if there is
one) of the rinsing device for refrigerant circuits is switched off
rrectness of i
(it is possible that the refrigerant circuit will then be briefly

l purpos
evacuated again, depending on the type of equipment). After

evacuation, the refrigerant oil extracted from the refrigerant
circuit is separated by the air conditioning service station .
nf
ercia
or
♦ The sequence for filling with refrigerant, extracting (and evac‐

m
m
atio
uating) is carried out twice (that means a total of three times).

om
n in
or c
♦ After the third extraction, the rinsing circuit is evacuated, de‐

thi
te
pending on the type of air conditioning service station .

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.

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

device for refrigerant circuits and, if they are dirty, clean them
in accordance with the operating instructions for the rinsing
device for refrigerant circuits or the air conditioning service
station . Carry out a purging cycle once more as a precaution‐
ary measure. One flushing sequence is sufficient (approx.
30 min.)
– Check the pressure in the refrigerant circuit. There must be no
pressure in the refrigerant circuit (evacuate again briefly if
necessary).
– Remove the connections to the air conditioning service station
from the refrigerant circuit of the vehicle. There must be no
overpressure in the refrigerant circuit.
– Renew these components according to the type of vehicle.
♦ Restrictor and reservoir
♦ Expansion valve and liquid container or desiccant cartridge in
the liquid container
– ⇒ Heating, air conditioning and ⇒ Parts catalogue .
– Replace air conditioner compressor depending on complaint
⇒ Heating, air conditioning and ⇒ Parts
olkswagcatalogue or drain
en AG. V en AG
the remaining refrigerant olksoil
wagfrom the removed air
doesconditioner
not g
compressor ⇒ page b185
y V (renewing components of refrigerant ua
ed ran
circuit) and fill it owith
ris the prescribed amount of fresh refrigerant tee
oil ⇒ vehicle-specific
au
th
workshop manual . or
a
ss c
ce
le
un
pt
an
d
Note
itte
y li
erm
ab
ility
♦ There is a predetermined amount of refrigerant oil in the gen‐

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

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

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

ual .
t to the co
♦ If the air conditioner compressor does not have to be renewed,

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

out refrigerant oil and refill the prescribed amount in the air
conditioner compressor or the refrigerant circuit)
ss
⇒ page 185 (renewing components of refrigerant circuit) and

o
cial p
⇒ vehicle-specific workshop manual .

inform
mer
atio
– Assemble the refrigerant circuit back together again complete‐

om
ly ⇒ Heating, air conditioning .

n
c
i
or
n thi
e
– Evacuate and fill the refrigerant circuit as per specifications

t
sd
iva
⇒ page 48 and ⇒ page 49 .

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

t.
yi Co
op
fications ⇒ Heating, air conditioning and ⇒ page 50 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7.3.1 Principle circuit diagrams for various

purging circuits agen
AG. Volkswagen AG d
oes
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d by ara
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Note ris
tho eo
au ra
c
ss
♦ The arrows in the following illustrations show the direction of
ce
le
un
pt
flow of the refrigerant during purging. The refrigerant flows
an
d
itte
against the direction of flow during normal conditioning of the
y li
rm
ab
air, which is why the high-pressure system of the air condi‐
pe
ility
tioning service station is connected to the low-pressure con‐
ot
wit
, is n
nection of the refrigerant circuit to the air conditioner
h re
compressor.
hole
spec
es, in part or in w
♦ These principle circuit diagrams show a refrigerant circuit with
t to the co
restrictor and reservoir and a refrigerant circuit with expansion
valve, receiver and a second evaporator (extra equipment on
certain vehicles).
rrectness of i
♦ Depending on the design of the air conditioning service sta‐
l purpos
tion , non-return valves may be installed between the refriger‐

ant circuit and the air conditioning service station . This
ensures the correct direction of flow of refrigerant during purg‐
nform
ercia
ing.
m
a
com
tio
Refrigerant circuit with restrictor and reservoir
n in
r
te o
thi
s
iva
do
r
rp
c
Note
um
fo
en
ng
t.
yi Co
op
On vehicles with restrictor and reservoir, the restrictor and the C py
t. rig
reservoir are removed. The refrigerant pipes of the restrictor are
gh ht
yri by
assembled again. The refrigerant pipes to the removed reservoir
op Vo
by c lksw
are joined together with two adapters and the charging hose -
cted agen
Prote AG.
VAS 6338/31- (from adapter case VW/Audi passenger vehicle set
- VAS 6338/1- .

1 - Air conditioner service sta‐

tion
❑ with an electronic con‐
trol and a flushing pro‐
gramme, e.g. air condi‐
tioner service station n AG. Volkswagen AG do
swage es n
with flushing device - byV
olk ot g
ua
VAS 6337- ir se
d ran
tee
ho
❑ If an air conditioner aut or
ac
service station without ss
ce
le
flushing program is
un
pt
an
used, the sequence has
d
itte
y li
to be carried out man‐ erm
ab
ually (evacuate, flush
ility
ot p
3 times with at least 4 kg
wit
is n
of refrigerant each time
h re
ole,
and extract refrigerant
spec
again, evacuate).
t to the co
2 - Refrigerant hose of air con‐
ditioner service station
rrectne
❑ From high pressure side
of air conditioning serv‐
ice station (normally col‐
ss
oured red) to connection
o
cial p
f
for low pressure side of
inform
air conditioner compres‐
mer
sor on refrigerant circuit
atio
m
(larger diameter)
o
n
c
i
or
n thi
e
3 - Adapter for connection to

t
sd
va
low pressure side in refrigerant

i
o
pr
cum
circuit
r
fo
en
ng
t.
yi
❑ Different versions de‐
Co
op py
pending on vehicle t. C rig
gh ht
⇒ page 82 . yri
p by
co Vo
by lksw
❑ From adapter case VW/ cted agen
Prote AG.
Audi passenger vehicle
set - VAS 6338/1- .
4 - Connection of low pressure side in refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 82 .
❑ On refrigerant line from air conditioner compressor to reservoir.
5 - Connection to reservoir
❑ On refrigerant line from air conditioner compressor to reservoir.
6 - Adapter for bridging removed reservoir
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
7 - Charging hose for refrigerant ⇒ page 82
❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS
6338/1- ).
8 - Adapter for bridging removed reservoir
9 - Connection to reservoir

10 - Evaporator
11 - Location of restrictor
❑ The restrictor is removed.
❑ Removing restrictor ⇒ Heating, air conditioning .
12 - Threaded connection in refrigerant line
❑ After removing the restrictor, screw back together again ⇒ Heating, air conditioning .
13 - Condenser
14 - Connection for high pressure side on refrigerant circuit
15 - Adapter for connection of high pressure side in refrigerant circuit
AG. Volkswagen AG d
❑ From adapter case VW/Audi
ksw
agen passenger vehicle oesset - VAS 6338/1- .
n ol ot g
yV u
16 - Charging hose ofiseflushing
db device for refrigerant circuits aran
or tee
❑ From connectiona ut
h to high-pressure side of air conditioner compressor
or
a on refrigerant circuit (smaller di‐
ameter) to ss inlet of purging device for refrigerant circuits - VASc 6336/1- or purging device for refrigerant
circuits - VAS 6337/1- .
ce
le
un
pt
an
d
itte
17 - Flushing device for refrigerant circuits
y li
rm
ab
❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging
pe
ility
ot
device for refrigerant circuits - VAS 6337/1- .
wit
, is n
h re
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
hole
spec
es, in part or in w
Note
t to the co
Depending on the layout of the air
conditioner service station and the rrectness of i
flushing device for refrigerant cir‐
cuits, there may be a service cou‐
l purpos
pling for refrigerant circuits fitted at

the outlet and in some cases at the
nform
ercia
inlet of the flushing device. If a serv‐

ice connection with a valve is instal‐
m
a
com
led to the outlet of the flushing

ion in
device, this valve must be opened

r
te o
thi
completely when the service cou‐

s
iva
pling is connected. If the valve is not

do
r
rp
opened completely, it restricts the

um
fo
en
g
refrigerant flow.
n
t.
yi Co
Cop py
t. rig
gh
– If there is a connection for a service coupling fitted at the inlet of the flushing device, the inlet must be
ht
pyri by
Vo
adapted to allow for the refrigerant hose coming from the vehicle to be connected directly.
o
by c lksw
cted agen
Prote AG.
Note
A service coupling and a valve in the

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

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

Refrigerant circuit with expansion valve, receiver and second

evaporator
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ This principle circuit
by
V diagram shows a refrigerant
o gcircuit
ua with
expansion valve, receiver and a second evaporator (extra
ed ran
ris te
equipment tho
au on certain vehicles).
eo
ra
ss c
♦ On vehicles with expansion valve and receiver, the expansion
ce
e
nl
pt
valve is removed and an adapter installed in its place. The
du
an
itte
receiver must be purged, depending on the vehicle or the dryer
y li
erm
ab
cartridge removed. Depending on the type of receiver, this
ility
ot p
should be removed and the line connections to the receiver
wit
, is n
joined together using two adapters and a charging hose.
h re
hole
♦ On vehicles with just one evaporator, the components from
spec
position “16” are not installed or not required.
es, in part or in w
t to the co
rrectness of i
tion
l purpos
❑ with an electronic con‐

trol and a flushing pro‐
gramme, e.g. air condi‐
nf
ercia
tioner service station orm

m
with flushing device -

atio
om
VAS 6337-
n in
or c
thi
❑ If an air conditioning
te
sd
a
service station is used

iv
o
r
rp
cu
which does not have a

o
m
f
en
ng
purging programme,
t.
yi Co
then the sequence must t. Cop py
be performed manually.
rig
gh ht
pyri by
Vo
o
by c
– Extract refrigerant, if
lksw
cted agen
Prote
there is any in the sys‐
AG.
tem.
– Connect flushing device

for refrigerant circuits -
VAS 6337/1- between
air conditioner service
station and return line
for refrigerant circuit.
– Evacuate refrigerant cir‐

cuit for 20 minutes, then
fill system with 4 kg of
refrigerant R134a. Then
extract again and repeat
process two further
times. If after the 3rd
purging process the re‐
frigerant in the sight
glass/glasses is not
clear, repeat process
again.
2 - Refrigerant hose of air con‐

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

4 - Connection of low pressure side in refrigerant circuit

5 - Adapter for removed expansion valve
6 - Evaporator
7 - Connection to receiver
❑ Not included on vehicles with a dryer cartridge in the receiver on the condenser or one in the receiver
integrated within the condenser ⇒ Heating, air conditioning .
8 - Adapter for bridging removed receiver
❑ Not required on all vehicles.
❑ From adapter case VW/Audi passengerwage vehicle set - VAS
n AG. Volkswagen AG do 6338/1- .
es ks not
Vol g
9 - Charging hose for refrigerante⇒ d b page 82
y ua
ran
ris tee
❑ For example charginguthose - VAS 6338/31- (from adapter case VW/Audi
ho
or passenger vehicle set - VAS
6338/1- ). ss
a ac
ce
le
un
10 - Condenser
pt
an
d
itte
y li
❑ If there is a receiver with dryer cartridge installed on the condenser, the dryer cartridge must be removed
rm
ab
(seal receiver again on or in condenser following removal) ⇒ Heating, air conditioning .
pe
ility
ot
❑ If the receiver is attached directly to the condenser, remove the receiver after purging and renew ⇒
wit
, is n
h re
Heating, air conditioning .
hole
spec
11 - Connection for high pressure side on refrigerant circuit
es, in part or in w
t to the co
12 - Adapter for connection of high pressure side in refrigerant circuit
rrectness of i
l purpos

13 - Charging hose of flushing device for refrigerant circuits
nform
ercia
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
ameter) to inlet of flushing device for refrigerant circuits.
m
a
com
tion in

r
te o
thi
❑ Different versions and different design, e.g. flushing device for refrigerant circuits - VAS 6337/1- .
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
Depending on the layout of the air cop Vo
by lksw
conditioner service station and the
cted agen
Prote AG.
refrigerant flow.

Note


16 - Adapter to seal outlet to second evaporator
❑ Only fitted on certain vehicles with “second evaporator” as optional equipment.
❑ From adapter case commercial vehicle set - VAS 6338/50- .
17 - Adapter to seal outlet to second evaporator
❑ From adapter case commercial vehicle set - VAS 6338/50- .
18 - Connection of low pressure side in refrigerant circuit to second evaporator
19 - Connection of high pressure side on refrigerant circuit to second evaporator
20 - Adapter for removed expansion valve on second evaporator
❑ From adapter case commercial vehicle set - VAS a6338/50-
gen AG
. Vol.kswagen AG
do w es n
olks o
21 - Second evaporator db
yV t gu
ara
ir se nte
❑ Only fitted on certain vehicles with “second
utho evaporator” as optional equipment. eo
a ra
ss c
ce
e
nl
pt
du
an
7.3.2 Purging electrical air conditioner com‐

itte
y li
erm
ab
pressor
ility
ot p
wit
, is n
Vehicles with high-voltage system

h re
hole
spec

es, in part or in w
t to the co

electric shock.
rrectness of i

l purpos
voltage cables.
nform
ercia
tools.
m

at
om
io

n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
If repair work in the vicinity of high-voltage components and ca‐ . Cop py
t rig
gh ht
yri by
voltage components and cables ⇒ Electrical system; Rep. gr. cop Vo
by lksw
93 ; General warning instructions for work on the high-voltage cted agen
Prote AG.
system .


ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;
De-energising high-voltage system , and “observe the general
warning instructions for work on the high-voltage system” ⇒ Elec‐
trical system; Rep. gr. 93 ; General warning instructions for work
on the high-voltage system .
Note
The electrical air conditioner compressor must be purged, if you

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

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

extract the refrigerant oil which needs to be determined.
♦ Purge the air conditioner compressor in normal direction of
flow (from low-pressure inlet to high-pressure outlet).
♦ In order to purge as much refrigerant oil from the air condi‐
tioner compressor as possible make sure that the high-pres‐
sure outlet of the air conditioner compressor is in the lowest
position possible.
♦ If an air conditioning service station without purging pro‐ olkswagen AG
gramme is used, the sequence has to be carried out manuallyksw
agen
AG. V does
(evacuate, purge 3 times with at least 2 kg of refrigerant
by
Vol
each not
gu
time and extract refrigerant again, evacuate). rised ara
nte
tho eo
s au ra
c
Determined amount e.g. 50 cm³ s
ce
le
un
pt
Then, remove as much refrigerant oil from the new air conditioner
an
d
itte
y li
compressor as is necessary to ensure that only the same amount

rm
ab
of refrigerant oil which has been purged from the old air condi‐
pe
ility
tioner compressor remains in the new one (plus 10 cm 3). If, for
ot
wit
, is n
example, the new original air conditioner compressor is filled with

h re
hole
e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
spec
es, in part or in w
– Pour old refrigerant oil out of air conditioner compressor. Han‐

t to the co
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐

book; Environmental protection; Waste disposal; Current
situation; Disposal channels; Disposal of used oils; Refrigerant
rrectness of i
oils .
l purpos
Note
nform
mercia
If the amount of refrigerant oil which can be removed from the

a
com
tio
new air conditioner compressor is not sufficient, the new air con‐
n in
r
ditioner compressor must be purged. After the new air conditioner

te o
thi
compressor has been purged, fill the amount of refrigerant oil

s
iva
do
which has been determined when purging the old air conditioner
r
rp
cum
fo
compressor.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
79
AG.
7. Clearing refrigerant circuit of contaminants

tion
Note
The air conditioner compressor is

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

container of the air con‐ agen oes
olksw not
d byV . gu
ara
e nte
ris
tho eo
au ra
Note ss c
ce
le
un
pt
Some air conditioner service sta‐
an
d
itte
tions first separate the oil in the vac‐
y li
rm
ab
uum phase and then fill it into the
pe
ility
used-oil container.
ot
wit
, is n
h re
hole
– At the air conditioner
spec
service station , set the
es, in part or in w
t to the co
amount of refrigerant to
2 kg and the amount of
oil to 0.
– Connect purging device rrectness of i

l purpos
for refrigerant circuits -

VAS 6336/1- or purging
device for refrigerant cir‐
nform
ercia
cuits - VAS 6337/1- be‐

tween air conditioner
m
a
com
ti
service station and re‐

on in
turn line for refrigerant

r
te o
thi
circuit.
s
iva
do
r
rp
cum
– Evacuate the refrigerant

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

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

Note
Depending on the layout of the air

conditioner service station and the
refrigerant flow.
Note

4 - Charging hose of flushing device for refrigerant circuits

❑ From connection to
genhigh-pressure
AG. Volkswagen Aside
G do of air conditioner compressor on refrigerant circuit (smaller di‐
swa es n
ameter) to yinlet
Volk of purging device for refrigerant
ot g
ua
circuits - VAS 6336/1- or purging device for refrigerant
circuitsrise-dVAS 6337/1- .
b ran
t ee
tho o
5 - Adapter
au for connection of high pressure side in refrigerant
ra
c circuit
ss
❑ Adapter - VAS 6338/1- from adapter set for refrigerant circuits - VAS 6338/3-
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
If the adapter - VAS 6338/40- is

wit
, is n
available, the charging hose can be

h re
hole
connected directly to the air condi‐

spec
tioner compressor.
es, in part or in w
t to the co
6 - High-pressure side refrigerant line from air conditioner compressor

rrectness of i
Note
l purpos
Will not be used if the adapter - VAS

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

r
te o
thi
s
iva
❑ Purge the air conditioner compressor in normal direction of flow (from low-pressure inlet to high-pressure
do
r
outlet).
rp
cum
fo
en
g
❑ In order to purge as much refrigerant oil from the air conditioner compressor as possible make sure that
n
t.
yi Co
op
the high-pressure outlet of the air conditioner compressor is in the lowest position possible.
C py
ht. rig
rig ht
8 - Low-pressure side refrigerant line to air conditioner compressor
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Will not be used if the adapter - VAS

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

9 - Adapter for connection to low pressure side in refrigerant circuit

❑ Adapter - VAS 6338/1- from adapter set for refrigerant circuits - VAS 6338/6-
Note
If the adapter - VAS 6338/41- is

available, the charging hose can be
connected directly to the air condi‐
tioner compressor.

❑ From high-pressure side of the air conditioning service station (usually coloured in red) for connection
to low-pressure line or directly to air conditioner compressor using adapter - VAS 6338/41- .
7.3.3 Adapters for setting up flushing circuits

– The desiccant bag and the desiccant cartridge must always
be removed before any flushing routine. Then close the re‐
ceiver again.
– On condensers with a permanent dryer, this can be flushed
along with the other components. A new condenser must then
be installed. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
Note thoris nte
eo
au ra
c
ss
If a flushed refrigerant circuit is not reassembled immediately after
ce
e
nl
flushing, the adapters must be left on the connections. These as

pt
du
an
well as components that are still open must be sealed with clean
itte
y li
erm
bungs from engine bung set - VAS 6122- .

ab
ility
ot p
wit
, is n
On successful completion of flushing procedure, remove all

h re
hole
adapters and renew following components during assembly

spec
es, in part or in w
♦ Air conditioner compressor (only after renewal of air condi‐

t to the co
tioner compressor due to internal damage)

♦ Restrictor and expansion valve
rrectness of i
♦ Desiccant bag and desiccant cartridge

l purpos
♦ Evacuating and charging valve, high-pressure side and low-

pressure side
nf
ercia
♦ Oil seals
rm
m
atio
m
Ameo 2017 ▶
o
n in
or c
thi
e
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
t
sd
iva
compressor
o
r
rp
cu
o
m
f
en
Low-pressure side ♦ Adapter - VAS 6338/34-

ng
t.
yi Co
♦ Adapter - VAS 6338/12- op py
or
t. C rig
gh ht
High-pressure side ♦ Drilled out expansion valve ⇒ page 67
pyri by
Vo
o
by c
♦ Adapter - VAS 6338/3-
lksw
cted agen
Prote AG.

. Volkswagen AG
gen AG d
Amarok 2011 ➤Vo,lkAmarok
swa 2017 ➤ , Ameooe2017
s no ➤ , Arteon 2018 ➤ , Atlas 2 ...
tg
y
ise
d b with refrigerant R134a - Generaluainformation
ran - Edition 08.2019
r tee
ho
ut or
Arteon 2018 ▶ ss
a ac
ce
le
un
pt
an
d
itte
compressor
y li
rm
ab
pe
ility
ot
wit
, is n
or
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Atlas 2017 ▶
l purpos
Flushing adapter refrigerant lines to Flushing adapter expansion valve Sealing adapter and flushing adapt‐
air conditioner compressor er for vehicles with second evapo‐
nform
ercia
rator
m
Low-pressure side ♦ Adapter - VAS 6338/38- Low-pressure side of front refriger‐
a
com
tio
♦ Adapter - VAS 6338/12- ant circuit
n in
or ♦ Sealing adapter - VAS 6338/63-
r
te o
thi
High-pressure side ♦ Drilled out expansion valve
s
iva
do
♦ Adapter - VAS 6338/3- ⇒ page 67 High-pressure side of front refriger‐
r
rp
cum
ant circuit
fo
Rear refrigerant circuit
en
g
♦ Sealing adapter - VAS 6338/5-

n
t.
yi
♦ Drilled out expansion valve
Co
Cop py
⇒ page 67 Low-pressure side to second evap‐
t. rig
gh ht
yri
orator
p by
o Vo
by c lksw
Prote
cted AG.
agen
High-pressure side to second evap‐
orator
Beetle 1999 ▶; Beetle Cabriolet 2003 ▶

Flushing adapter refrigerant lines to Flushing adapter expansion valve Other adapters
air conditioner compressor
Low-pressure side ♦ Adapter - VAS 6338/19- Bridge removed refrigerant lines on
♦ Adapter - VAS 6338/7- condenser
or ♦ Adapter - VAS 6338/2- , qty. 2
♦ Adapter - VAS 6338/2- ⇒ page 67 ♦ Hose - VAS 6338/31-
Beetle 2012 ▶; Beetle Cabriolet 2013 ▶

compressor
or

Bora 1999 ▶
♦ Adapter - VAS 6338/2- ⇒ page 67 ♦ Hose - VAS 6338/31-
AG. Volkswagen AG d
agen
CC 2009 ▶ Volksw
oes
not
by gu
d ara
Flushing adapter refrigerant lines to air conditioner rise Flushing adapter expansion valve
nte
tho eo
compressor s au ra
c
s
ce
e
nl
pt
du
an
itte
or
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
e-Golf 2014 ▶
rrectness of i
compressor
l purpos

or
nf
ercia
o
rm
m
atio
m
Electrical air conditioner compressor

o
n in
c
♦ Adapter - VAS 6338/40- and adapter - VAS

or
thi
e
6338/41-
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
e-Golf 2014 ▶ with heat pump opyri
gh by
Vo
ht
c by lksw
Flushing adapter refriger‐ Flushing adapter expan‐ Other adapters
cted Miscellaneous
agen
Prote AG.
ant lines to air conditioner sion valve
compressor
Low-pressure side Install adapter
– - VAS Bridge removed
– refrig‐ Start “Basic
– setting” in
♦ Adapter - VAS 6338/38- in place of ex‐ erant lines on condens‐ ⇒ Vehicle diagnostic
6338/12- connected to pansion valve (or a dril‐ er tester, and start the
air conditioner service led out expansion valve ♦ Adapter - VAS function “Charge refrig‐
station and adapter - ⇒ page 67 ) 6338/6- , qty. 2 erant circuit”.
VAS 6338/48- . ♦ This will open the elec‐
After flushing,
– install a ♦ Hose - VAS 6338/31- trical valves in the re‐
High-pressure side new expansion valve. frigerant circuit.
♦ Adapter - VAS 6338/3- After purging,
– install a
new reservoir (dryer). ♦ The function is active
Purging electrical air con‐ and must not be termi‐
ditioner compressor nated until purging of
♦ Adapter - VAS the refrigerant circuit
6338/40- and adapter - has been completed.
VAS 6338/41-
♦ Leave ⇒ Vehicle diag‐
Adapter - VAS 6338/48- to nostic tester connected
air conditioner service sta‐ to keep the valves
tion Observe notes: open.
⇒ page 78

Eos 2006 ▶
compressor
or
Fox 2005 ▶
compressor
or
Golf 1992; Vento 1992; Passat 1994

♦ Adapter - VAS 6338/14- ♦ Adapter - VAS 6338/19- Bridge removed refrigerant lines on
condenser
or ♦ Adapter - VAS 6338/28- and
♦ Drilled out expansion valve adapter - VAS 6338/29-
⇒ page 67
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Golf 1998 … 2003; Golf Variant 1998 … 2003; Golf Cabriolet
s aut 1998 ra
c
… 2002; Vento 1993 … 1999 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
♦ Adapter - VAS 6338/2- ⇒ page 67 ♦ Hose - VAS 6338/31- t to the co

rrectness of i
Golf 2013 ▶, Golf Estate 2014 ▶, Golf 2017 ▶; Golf Estate 2017 ▶
l purpos
compressor
nform
ercia
Low-pressure side ♦ Adapter - VAS 6338/18- or adapter - VAS 6338/38-

m

com
tio
or
n 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.

Golf 2004 ▶; Golf Estate 2004 ▶; Golf Cabriolet 2012 ▶; Golf Plus
2005 … 2014; Golf SV 2014 ▶; Golf 2014 (NAR)
compressor
or
♦ Adapter - VAS 6338/3- AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Golf MEX 2018 ▶ ss a c
ce
e
nl
pt
du
an
itte
compressor
y li
erm
ab
ility
ot p
wit
, is n
or
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Golf GTE 2014
l purpos
nform
ercia
Low-pressure side ♦ Adapter - VAS 6338/38- Renew shut-off valves -N541- and -
m
♦ Adapter - VAS 6338/12- N542-
at
om
or
io
♦ Shut-off tap - VAS 6338/42- ,
n
c
in t
qty. 2
or
♦ Adapter - VAS 6338/3- ⇒ page 67
his
ate
do
riv
Remove restrictor in refrigerant line

p
c
Electrical air conditioner compres‐
um
to heat exchanger for high-voltage
for
sor en
g
battery and drill it out

n
t.
yi
♦ Adapter - VAS 6338/40- and
Co
Cop py
adapter - VAS 6338/41-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Jetta 2005 … 2012

compressor
or
Jetta 2013 … 2014

compressor
or

Jetta 2015 ▶
compressor
or
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Lupo 1999 ▶, up to VIN 70000 horis nte
eo
aut ra
s c
Flushing adapter refrigerant lines to Flushing adapter expansion valve s Other adapters
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
or
ot p
wit
is n
h re
♦ Adapter - VAS 6338/2- ⇒ page 67
ole,
spec
t to the co
Lupo 1999 ▶, from VIN 70001
rrectne
ss o
cial p
f in
form
or
mer

atio
om
♦ Adapter - VAS 6338/2- and ⇒ page 67
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Passat 1997… 09/2000 C py
t. rig
gh ht
yri by
Flushing adapter refrigerant lines to air conditioner Other adapters and work steps
op Vo
by c lksw
cted
compressor
agen
Prote AG.
Low-pressure side Bridge removed refrigerant lines on condenser

♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/9- and adapter - VAS 6338/10-
High-pressure side ♦ Hose - VAS 6338/31-
Remove restrictor and seal refrigerant lines again
Passat 10/2000 … 12/2000

compressor
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/10- , qty. 2
High-pressure side ♦ Hose - VAS 6338/31-
Remove restrictor and seal refrigerant lines again

Passat 2001 … 2005

compressor
or
Passat 2006 … 2014

compressor
or
Note
In the Passat 2015 and Passat Estate 2015 with bi-turbo engine,
the refrigerant circuit is not flushed. In these vehicles, it would
require too much effort to remove the expansion valve. If the air
conditioner compressor is defective, check whether swarf has
entered the condenser or whether there is swarf in the condenser
outlet. If there is only swarf on the inlet side but not on the outlet
side, renew only the condenser and the air conditioner compres‐
sor.
Passat 2015 ▶; Passat Estate 2015 ▶; Passat GTE 2015 ▶; wPas‐

agen
AG. Volkswagen AG d
oes
sat (NMS-US) 2016 ▶ yV
olks not
gu b ara
ed n
ris
Flushing adapter refrigerant lines to air conditioner
tho Flushing adapter expansionteevalve
o
compressor au ra
c
ss
ce
le
Low-pressure side ♦ Adapter - VAS 6338/18- , adapter - VAS 6338/38-

un
pt
an
d
♦ Adapter - VAS 6338/12- or adapter - VAS 6338/74-

itte
y li
rm
ab
High-pressure side or
pe
ility
♦ Adapter - VAS 6338/3- ♦ Drilled out expansion valve ⇒ page 67

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Phaeton 2003 ▶
rrectness of i
compressor
l purpos

♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/6- , qty. 2
nform
ercia
High-pressure side on 6-cylinder petrol engine, 8- and ♦ Hose - VAS 6338/31-

12-cylinder diesel engine
m
Remove restrictor and– seal refrigerant lines again.

com

tion in
r
te o
High-pressure side on 6- and 10-cylinder diesel engine

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
88
cted agen
Prote AG.
Polo 1995 … 2001, up to VIN 50000

♦ Adapter - VAS 6338/14- ♦ Adapter - VAS 6338/19- Bridge removed refrigerant lines on
condenser
♦ Drilled out expansion valve adapter - VAS 6338/29-
⇒ page 67
Polo 1995 … 2001, from VIN 50001

compressor
or
Polo 2002 … 2009

compressor
♦ Adapter - VAS 6338/12- AG. Volkswagen AG d
lksw
agen oes
n
or
High-pressure side by Vo ♦ Drilled outot expansion
gu
ara valve ⇒ page 67
♦ Adapter - VAS 6338/2- orise
d
nte
th eo
au ra
ss c
ce
le
un
pt
an
d
Polo 2010 … 2013

itte
y li
erm
ab
ility
ot p
wit
compressor
is n
h re
ole,

spec

or
t to the co

rrectness
Polo IND 2010 ▶; Polo RUS 2011 ▶; Polo MY 2014 ▶

o
cial p
f inform
mer
compressor
atio
om
n
c

i
or
n thi
e

t
sd
a
or
iv
o
pr

um
r
fo

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

Polo 2014 … 2017

compressor
or
Polo 2018 ▶
compressor
or
Scirocco 2009 ▶
compressor
or
AG. Volkswagen AG d
agen oes
lksw not
Sharan 1996 … 2010 by Vo gu
ara
d
rise nte
Flushing adapter refriger‐ Flushing adapter
autho
expan‐ Sealing adapter and flush‐ Othere o adapters
ra and work
ant lines to air conditioner sion
ss valve ing adapter for vehicles c steps
compressor with second evaporator
ce
e
nl
pt
du
an
Low-pressure side ♦ Adapter - VAS ♦ Lower-pressure line for Remove – receiver and
itte
y li
erm
♦ Adapter - VAS 6338/7- 6338/35- 2nd evaporator adapt‐ connect refrigerant

ab
ility
er - V.A.G 1785/7- pipes to adapter - VAS

ot p
wit
6338/37- .
, is n
♦ Adapter - VAS 6338/2- ♦ Drilled out expansion ♦ High-pressure line for

h re
hole
valve ⇒ page 67 2nd evaporator adapt‐

spec
er - V.A.G 1785/5-
es, in part or in w
t to the co
♦ Adapter - V.A.G
1785/3- with sealing
cap -VAS 6338/30- to
rrectness of i
seal front refrigerant

l purpos
circuit.
♦ Adapter - V.A.G
nf
ercia
1785/1- with sealing

or
cap -VAS 6338/30- to

m
m
atio
seal front refrigerant

om
n in
circuit.
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 2011 ▶
rator
Low-pressure side Front refrigerant circuit Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/18- ant circuit
♦ Adapter - VAS 6338/3- ♦ Drilled out expansion valve High-pressure side of front refriger‐
⇒ page 67 ant circuit
♦ Adapter - VAS 6338/33- Low-pressure side to second evap‐
orator
or ♦ Adapter - VAS 6338/3-
⇒ page 67 High-pressure side to second evap‐
orator
n AG. Volkswagen AG do ♦ Adapter - VAS 6338/4-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
T-Cross 2019 ▶ ss
ce
le
un
pt
an
d
itte
y li
compressor
erm
ab
ility
ot p
wit
is n
h re
or
ole,
spec
t to the co
rrectne
T-Roc 2018 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve ss o
cial p
compressor
f inform
mer

atio

m
or
o
n
c

or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
. rig
Tiguan 2008 … 2015
t
gh ht
pyri by
Vo
co lksw
by
Flushing adapter refrigerant lines to air conditioner cted Flushing adapter expansion valve
agen
Prote AG.
compressor
or

Air conditioning systems with refrigerant R134a w
- aGeneral
gen AG information
. Volkswagen AG - Edition 08.2019
doe
ks s no
Vol t gu
by ara
Tiguan 2016 ▶; Tiguan RUS 2017 ▶ ris
ed
nte
utho eo
r
Flushing adapter refrigerant lines to air conditioner
ss
a
Flushing adapter expansion avalvec
compressor
ce
le
un
pt
an
d
itte
y li
erm
ab
or
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Touareg 2003 … 2010, up to VIN 50000
rrectne
s
rator
s o
cial p
f i
nform
mer
atio
m

o
n
c
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 67 High-pressure side of front refriger‐
i
or
n thi
e
er - VAS 6338/3- ant circuit

t
sd
va

i
o
pr
cum
r
fo
en
Low-pressure side to second evap‐
ng
t.
yi Co
Cop
orator py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
orator
AG.
Touareg 2003 … 2010, from VIN 50001

rator
Low-pressure side ♦ Adapter - VAS 6338/17- or Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- adapter - VAS 6338/33- ant circuit
♦ Adapter - VAS 6338/2- or adapt‐ ♦ Drilled out expansion valve High-pressure side of front refriger‐
er - VAS 6338/3- ⇒ page 67 ant circuit
orator
orator

Touareg 2010 … 2018; Touareg Hybrid 2010 ▶

rator
Low-pressure side ♦ gAdapter
AG. Vol-ksVAS
wagen6338/17-
AG do or Low-pressure side of front refriger‐
a en
♦ Adapter - VAS 6338/12- olksw adapter - VAS 6338/33- es n
ot gu ant circuit
yV ara ♦ Sealing adapter - VAS 6338/11-
db
High-pressure side oris e or nte
eo
♦ Adapter - VAS 6338/2- or
aut adapt‐ ♦
h Drilled out expansion valve High-pressure
ra side of front refriger‐
er - VAS 6338/3-
ss ⇒ page 67 c ant circuit
ce
e

nl
pt
Electrical air conditioner compres‐
du
an
itte
sor Low-pressure side to second evap‐
y li
erm
ab
♦ Adapter - VAS 6338/40- and orator
ility
ot p
adapter - VAS 6338/41- ♦ Adapter - VAS 6338/3-
wit
, is n
h re
hole
spec
orator
es, in part or in w
t to the co
rrectness of i
Touareg 2018 ▶
l purpos
compressor
nf
ercia
or
m
m
atio
m
or
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Touran 2003 … 2015 gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
compressor
or
Touran 2016 ▶
compressor
or

up! 2012 ▶, e-up! 2014 ▶

compressor
♦ Adapter - VAS 6338/12- G. Volkswagen AG d
l
oragen A
ksw
oes
not
High-pressure side byV
o ♦ Drilled out expansion valve gu ⇒ page
ara 67
♦ Adapter - VAS 6338/3- orised
nte
h eo
ut ra
Electrical air conditioner compressor ss a c
♦ Adapter - VAS 6338/40- and adapter - VAS
ce
le
un
pt
6338/41-
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.

8 Clearing refrigerant circuit of contam‐

inants, commercial vehicles
⇒ “8.1 Vehicles with high-voltage system”, page 95
⇒ “8.2 Flushing refrigerant circuit with refrigerant R134a”,
page 96
⇒ “8.3 Adapters for setting up flushing circuits”, page 96
⇒ “8.4 Procedure for setting up and flushing refrigerant circuit,
Amarok 2010 ►”, page 100
Caddy 2004 ►”, page 105
Crafter ►2017”, page 112 . Volkswage n AG n AG d
wage oes
⇒ “8.7 Procedure for setting up and flushing refrigerant
yV
olks circuit, not
gu
Crafter 2017 ► or MAN TGE ►, Crafter Grand ed California
b ►”, page ara
nte
ris
125 utho eo
ra
sa c
⇒ “8.8 Procedure for setting up and flushing
s refrigerant circuit,
ce
le
Transporter 2016 ►”, page 138

un
pt
an
d
itte
y li
8.1 Vehicles with high-voltage system
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
electric shock.
t to the co
voltage cables.
rrectness of i
l purpos
tools.
nform
ercia

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

rp
cum
fo

en
ng
t.
yi
Co
op py
93 ; General warning instructions for work on the high-voltage t. C rig
gh ht
system . yri
p by
o Vo
by c lksw
cted
agen
Prote AG.
8. Clearing refrigerant circuit of contaminants, commercial vehicles 95

Note

gen AG
. Volkswagen AG
poses of sealing leaks in refrigerant circuits. olks
wa d oes
not
byV gu
ara
Chemical substances used for sealing leaks ise in refrigerant cir‐
d
♦ or
nte
cuits often react with the surrounding aair
u and the humidity
th eo
ra
contained within. They cause depositsss to build up in the re‐ c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
The refrigerant circuit can only be repaired by replacing all
wit
, is n
components that have come into contact with this substance.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
• In order to remove dirt (e.g. abraded matter from a defective

air conditioner compressor) as well as old refrigerant oil as
cleanly as possible and with as little work as possible, flush
nf
ercia
the refrigerant circuit with R134a refrigerant.
orm
m
atio
m
8.2 Flushing refrigerant circuit with refriger‐

o
n in
or c
ant R134a
thi
te
sd
iva
o
r
The refrigerant circuit must be flushed with refrigerant R134a if

rp
cu
o
m
f
en
ng
♦ Dirt or other contaminants are in the refrigerant circuit.

t.
yi Co
Cop py
t. rig
♦ If during evacuation of a leak-tight refrigerant circuit the vac‐ yri
gh by
ht
uum display is not constant on gauge (moisture in the refrig‐ cop Vo
by lksw
cted agen
Prote AG.
♦ Pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the refrigerant circuit.
♦ There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit. If the air conditioner compressor is to be reinstal‐
led, drain refrigerant oil out of air conditioner compressor via
the block connections. To facilitate this process, turn the air
conditioner compressor over by hand at the poly V-belt pulley
or coupling disc of the magnetic coupling. After purging, fill
refrigerant circuit with total amount of refrigerant oil (50 g direct
into air conditioner compressor) according to ⇒ vehicle-spe‐
cific workshop manual . Take account of oil volume for
2nd evaporator system.
♦ The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power).
♦ If it is required by the workshop manual for the specific vehicle
following the renewal of certain components.
♦ a different air conditioner compressor with other refrigerant oil
is to be fitted.
8.3 Adapters for setting up flushing circuits

– The desiccant bag and the desiccant cartridge must always
be removed before any flushing routine. Then close the re‐
ceiver again.

– On condensers with a permanent dryer, this can be flushed

along with the other components. A new condenser must then
be installed.
Note

flushing, the adapters must be left on the connections. These as en AG. V
olkswagen AG
well as components that are still open must be sealed with cleanolkswag does
not
bungs from engine bung set - VAS 6122- . ed byV gu
ara
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utho eo
On successful completion of flushing procedure, remove
ss
a all ra
c
ce
le
un
pt
an
d
♦ Air conditioner compressor
itte
y li
rm
ab
♦ Restrictor and expansion valve
pe
ility
ot
wit
, is n
♦ Desiccant bag and desiccant cartridge
h re
hole
spec
es, in part or in w
pressure side
t to the co
♦ Oil seals
rrectness of i
Note
l purpos
Only flushing adapters for the following commercial vehicles are

listed:
nform
mercia
a
com
t
♦ Caddy 1996 … 2004 ⇒ page 98
ion in
r
te o
♦ LT 2 from 1997 ⇒ page 98
thi
s
iva
do
♦ Transporter 1991 … 1995 ⇒ page 98
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
♦ Transporter model 7H 2004 … 2010 ⇒ page 99
t. rig
gh ht
pyri by
Vo
co
♦ Transporter model 7J 2004 … 2010 ⇒ page 99
by lksw
cted agen
Prote AG.
♦ e-Crafter 2019 ▶; e-TGE 2019 ▶ with heat pump
⇒ page 100
Note
All commercial vehicles listed here are described in separate

chapters:
♦ Amarok 2010 ► ⇒ page 100

♦ Caddy 2004 ► ⇒ page 105
♦ Crafter ►2017 ⇒ page 112
♦ Crafter 2017 or MAN TGE ►, Crafter Grand California ►
⇒ page 125
♦ Transporter 2016 ► ⇒ page 138

Caddy 1996 … 2004

High-pressure side ♦ Drilled out expansion valve adapter - VAS 6338/29-
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 67
er - VAS 6338/14-
LT 2 from 1997
rator
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 67 ♦ Hose - VAS 6338/31-
er - VAS 6338/20-
Transporter 1991 … 1995

Flushing adapter refriger‐ Flushing adapter expan‐ Sealing adapter and flush‐ Miscellaneous
ant lines to air conditioner sion valve ing adapter for vehicles
♦ Adapter - VAS ♦ Adapter - VAS ♦ Adapter - VAS Vehicles with auxiliary
6338/54- 6338/55-
n AG. Volkswagen AG
6338/29- for receiver evaporator on roof
ksw
age does ♦ Adapter - VAS
by
Vol
or not
gu ♦ Adapter - VAS
ara 6338/51- and adapter -
ris
ed ♦ Drilled out expansion nt6338/57-
ee
for refrigerant VAS 6338/52-
ut
ho
valve ⇒ page 67 line
or of 2nd Evaporator
a ac
ss
♦ Adapter - VAS
ce
e
nl
6338/58- for refrigerant

pt
du
an
line of 2nd Evaporator

itte
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erm
ab
ility
ot p
wit
, is n
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hole

spec
es, in part or in w
t to the co
Flushing adapter refriger‐ Flushing adapter expan‐ Sealing adapter and flush‐ Miscellaneous
ant lines to air conditioner sion valve ing adapter for vehicles
rrectness of i
Low-pressure side ♦ Adapter - VAS ♦ Adapter - VAS Vehicles with auxiliary

♦ Adapter - VAS 6338/7- 6338/55- 6338/29- for receiver evaporator on roof
l purpos
♦ Adapter - VAS
High-pressure side or ♦ Adapter - VAS 6338/51- and adapter -
♦ Adapter - VAS 6338/2- ♦ Drilled out expansion 6338/57- for refrigerant
nf
ercia
VAS 6338/52-
o
valve ⇒ page 67 line of 2nd Evaporator

rm
m
atio
m
♦ Adapter - VAS
o
n in
c
6338/58- for refrigerant

or
thi
e
line of 2nd Evaporator

t
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Transporter model 7H 2004 … 2010

rator
♦ Adapter - VAS 6338/7- or adapt‐ ♦ Adapter - VAS 6338/56- ant circuit
er - VAS 6338/12- ♦ Sealing adapter - VAS 6338/11-
or
High-pressure side ♦ Drilled out expansion valve High-pressure side of front refriger‐
♦ Adapter - VAS 6338/2- or adapt‐ ⇒ page 67 ant circuit
er - VAS 6338/3- ♦ Sealing adapter - VAS 6338/5-
♦ Adapter - VAS 6338/33- Low-pressure side to second evap‐
orator
or ♦ Adapter - VAS 6338/3-
orator
Transporter model 7J 2004 … 2010

rator
♦ Adapter - VAS 6338/7- , adapter ♦ Adapter - VAS 6338/56- ant circuit
- VAS 6338/12- or adapter - VAS ♦ Sealing adapter - VAS 6338/11-
6338/52- or
♦ Drilled out expansion valve High-pressure side of front refriger‐
High-pressure side ⇒ page 67 ant circuit
. V lkswagen AG
♦ Adapter - VAS 6338/2- , adapter agen AG ♦ Sealing
o
dadapter
oes - VAS 6338/5-
- VAS 6338/3- or adapter - VAS Rear refrigerant circuit
w
olks not
yV gu
6338/51- ♦ Adapter - VASse6338/56-
d b Low-pressure side to arasecond evap‐
nte
ho
ri orator eo
or ut
♦ Adapter - VAS 6338/3-r ac
sa
s
ce
le

un
pt
orator
an
d
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rator
rrectne

ss

o
cial p

inform
♦ Adapter - VAS 6338/3- ⇒ page 67 High-pressure side of front refriger‐

mer
ant circuit
atio
m

o
n
c
i
or

thi
te
sd
a
orator
iv
o
pr

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

e-Crafter 2019 ▶; e-TGE 2019 ▶ with heat pump

Flushing adapter refriger‐ Flushing adapter expan‐ Other adapters Miscellaneous
ant lines to air conditioner sion valve
compressor
Low-pressure side Use ⇒ Vehicle
– diagnos‐ Bridge removed refriger‐ Start function
– “Charge
♦ Adapter - VAS tic tester to perform ant lines on
nA
condenser
G. V olkswagen AG do refrigerant circuit” us‐
6338/12- function Charge re- ♦ olksAdapterwage - VAS ing
es n ⇒ Vehicle diagnos‐
o
V 6338/6- , qty. 2
atic
ra tester.
t gu
frigerant circuit . ed by
High-pressure side ris nte
♦ Adapter - VAS 6338/3- tho ♦ Hose - VAS 6338/31- Leave ⇒– Vehicle
or e
diag‐
The function
– is active
au ac
Electrical air conditioner
ss
and must not be termi‐ nostic tester connected
ce
le
nated until purging of to keep the valves
un
compressor
pt
open.
an
d
♦ Adapter - VAS the refrigerant circuit
itte
y li
has been completed.
rm
6338/40- and adapter -
ab
pe
ility
VAS 6338/41-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
8.4 Procedure for setting up and flushing re‐
frigerant circuit, Amarok 2010 ►
rrectness of i
⇒ “8.4.1 Connection diagram for flushing circuit”, page 100
l purpos
⇒ “8.4.2 Procedure for setting up and flushing refrigerant circuit”,

page 101
nform
ercia
8.4.1 Connection diagram for flushing circuit

m
a
com
tion in
r
te o
thi
Note
s
iva
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rp
cum
The following connection diagram was created for the 2.0 l common rail engine equipped for left-hand drive.
fo
en
ng
The connection diagram for other engines should be adapted accordingly.

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

1 - Refrigerant lines
❑ Qty. 2
❑ High-pressure and low-
pressure side
2 - Expansion valve adapter -
VAS 6338/33-
❑ from adapter set for re‐
frigerant circuit - VAS
6338/50-
3 - Refrigerant line
❑ Low-pressure side
❑ High-pressure side
5 - Adapter - VAS 6338/3-
6338/50-
6 - Refrigerant hose
❑ from air conditioner
service station
7 - Adapter - VAS 6338/12-
6338/50-
❑ from air conditioner AG. Volkswagen AG d
agen oes
ksw
service station by Vol not
gu
ara
d
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
8.4.2 Procedure for setting up and flushing re‐

itte
y li
erm
ab
frigerant circuit
ility
ot p
wit
, is n

h re
hole
spec
♦ Torque wrench - V.A.G 1410-

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.

Air conditioning systems with refrigerant R134a - General information
AG. Volk-swEdition
agen A 08.2019 n G do
wage es n
Volks ot g
♦ Engine bung set - VAS 6122- ed
by ua
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
rrectne
♦ Adapter set for refrigerant circuit - VAS 6338/50-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
♦ Air conditioner service station , e.g. air conditioner service Prote AG.
station - VAS 6746A-
♦ Drill bit, ∅ 6 mm
Note
♦ The following procedure was created for the 2.0 l common rail
engine equipped for left-hand drive. The procedure for other
engines should be adapted accordingly.
♦ Flushing a contaminated refrigerant circuit is carried out
against the direction of normal flow.
♦ To install the individual flushing adapters, the original threaded
connections (nuts and bolts) are to be used and tightened to
the respective torque.

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

pressure side (blue) -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Air conditioner service station with external flushing device
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
o
by c lksw
cted agen
Prote AG.

– Connect coolant hose on low-pressure side (blue) -1- from air

conditioner service station to filter cartridge -3- of flushing de‐
vice using quick-release fastener -2-. wage
es n
olks ot g
byV ua
d ran
ir se tee
Note utho
or
a ac
ss
The flushing procedure is carried out with the existing coolant
ce
e
nl
pt
du
hose (blue) of the external flushing device.
an
itte
y li
erm
ab
ility
Continuation for all
ot p
wit
, is n
– Check quantity of refrigerant oil in refrigerant bottle via menu
h re
hole
of air conditioner service station .
spec
es, in part or in w
• There must be at least 7 kg of R134a refrigerant.
t to the co
– Remove expansion valve ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; Removing and installing expansion
rrectness of i
valve .
l purpos
– Install expansion valve adapter - VAS 6338/33- from adapter

set for refrigerant circuit - VAS 6338/50- .
nf
ercia
– Connect refrigerant lines to expansion valve adapter - VAS
orm
6338/33- .
m
atio
om
– Remove desiccant bag ⇒ Heating, air conditioning system;
n in
or c
Rep. gr. 87 ; Refrigerant circuit; Removing and installing des‐
thi
te
sd
a
iccant bag/desiccant cartridge .

iv
o
r
rp
cu
o
m
– Close receiver on condenser again.
f
en
ng
t.
yi Co
op
– Remove air conditioner compressor ⇒ Heating, air condition‐ C py
t. rig
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
gh ht
yri by
installing air conditioner compressor .
cop Vo
by lksw
cted agen
Prote AG.
– Connect refrigerant line of air conditioner compressor on high-

pressure side (smaller diameter) -1- to adapter - VAS 6338/3-
-4-.
– Connect refrigerant line of air conditioner compressor on low-
pressure side (larger diameter) -2- to adapter - VAS 6338/12-
-3-.

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

conditioner service station to threaded connection of adapter
- VAS 6338/3- -2- of refrigerant line for air conditioner service
station on high-pressure side (smaller diameter) -3-.
– Connect refrigerant hose on high-pressure side (red) -6- of air
station on low-pressure side (largerendiameter) -4-.
AG. Volkswagen AG
ag does
ksw not
Flush y Vol gu
b ara
ed nte
ris
– Start flushing procedure
tho via menu of air conditioner service eo
station . s au ra
c
s
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
s
♦ Expansion valve
s o
cial p
f i
♦ Desiccant bag
nform
mer
atio
m
pressure side
o
n
c
i
or
♦ Oil seals n thi

te
sd
iva
o
pr
– Charge refrigerant circuit ⇒ page 49 .

um
r
fo
en
ng
t.
– Perform leakage test on reattached line connections of refrig‐
yi Co
op
C py
t. rig
gh ht
yri by
– Bring air conditioning system into operation after charging re‐
cop Vo
by lksw
cted
frigerant circuit ⇒ Heating, air conditioning; Rep. gr. 87 ;
agen
Prote AG.
Refrigerant circuit; Bringing air conditioning system into oper‐
ation after charging refrigerant circuit .

frigerant circuit, Caddy 2004 ►
⇒ “8.5.1 Connection diagram for flushing circuit”, page 105
⇒ “8.5.2 Procedure for setting up and flushing refrigerant circuit”,
page 106
8.5.1 Connection diagram for flushing circuit
Note
The following connection diagram was created for the 2.0 l com‐
mon rail engine equipped for left-hand drive. The connection
diagram for other engines should be adapted accordingly.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo 2017tho➤ , Arteon 2018 ➤ , Atlas 2 ...
r eo
u ra
Air conditioning systems with refrigerant R134a
ss a - General information - Edition 08.2019 c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
service station
h re
hole
2 - Adapter - VAS 6338/3- or
spec
es, in part or in w
t to the co
6338/1-
rrectness of i
l purpos
nform
4 - Refrigerant line ercia
m
at
om
ion
c
in t
or
his
ate
do
riv

p
cum
or

f
en
g
6338/1-
n
t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
service station
VAS 6338/18-
6338/1-
8.5.2 Procedure for setting up and flushing re‐

frigerant circuit

♦ Engine bung set - VAS 6122-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
♦ Air conditioner service station , e.g. air conditioner service
t. rig
gh ht
yri by
station - VAS 6746A- cop Vo
by lksw
cted agen
Prote AG.
Note

Setting up
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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.


vice using quick-release fastener -2-.
Note
AG. Volkswagen AG d
agen oes
o lksw not
yV gu
The flushing procedure
ised b is carried out with the existing coolant
ara
nte
hose (blue) of thehor external flushing device. eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
valve .
t to the co
rrectness of i
l purpos
6338/18- .
Vehicles with Modine condenser
nf
ercia
or
m
m
atio
m

o
n in
c

or
thi
te
sd

iva
o
r
rp
cu
Vehicles with Showa condenser

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
Note
rig by
copy Vo
by lksw
cted agen
Prote
On vehicles with Showa condenser, the desiccant cartridge is
AG.
flushed and renewed upon successful completion of the flushing

procedure.


Vehicles with air conditioner compressor 7H0.820.803.F

-1-.
-4-.

station on low-pressure side (larger diameter) -4-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec

es, in part or in w
t to the co

-1-.
rrectness of i

l purpos

-4-.
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.

AG. Volkswagen AG d
agen oes
lksw not
– Connect refrigerant hose on low-pressure side (blue) byV
o -1- of air gu
ara
conditioner service station to threaded connection
rised
of adapter nte
- VAS 6338/3- or adapter - VAS 6338/2-au-2- th of refrigerant line
o eo
ra
for air conditioner service station on high-pressure
ss side (small‐ c
er diameter) -3-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
- VAS 6338/12- or adapter - VAS 6338/7- -5- of refrigerant line
wit
for air conditioner service station on low-pressure side (larger
is n
h re
diameter) -4-.
ole,
spec
Flush urposes, in part or in wh
t to the co
– Start flushing procedure via menu of air conditioner service
station .
rrectne
Note
ss o
cial p
f i
nform
mer
atio
m

o
n
c
i
or
n thi
te
sd
a

iv
o
pr
c
um
r
fo
en
ng
t.
yi
Co
Cop py
ht. rig
♦ Expansion valve rig ht
py by
co Vo
by lksw
♦ Depending on condenser manufacturer, desiccant bag or des‐
cted agen
Prote AG.
iccant cartridge
pressure side
♦ Oil seals


frigerant circuit, Crafter ►2017
⇒ “8.6.1 Connection diagram for flushing circuit, vehicles with one
evaporator”, page 112
⇒ “8.6.2 Connection diagram for flushing circuit, vehicles with
second evaporator”, page 113
⇒ “8.6.3 Procedure for setting up and flushing refrigerant circuit,
vehicles with one evaporator”, page 114
vehicles with second evaporator”, page 119
8.6.1 Connection diagram for flushing circuit,

vehicleslkwith
swa
genone
AG. Voevaporator
lkswagen AG
does
n
o ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
le
The following connection diagrams were created for the 2.0 l

un
pt
an
d
common rail engine equipped for left-hand drive. The connection

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
1 - Drilled out expansion valve
hole
spec
❑ Removing and installing

es, in part or in w
t to the co
⇒ Heating, air condi‐

tioning; Rep. gr. 87 ;
Refrigerant circuit; Re‐
rrectness of i
moving and installing

expansion valve
l purpos
nform
ercia

m
a
com
service station
tion in
r
te o

thi
s

iva
do
r
rp
cum

fo
en
g

n
t.
yi Co
6338/50- Cop py
t. rig
gh ht
yri
4 - Refrigerant line p by
o Vo
by c lksw
cted
agen
Prote AG.
6338/50-
service station

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

9 - Condenser
❑ Assembly overview ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit; Assembly
overview - condenser
AG. Volkswagen AG d
agen oes
ksw
8.6.2 Connection diagram for flushing circuit, d byV
ol not
gu
ara
vehicles with second evaporator ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1 - Adapter for connecting ex‐
pansion valve - VAS 6338/69-
❑ For sealing front refrig‐
rrectne
erant circuit when rear
refrigerant circuit is be‐
ss
ing flushed
o
cial p
f in
form
mer
❑ Qty. 2
atio
om
n
c
i
or
n
pressure side of front re‐
thi
te
sd
frigerant circuit
iva
o
pr
cum
r
fo
en
ng
t.
yi
❑ Qty. 2
Co
Cop py
ht. rig
❑ High-pressure and low- rig ht
py by
pressure side of rear re‐
co Vo
by lksw
cted
frigerant circuit
agen
Prote AG.
4 - Adapter for connecting ex‐

pansion valve - VAS 6338/69-
❑ For sealing rear refriger‐
ant circuit when front re‐
frigerant circuit is being
flushed
6338/50-
service station
❑ from adapter set for refrigerant circuit - VAS 6338/50-

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

equipment required
AG. Volkswagen AG d
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rise nte
tho eo
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nl
pt
du
an
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erm
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ility
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es, in part or in w
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rrectness of i
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nform
ercia

m
at
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io

n
c
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or
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e
♦ Adapter for connecting desiccant cartridge connection - VAS

at
do
riv
6338/68-
p
cum
for
en
g

n
t.
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op
station - VAS 6746A- C py
t. rig
gh ht
pyri by
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o
114
c by lksw
cted agen
Rep. gr.00 - Technical data Prote AG.
Note
♦ The following procedure wasswcreated

agen
AG.for the 2.0 l common
Volkswagen AG
does rail
engine equipped for left-hand
by
Vol
k drive. The procedure fornother
ot g
ua
engines should be adapted
rised accordingly. ran
t ee
tho or
♦ Flushing a contaminated
sa
u refrigerant circuit is carried out ac
against the direction
s
of normal flow.
ce
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nl
pt
du
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erm
ab
ility
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Setting up
hole
spec
es, in part or in w
t to the co
CAUTION
rrectness of i
erant.
l purpos
freezing.
nform
ercia

m
at
om
ion
– Extract refrigerant and open the refrigerant circuit immedi‐
c
in t
or
ately afterwards.
his
ate
do
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p
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or

f
en
ng

t.
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op
C py
t. rig
gh ht
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by
Prepare air conditioner service station as follows cted agen
Prote AG.



olkswagen AG
en AG. V
Air conditioner service stationolwith
ksw external flushing device
ag does
no
yV t gu
b ara
– Unscrew quick-release ris fastener -1- on refrigerant hose on
ed nte
high-pressure side
aut (red) -2-.
ho eo
ra
s c s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
mercia
at
om
io
n
c
in t
or
his
ate
do
riv

p
cum
for

en
ng
t.
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of air conditioner service station . t. Cop py
rig
gh ht
• There must be at least 7 kg of R134a refrigerant. yri
p by
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by c lksw
cted
agen
Prote AG.
valve .
Note
– Drill out expansion valve -1- as shown using ∅ 6 mm bit -3-.

– Clean drilled out expansion valve -1- of dirt.
– Install drilled out expansion valve -1-.
– Connect refrigerant lines to drilled out expansion valve -1-.
– Remove desiccant cartridge ⇒ Heating, air conditioning sys‐
tem; Rep. gr. 87 ; Refrigerant circuit; Removing and installing
desiccant cartridge .

– Close and secure desiccant cartridge connection on condens‐

er -1- using adapter for connecting desiccant cartridge con‐
nection - VAS 6338/68- -2-.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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un
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an
d
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Vehicles with PR numbers 9AS or 9AP
rm
ab
pe
ility
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-2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
ti
on in
-2-.
r
te o
thi
s
iva
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r
rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Vehicles with PR number 2AB

-2-.

AG. Volkswagen AG d
Air conditionings agen
wsystems with refrigerant
oes R134a - General information - Edition 08.2019
olk t gu no
V
by ara
ed nte
– Connect refrigerant
tho
ris
line of air conditioner compressor on e olow-
pressure auside (larger diameter) -1- to adapter - VAS 6338/7-ra
c
ss
-2-.
ce
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nl
pt
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ab
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rrectness of i
Continued for all vehicles
l purpos

nf
ercia
orm
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or c
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Cop py
t. rig
gh ht
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Vo
co lksw
by
cted agen
Prote AG.


diameter) -1-.
Flush
station .
Note


♦ Expansion valve
♦ Desiccant cartridge
pressure side Volkswa n AG. gen AG
wage does
♦ Oil seals y Volks not
gu
d b ara
– Charge se
rirefrigerant circuit ⇒ page 49 . nte
tho eo
au ra
– Perform
ss leakage test on reattached line connections ofc refrig‐
ce
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un
pt
an
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itte

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rm
ab

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hole
Specified torques
spec
es, in part or in w
♦ Refrigerant circuit; Assembly overview - expansion valve ⇒

t to the co
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐

cuit; Assembly overview - expansion valve
rrectness of i
Component Specified torque

l purpos
Bolt securing desiccant cartridge on condenser ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
frigerant circuit; Removing and installing desiccant
nform
ercia
cartridge
m
a
com
tion in
r
te o
thi
8.6.4 Procedure for setting up and flushing refrigerant circuit, vehicles with sec‐
s
iva
do
r
rp
ond evaporator
um
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos
♦ Adapter for connecting desiccant cartridge connection - VAS

6338/68-
nf
ercia
or
♦ Adapter for connecting expansion valve - VAS 6338/69-

m
m
atio
om

n in
or c

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

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

cuit (roof air conditioning system) must be rinsed first.
Setting up
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
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ce
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nl
pt
du
an
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c

in t
or
his
ate

do
priv

um
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Note


– Remove expansion valve with refrigerant circulation solenoid
valve - N43- ⇒ Heating, air conditioning system; Rep. gr. 87 ;
Refrigerant circuit of roof air conditioning system; Evaporator;
Removing and installing expansion valve with refrigerant cir‐
culation solenoid valve - N43- .
valve .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Note ut
hor eo
ra
s a c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
– Drill out expansion valve and expansion valve with refrigerant
t to the co
circulation solenoid valve - N43- -1- as shown using ∅ 6 mm
drill bit -3-.
rrectne
– Clean drilled out expansion valve and drilled out expansion
valve with refrigerant circulation solenoid valve - N43- -1- of
s
dirt.
s o
cial p
f i
– Install drilled out expansion valve and drilled out expansion
nform
valve with refrigerant circulation solenoid valve - N43- -1-.
mer
atio
m
– Connect refrigerant lines to drilled out expansion valve with

o
n
c
refrigerant circulation solenoid valve - N43- -1-.

or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
valve .
t.
yi Co
op py
– Attach and secure refrigerant lines of first refrigerant circuit to
t. C rig
gh ht
yri
adapter for connecting expansion valve - VAS 6338/69- . p by
o Vo
by c lksw
cted agen
– Remove desiccant cartridge ⇒ Heating, air conditioning sys‐ Prote AG.
tem; Rep. gr. 87 ; Refrigerant circuit; Removing and installing
desiccant cartridge .

– Close and secure desiccant cartridge connection on condens‐

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

-2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
-2-.
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
Vehicles with PR number 2AB

thi
te
sd
iva

o
r
rp
cu
o

m
f
en
ng
t.
-2-. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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Amarok 2011 ➤ , Amarok d by
V
2017 ➤ , Ameo 2017 ➤ , Arteon gu
ara 2018 ➤ , Atlas 2 ...
e nte
Air conditioning thsystems
oris
with refrigerant R134a - General information
eo - Edition 08.2019
au ra
ss c
ce
le
un
pt
an
d
itte
-2-.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
Continued for all vehicles
cial p
f inform
mer
atio
m

o
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.

diameter) -1-.
Flush
– Start first flushing sequence via menu of air conditioner service
station .
Note

– Remove adapter for connecting expansion valve - VAS

6338/69- .
– Connect refrigerant lines to drilled out expansion valve of first
– Remove drilled out expansion valve with refrigerant circulation
solenoid valve - N43- ⇒ Heating, air conditioning system; Rep.
gr. 87 ; Refrigerant circuit of roof air conditioning system;
Evaporator; Removing and installing expansion valve with re‐
frigerant circulation solenoid valve - N43- .

– Attach and secure refrigerant lines -1- to adapter for connect‐

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


♦ Expansion valve AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Expansion valve
ised with refrigerant circulation solenoid
b arvalve
an -
N43- thor tee
o
au ra
c
♦ ss cartridge
Desiccant
ce
le
un
pt
an
d
itte
y li
pressure side
erm
ab
ility
ot p
♦ Oil seals
wit
is n
– Charge refrigerant circuit ⇒ page 49 . h re

ole,
spec

t to the co

rrectne

ss
Specified torques
o
cial p
f inform
♦ Refrigerant circuit; Assembly overview - expansion valve ⇒

mer
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐

atio
m
cuit; Assembly overview - expansion valve

o
n
c
i
or
n thi
te
sd
a
Component Specified torque

iv
o
pr
cum
r
fo
Bolt securing desiccant cartridge on condenser ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
en
ng
t.
frigerant circuit; Removing and installing desiccant
yi Co
op py
cartridge
. C rig
ht ht
rig by
py
Bolts securing expansion valve on refrigerant circula‐ ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
co Vo
by lksw
tion solenoid valve - N43- frigerant circuit of roof air conditioning system; Evap‐
cted agen
Prote AG.
orator; Removing and installing expansion valve with
refrigerant circulation solenoid valve - N43-

frigerant circuit, Crafter 2017 ► or MAN
TGE ►, Crafter Grand California ►
Note
If the vehicle has a second evaporator, the rear refrigerant circuit

(roof air conditioning system) must be rinsed first ⇒ page 131 .



vehicles with one evaporator
Note

VAS 6338/38-
4 - Adapter for refrigerant cir‐
cuit on low-pressure side - air
conditioner service station -
VAS 6338/12-
6338/50- AG. Volkswagen AG d
agen oes
olksw not
y V gu
5 - Refrigerant hose ise
d b ara
nte
or
❑ High-pressure side auth eo
ra
s c
❑ from air conditioner s
ce
le
service station
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n

h re
ole,
service station
spec
7 - Adapter for refrigerant cir‐

t to the co
cuit on high-pressure side - air

conditioner service station -
VAS 6338/3-
rrectne

s
6338/50-
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
126
cted agen
Prote AG.

vehicles with second evaporator
Note


moving and installing agen
AG. Volkswagen AG d
oes
expansion valve olksw not
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ara
ed
is nte
2 - Refrigerant lines hor eo
ut ra
❑ Qty. 2 ss a c
ce
le

un
pt
an
pressure side of rear re‐
d
itte
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frigerant circuit
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5 - Adapter for connecting re‐
frigerant circuit on high-pres‐
rrectness of i
sure side - VAS 6338/63-
l purpos
❑ Only on vehicles with

second evaporator
nform
ercia
❑ For connecting front re‐

frigerant circuit on high-
m
a
com
pressure side when this

ion in
is to be flushed on vehi‐
r
te o
thi
cles with second evapo‐

s
iva
do
rator
r
rp
cum
fo
en
ng
t.
yi Co
op
❑ Low-pressure side C py
ht. rig
rig ht
❑ from air conditioner py by
co Vo
service station
by lksw
cted agen
Prote AG.
8 - Adapter for connecting refrigerant circuit on low-pressure side - VAS 6338/5-
❑ Only on vehicles with second evaporator
❑ For connecting front refrigerant circuit on low-pressure side when this is to be flushed
9 - Adapter for refrigerant circuit on low-pressure side - air conditioner service station - VAS 6338/3-
10 - Adapter for refrigerant circuit on high-pressure side - air conditioner service station, low-pressure side -
VAS 6338/60-
11 - Adapter for refrigerant circuit on low-pressure side - air conditioner service station - VAS 6338/12-

. Volkswagen AG
gen AG doe
swa
Amarok 2011 ➤ , Amarok 2017 ➤ , yAmeo Volk 2017 ➤ , Arteon 2018 s➤ no,t Atlas 2 ...
gu
b ara
rised
R134a - General information - Edition nte 08.2019
ho eo
aut ra
12 -Adapter for refrigerant circuit onss high-pressure side - air conditioner service station c- VAS 6338/3-
ce
le
un
pt
an
d
itte
y li
13 - Expansion valve adapter - VAS 6338/38-
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
evaporator
es, in part or in w
t to the co
rrectness of i
equipment required
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.

♦ Expansion valve adapter - VAS 6338/38-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Amarok 2011 ➤uth, Amarok 2017 ➤ , Ameo 2017 ➤ , Arteon 2018
o e o ➤ , Atlas 2 ...
ra
a
ss with refrigerant R134a - General information - Edition c 08.2019
ce
e
nl
pt
du
an
itte
y li
erm
Note
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
Setting up
orm
m
atio
om
n in
c

or
thi
te
sd
a

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




Note


AG. Volkswagen AG d
valve . lksw
agen oes
n o ot g
yV ua
– Install expansion valve adapter - VAS 6338/38-
ise
db . ran
r tee
tho
– Connect refrigerant lines to expansion svalve
au adapter - VAS or
ac
6338/38- . s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
-1-.
l purpos

nf
ercia
-4-. orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Flush
station .
Note

bungs from engine bung set - VAS 6122- . . Volkswag
AG en AG
agen does
olksw not
On successful completion of flushing procedure,
db
yV remove all gu
ara
adapters and renew following components rise during assembly nte
tho eo
au ra
♦ Air conditioner compressor ss c
ce
le
un
pt
♦ Expansion valve
an
d
itte
y li
♦ Desiccant bag
rm
ab
pe
ility
ot
wit
, is n
pressure side
h re
hole
spec
♦ Oil seals
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
Specified torques
com
tion in
♦ Refrigerant circuit; Assembly overview - refrigerant lines ⇒

r
te o
thi
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; As‐

s
iva
do
sembly overview - refrigerant lines

r
rp
cum
fo
en
g
♦ Air conditioner compressor; Assembly overview - drive unit for

n
t.
yi Co
air conditioner compressor ⇒ Heating, air conditioning; Rep. Cop py
t. rig
gr. 87 ; Air conditioner compressor; Assembly overview - drive yri
gh by
ht
unit for air conditioner compressor cop Vo
by lksw
cted agen
Prote
♦ Front heater and air conditioning unit; Assembly overview -
AG.
evaporator housing ⇒ Heating, air conditioning; Rep. gr. 87 ;

Front heater and air conditioning unit; Assembly overview -
evaporator housing
ond evaporator


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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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.

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

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Note orise nte
eo
h
aut ra
s c
♦ If the vehicle has a second evaporator, the rear refrigerant cir‐
s
ce
le
cuit (roof air conditioning system) must be rinsed first.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Setting up
ss o
cial p
f inform
mer
atio
m

o
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.




Note


wage
– Remove expansion valve for air conditioneryV
o refrigerant - N697-
lks es n
ot g
⇒ Heating, air conditioning; Rep. gr.ise87
d ; Refrigerant circuit;
b ua
ran
Removing and installing expansion th valve .
or tee
or
au ac
ss
ce
e
nl
pt
du
an
Note
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
– Drill out expansion valve for air conditioner refrigerant - N697-
-1- as shown using ∅ 6 mm drill bit -3-.
l purpos
– Clean drilled out expansion valve for air conditioner refrigerant

- N697- -1- of dirt.
nf
ercia
orm
– Install drilled out expansion valve for air conditioner refrigerant
m
atio
m
- N697- -1-.
o
n in
or c
thi
– Connect refrigerant lines to drilled out expansion valve for air

te
sd
a
conditioner refrigerant - N697- -1-.

iv
o
r
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o
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

f
en
ng
t.
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Removing and installing battery tray .
Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
Note Prote
cted AG.
agen
When unclipping and detaching hydraulic line, be aware of slave

cylinder.
– Unscrew nuts -1-.

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

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

-4- to adapter - VAS 6338/3- -3-.
– Connect refrigerant line on high-pressure side (smallerwadiam‐ gen AG
. Volkswagen AG
does
eter) -1- to refrigerant circuit adapter high-pressure yV
oside - air
lks not
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conditioner service station low-pressure side i-seVAS
d b 6338/60- ara
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es, in part or in w
t to the co
rrectness of i
conditioner service station to threaded connection of refriger‐
l purpos
ant circuit adapter high-pressure side - air conditioner service

station low-pressure side - VAS 6338/60- -2- of refrigerant line
nform
for air conditioner service station on high-pressure side (small‐
ercia
er diameter) -1-.
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Flush
n in
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station .
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Note C py
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rig ht
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If a flushed refrigerant circuit is not reassembled immediately after by c lksw
cted agen
Prote AG.
– Remove adapter - VAS 6338/3- and refrigerant circuit adapter

high-pressure side - air conditioner service station low-pres‐
sure side - VAS 6338/60- .
– Connect refrigerant line low-pressure side (larger diameter)

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

– Connect refrigerant line high-pressure side

gen AG. Vo(smaller diameter)
lkswagen AG do
-1- to refrigerant circuit adapter
ol swa
khigh-pressure side - VASes not g
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6338/63- -2- and nut -3-.sed b ua
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ri tee
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– Remove expansion avalveut ⇒ Heating, air conditioning; Rep. or
ac
gr. 87 ; Refrigerantsscircuit; Removing and installing expansion
ce
le
valve .
un
pt
an
d
itte
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– Install expansion valve adapter - VAS 6338/38- .
erm
ab
ility
ot p
wit
6338/38- .
is n
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spec
t to the co
rrectne
s
s o
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f inform
mer
atio
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-1-.
o
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um
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Cop py
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by
cted agen
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Amarok th 2011 ➤ , Amarok 2017 ➤ , Ameo 2017 ➤e ,o Arteon 2018 ➤ , Atlas 2 ...
o te
u ra
Air conditioning
ss
a
systems with refrigerant R134a - General information c - Edition 08.2019
ce
le
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an
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erm
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t to the co
Flush
rrectne
service station .
ss o
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Note
mer
atio
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On successful completion of flushing procedure, remove all Cop py
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adapters and renew following components during assembly opyri
gh by
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ht
c lksw
by
cted agen
Prote AG.
♦ Expansion valve
♦ Expansion valve for air conditioner refrigerant - N697- ,
♦ Desiccant bag
pressure side
♦ Oil seals
– Check for damage and note correct installation of hydraulic
line of slave cylinder.
Specified torques
♦ Refrigerant circuit; Assembly overview - refrigerant lines ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; As‐
sembly overview - refrigerant lines
air conditioner compressor ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor; Assembly overview - drive
unit for air conditioner compressor
♦ Front heater and air conditioning unit; Assembly overview -
evaporator housing ⇒ Heating, air conditioning; Rep. gr. 87 ;
Front heater and air conditioning unit; Assembly overview -
evaporator housing

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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Amarok 2011 ➤ , Amarok 2017 horis
➤ , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas e o2 ...
ut
Air conditioning systems swith
s a refrigerant R134a - General information - Edition ra
c 08.2019
ce
le
un
pt
an
d
itte
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frigerant circuit, Transporter 2016 ►
rm
ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
vehicles with one evaporator

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tion in
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Note
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Co
Cop py
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by c lksw
cted agen
Prote AG.
VAS 6338/56-
6338/50-
6338/50-
5 - Adapter - VAS 6338/12-
6338/50-
service station
service station


vehicles with second evaporator
Note

moving and installing
expansion valve
4 - Adapter for connecting re‐
frigerant circuit on high-pres‐
sure side - VAS 6338/63- swage
es n
olk ot g
yV
5 - Adapter for refrigerant cir‐ d b ua
ran
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cuit on high-pressure side - air tho tee
or
conditioner service station, s au ac
low-pressure side - VAS s ce
le
6338/60-
un
pt
an
d
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erm
ab
ility
ot p
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is n

h re
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service station
spec

t to the co
VAS 6338/56-
rrectne
6338/50-
s
8 - Adapter - VAS 6338/12-

s o
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inform

mer
6338/50-
atio
om
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c

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Cop py
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co
11 - Adapter for refrigerant circuit on low-pressure side - air conditioner service station, high-pressure side -
by lksw
cted agen
VAS 6338/61-
Prote AG.
12 - Adapter for connecting refrigerant circuit on low-pressure side - VAS 6338/62-

13 - Connecting adapter angle piece - VAS 6338/64-

evaporator

equipment required
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is n
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t to the co
rrectness o
cial p
f inform
mer
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c
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fo

en
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op py
♦ Engine bung set - VAS 6122- t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
♦ Connecting adapter angle piece - VAS 6338/64-

Note
Setting up
G. Volkswage
– Unscrew quick-release fastener -1- lksw
on refrigerant
agen
A
hose onoes n
n AG d
high-pressure side (red) -2-. by Vo ot g
ua
ed ran
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du
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rrectness of i
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or c
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t.
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Cop py
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– Unscrew quick-release fastener -1- on refrigerant hose on yri
gh by
ht
high-pressure side (red) -2-. cop Vo
by lksw
cted agen
Prote AG.


Note


– Remove expansion valve ⇒ Heating, air conditioning;
swage
n AG. VoRep.
lkswagen AG
does
gr. 87 ; Refrigerant circuit; Removing andby V installing expansion
o lk not
gu
valve . ris
ed ara
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– Install expansion valve adapter s a - VAS 6338/56- from adapter
u ac
set for refrigerant circuit - VASs 6338/50- .
ce
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un
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an
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itte
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6338/56- .
erm
ab
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spec
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s
s o
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-2-.
form
mer

atio
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o
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i
or
-4-.
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t.
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Cop py
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gh ht
pyri by
Vo
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by
cted agen
Prote AG.


Flush
station .
Note


♦ Expansion valve
♦ Desiccant bag
AG. Volkswagen AG d
♦ Evacuating and charging valve, high-pressure side and wlow-
agen oes
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pressure side db
y V gu
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ris
♦ Oil seals tho eo
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Specified torques
rrectne
ss o
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form
mer
ond evaporator
atio
om
n
c
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


equipment required
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spec
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t to the co
♦ Adapter for refrigerant circuit on high-pressure side - air con‐

ditioner service station, low-pressure side - VAS 6338/60-
♦ Adapter for refrigerant circuit on low-pressure side - air con‐
rrectness of i
ditioner service station, high-pressure side - VAS 6338/61-

l purpos
♦ Adapter for connecting refrigerant circuit on low-pressure side

- VAS 6338/62-
nf
ercia
♦ Adapter for connecting refrigerant circuit on high-pressure

rm
side - VAS 6338/63-

m
atio
om
n in
c
♦ Connecting adapter angle piece - VAS 6338/64-

or
thi
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t.
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Cop py
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gh ht
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by
cted agen
Prote AG.

Note
♦ To install the individual flushing adapters, the original
agthreaded
en AG. V
olkswagen AG
do
connections (nuts and bolts) are to be used yand
Vol tightened to
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the respective torque. ise
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Setting up ss
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cial p
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mer
atio
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o
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c
i
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en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.



Note


valve .
6338/56- . n AG. Volkswagen AG do
lkswage es n
o ot g
– Remove desiccant bag ⇒ Heating, air conditioning system; ed by V ua
ran
Rep. gr. 87 ; Refrigerant circuit; Removing and installing des‐horis tee
iccant bag/desiccant cartridge . aut or
ac
ss
ce
le
un
pt
an
d
itte
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
y li
rm
ab
and installing air filter housing .
pe
ility
ot
– Remove right headlight ⇒ Electrical system; Rep. gr. 94 ;
wit
, is n
h re
Headlights; Removing and installing headlights .
hole
spec
– Disconnect refrigerant line in area of angle piece.
es, in part or in w
t to the co
– Install connecting adapter angle piece - VAS 6338/64- -3- on
nuts -1- and refrigerant lines -2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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rp
cum
fo
en
ng
t.
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op py
– Disconnect refrigerant lines on high-pressure side (smaller di‐ t. C rig
gh ht
ameter) -1- and -5-. yri
p by
co Vo
by lksw
cted
– Connect refrigerant lines high-pressure side (smaller diame‐
agen
Prote AG.
ter) -1- to refrigerant circuit adapter high-pressure side - VAS
6338/63- -2- and nut -4-.
– Connect refrigerant lines on high-pressure side (smaller di‐
ameter) -5- to refrigerant circuit adapter high-pressure side -
air conditioner service station low-pressure side - VAS
6338/60- -3- and nut -4-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Amarok
autho
2011 ➤ , Amarok 2017
Arteon 2018 ➤ , Atlas 2 ... ➤ , Ameo 2017 e➤
or ,
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
-2-.
ility
ot p
wit
– Connect refrigerant line of air conditioner compressor on low- , is n
h re
hole
spec
-4-.
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
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f
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ng
t.
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op
– Connect refrigerant hose on low-pressure side (blue) -5- of air C py
t. rig
gh ht
yri by
cop Vo
by lksw
cted
agen
Prote AG.

Flush
station .
Note

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

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

Note
Disregard items 1, 2 and 4.
– Connect refrigerant hose on low-pressure side (blue) -6- of Aair

G. Volkswagen AG d
conditioner service station to threaded connectionolof agen
kswrefriger‐
oes
not
ant circuit adapter high-pressure side - air conditioner
d by
V service gu
ara
station low-pressure side - VAS 6338/60- -3- orisof refrigerant line
e nte
eo
on high-pressure side (smaller diameter) au -5-.
th
ra
ss c
– Remove rear expansion valve ⇒ Heating, air conditioning;
ce
le
un
pt
Rep. gr. 87 ; Refrigerant circuit; Removing and installing ex‐
an
d
itte
pansion valve .
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
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note
– Drill out expansion valve -1- as shown using ∅ 6 mm bit -3-.

– Clean drilled out expansion valve -1- of dirt.
– Install drilled out expansion valve -1-.
– Connect refrigerant lines to drilled out expansion valve -1-.
Flush
service station . n AG. Volkswagen A age G do
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y Vol ot g
ua
b
ed ran
Note horis tee
t or
au ac
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e
nl
pt
du
an
itte
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
♦ Front expansion valve
♦ Rear expansion valve
rrectness of i
♦ Desiccant bag
l purpos

pressure side
nf
ercia
orm
♦ Oil seals
m
atio
om
n in
c

or
thi
te
sd

iva
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rp
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f
en
ng
t.
– Bring air conditioning system into operation after charging re‐ op
yi Co
C py
t. rig
gh
ht
pyri by
Vo
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cted agen
Prote AG.
Specified torques

9 Complaints
wage es n
9.1 Possible complaints about refrigerant olks ot g
byV ua
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circuit utho
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or
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Note
du
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♦ The air conditioning system is operating correctly if the air
ility
ot p
emerging from the vent on the dashboard is at a temperature
wit
of 7°C or less. , is n
h re
hole
spec
♦ Set the Climatronic to: “LO”.
es, in part or in w
t to the co
♦ Set the air conditioning system: “A/C” on; “max”; “cold”.
9.1.1 Conditions for testing:
rrectness of i
l purpos
• Self-diagnosis of the air conditioning system with the Vehicle

diagnosis, testing and information system - VAS 5051A- using
“Guided Fault Finding” cannot detect any faults; no switch-off
nf
ercia
conditions for the air conditioner compressor are set in the
orm
measured value block (only when the vehicle “air conditioning
m
atio
m
system” is fitted with self-diagnosis).

o
n in
or c
⇒ Rep. gr. 87
thi
te
sd
iva
o
r
9.1.2 Possible complaints

rp
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Note
gh ht
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cted agen
For all complaints marked with * ⇒ page 155 . Prote AG.
♦ The cooling has failed completely. *

♦ Insufficient cooling output at all vehicle or engine speeds. *
♦ No or insufficient cooling after driving a few miles. *
♦ The air conditioner compressor, the air conditioning system
magnetic clutch - N25- or the air conditioner compressor reg‐
ulating valve - N280- have been switched off by low-pressure
switch for magnetic clutch - F73- , high-pressure switch for
magnetic clutch - F118- , air conditioning system pressure
switch - F129- or by operating and display unit for Climatronic
air conditioning system - E87- or Climatronic control unit -
J255- because pressure was too high or too low.* *
♦ No fresh air flow, or very much reduced fresh air flow after
driving some distance (evaporator iced up). *
In addition, the following problems may occur:
The air conditioner compressor is noisy
– Tighten the securing screws for the air conditioner compressor
and the air conditioner compressor bracket using a torque
wrench.
– Check routing of refrigerant pipes; they must not touch other
components and must be installed without tension (adjust if
necessary).

Noises (refrigerant hammering) occur immediately after the air

conditioning is switched on and/or in a curve or when the brakes
are applied:
– Discharge, evacuate and re-charge refrigerant circuit (too
much refrigerant in circuit).
Note
♦ Excess refrigerant oil in the circuit may also cause this problem
(e.g. if the refrigerant oil level was not checked after the air
conditioner compressor was renewed). In case of this com‐
plaint, the refrigerant circuit must be purged with R134a re‐
frigerant ⇒ page 65 .
♦ The refrigerant must be drained from the air conditioning com‐
pressor. To facilitate this process, turn the air conditioner
compressor over by hand at the poly V-belt pulley or coupling
disc of the magnetic coupling. Then fill refrigerant circuit with
total amount of refrigerant oil (50 g direct into air conditioner
compressor) according to ⇒ vehicle-specific workshop man‐
ual . AG. Volkswagen A
n G do
wage es n
Volks ot g
Water sprays out of the vents (in dash panel or footwell)ed although
by ua
ran
oris
air conditioning system is otherwise functioning tproperly: tee
h or
au ac
– Check proper routing of condensate drain; it must not be
ss
ce
e
crushed or kinked.
nl
pt
du
an
itte
– The condensed water drain valve must not be hindered in its
y li
erm
ab
operation by wax or underbody sealant and must open and
ility
ot p
close properly.
wit
, is n
h re
– Check the plenum chamber cover; it must be undamaged and
hole
spec
be installed correctly (no water must flow into the evaporator).
es, in part or in w
t to the co
– Check water drains in plenum chamber; they must not be
blocked (e.g. by leaves).
9.2 Odours from heater and air conditioner
rrectness of i
unit
l purpos
nform
ercia
9.2.1 Does the odour emanate from the evap‐

m
at
orator or heat exchanger?
om
ion
c
in t
or
♦ Fishy smell
his
ate
do
riv
– Due to leak in engine's cooling system or in heat exchanger of

p
cum
or
heater and air conditioner unit.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
If the fishy smell is weaker when the temperature is set to “cold”
or stronger when the temperature is set to “warm”, check the heat
exchanger for leaks.
♦ Smell of a burnt clutch

♦ Vapours from foot mats, retrospectively installed seat covers
etc.
♦ Putrid, mouldy smell
– Caused by accumulation of debris, pine needles etc. in plenum
chamber
9. Complaints 151
Note
Clean plenum chamber.

AG. Volkswagen AG d
agen oes
ksw
– Stagnant water that cannot flow out of plenum chamber. by V ol not
gu
ara
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Note ss c
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un
pt
Check water drains in plenum chamber.
an
d
itte
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rm
ab
pe
ility
♦ Smell from heater and air conditioner unit ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Smells that originate from the heater and air conditioner unit can
be detected in fresh air mode and in recirculation mode.
rrectness of i
– Due to too much condensate in the heater and air conditioner
l purpos
unit
nform
ercia
Note
m
a
com
tion in
Check the condensation water drains ⇒ Rep. gr. 87 as indicated
r
te o
thi
in the vehicle-specific repair manual.
s
iva
do
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rp
cum
fo
– Due to an old or very dirty dust and pollen filter
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote
Check the dust and pollen filter ⇒ Rep. gr. 80 as indicated in the
AG.
vehicle-specific repair manual.
– Due to deposits on the fins of the evaporator
Note
Clean the evaporator, using the ultrasonic air conditioner cleaning

unit - VAS 6189A- ⇒ page 152 or the suction feed spray-gun -
V.A.G 1538- and corresponding spray lance ⇒ page 153 .
9.2.2 Ultrasonic air conditioner cleaning unit -

VAS 6189A-
– The ultrasonic air conditioner cleaning unit - VAS 6189A- must
be placed in the front-passenger footwell and sprays the agent
Aero-Clean. Aero-Clean neutralises microbes and bacteria in
the heater and air conditioner unit.
The device is provided with instructions for use.
Current equipment ⇒ Electronic parts catalogue .

9.2.3 Spraying the evaporator with the suction

feed spray-gun - V.A.G 1538- and spray
lance
Directly spray the evaporator with cleaning solution using a spray
lance (approx. 10 bar). The cleaning solution neutralises mi‐
crobes and bacteria directly on the evaporator.
In order to enable access to the evaporator, preparatory work and
different spraying lances are necessary, e.g. V.A.G 1538/5; V.A.G
1538/6 or V.A.G 1538/7.
Volkswa
Vehicle-specific instructions
wage
n AG. for user are dprovided
gen AG
oes with the evap‐
orator cleaning Volks
solution “D 600 100 A2”. not
gu
by d a ran
se
Current tdevices
ho
ri and spray lances ⇒ Electronic partstecatalogue
eo .
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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.
9. Complaints 153
10 Connecting the air conditioning serv‐

ice station
10.1 For vehicles that have connections on

AG. Volkswagen AG d
agen
both low-pressure byV
oand
lksw high-pressure es not
o
gu
sides of refrigerant circuit
d ara
rise nte
ho e t or
au ac
ss
ce
e
nl
10.1.1 Connecting a air conditioner service sta‐
pt
du
an
itte
y li
tion for measuring and testing
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
ply.
es, in part or in w
t to the co
– Connect quick-release coupling adapters to filler hoses of air
conditioner service station (handwheels not turned inwards,
i.e. manual stop valves not open).
rrectness of i
– Switch on air conditioner service station in this state and evac‐
l purpos
uate charging hoses (necessary only if air is in the charging

hoses).
nform
ercia
– Switch off air conditioner service station .

m
at
– Unscrew sealing cap from service connections (with valve).
om
ion
c
in t
r
– Connect air conditioner service station via service connections

o
his
e
to vehicle refrigerant circuit using quick-release coupling

at
do
riv
adapters.
p
cum
for
en
g
– Turn handwheel of quick-release coupling adapter inwards

n
t.
yi Co
op
only far enough to ensure that valves on service connections C py
ht. rig
are open (check using a pressure gauge; do not overstress rig ht
py by
valves). co Vo
by lksw
cted agen
Prote AG.
– Perform the intended measuring and checking work.

11 Checking pressures on vehicles
11.1 Checking pressures in the refrigerant

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

correctly if the air emerging from the vent on the dashboard is
at a temperature of 7°C or less.
♦ Set the Climatronic to: “LO”.
♦ Set the air conditioning system: “A/C” on; “max”; “cold”.
♦ Connections with valve w
and
agenservice connections
AG. Volkswagen AG d for measure‐
oe
ment and testing Vol
ks s no
t gu
d by ara
e nte
ris
ho eo
11.1.1 ss
Conditions for testing
au
t ra
c
ce
e
• Radiator and condenser clean (clean if necessary)

nl
pt
du
an
itte
• The heat insulation on expansion valve is OK and properly y li

erm
ab
installed. See vehicle-specific repair manual ⇒ Rep. gr. 87 . ility
ot p
wit
• The poly V-belt is OK and properly tensioned. The V-belt for
, is n
h re
air conditioner compressor and alternator is in good condition

hole
spec
and correctly tensioned. See vehicle-specific repair manual ⇒

es, in part or in w
Rep. gr. 87
t to the co
• All air ducts, covers and seals are OK and properly installed.
• Fault-finding on the electrical systems and vacuum system
rrectness of i
has found no faults. See vehicle-specific repair manual ⇒ Rep.

l purpos
gr. 87
• Self-diagnosis of the air conditioning system with the vehicle
nform
ercia
diagnosis, testing and information system - VAS 5051A- using

“guided fault finding” cannot detect any faults; no switch-off
m
at
conditions for the air conditioner compressor are set in the

om
ion
measured value block (only when the vehicle “air conditioning

c
in t
or
system” is fitted with self-diagnosis).

his
ate
do
riv
• The passage of air through the dust and pollen filter is not im‐
p
cum
or
paired by dirt. See vehicle-specific repair manual ⇒ Rep. gr.

f
en
ng
t.
yi
87
Co
Cop py
t. rig
• The heater and air conditioner does not draw any secondary
gh ht
pyri by
air at highest fresh air blower speed. evaporator and heater
o Vo
by c lksw
cted
not drawing in secondary air at maximum fresh-air blower
agen
Prote AG.
speed See vehicle-specific repair manual ⇒ Rep. gr. 87
• The air duct flaps in the heater and air conditioner reach their
stop positions. See vehicle-specific repair manual ⇒ Rep. gr.
87
• The fresh air intake ducts under the bonnet and in the pas‐
senger compartment and their water drain valves are in good
condition. See vehicle-specific repair manual ⇒ Rep. gr. 87
• Engine warm.
• Vehicle not exposed to sunlight
• Ambient temperature is above 15°C.
• All dash panel vents open
11. Checking pressures on vehicles 155

• Engine running and air conditioner set to maximum cooling

output
⇒ Rep. gr. 87
Set maximum cooling output
Settings on operating and display unit for Climatronic air condi‐
tioning system - E87-
– Select “Auto” mode (air conditioner compressor switched on).
– Select temperature setting “LO” for driver and front passenger.
Setting on heating control:
– A/C button and Rec or recirculate buttons should be pressed.
– Set rotary temperature control to Cold stop.
– Set rotary fresh air blower control to position 4.
• The radiator fan(s) should be running radiator fan - V7- (at
least at speed 1).
Note
With some versions, the fan is not switched on until the pressure
in the refrigerant circuit has exceeded a specified value.
• The fresh air blower - V2- should be running at maximum

speed.
• The air flap for fresh air and air recirculation moves to the “re‐
circulation” position or the air flow flap closes and the recircu‐
lation flap opens (within 1 minute of starting the vehicle).
• The coolant shut-off valve is sclosed.
wage
es k not
Vol g
• The valves for the pump ed valve unit are closed (and the coolant
by ua
ran
ris pumping).
circulation pump isthonot tee
o u ra
sa
11.1.2 Checking pressures
s c
ce
le
un
pt
an
d

itte
y li
erm
ab
– Connect the air conditioner service station ⇒ page 154 .

ility
ot p
wit
is n
– Read pressures off pressure gauges; there may be two re‐

h re
sults.
ole,
spec
Ambient temperature (in de‐ Pressure in the refrigerant cir‐

t to the co
grees C) cuit in bar positive pressure

+15°C 3.9
rrectne
+20°C 4.7
+25°C 5.6
ss o
+30°C 6.7
cial p
f inform
+35°C 7.8
mer
atio
+40°C 9.1
om
n
c
+45°C 10.5
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.

Note
♦ The temperature of the components of the refrigerant circuit

should be the same as the ambient temperature.
♦ If individual components of the refrigerant circuit are warmer
or colder, the pressure will deviate from the values shown in
the tables.
♦ Absolute pressure means that 0 bar corresponds to an abso‐
lute vacuum. The normal ambient pressure corresponds to 1
bar absolute pressure. On the scales of most pressure
gauges, 0 bar corresponds to an absolute pressure of 1 bar
(indicated by -1 bar mark below 0).
♦ Where vehicles have a high-pressure sender - G65- which in‐
dicates the measured pressure in the measured values block,
the measured pressure should agree with the values in the
tables.
⇒ Rep. gr. 87
The pressure in the refrigerant circuit is lower than indicated in
the table
Too little refrigerant in circuit.
– Check for leaks in the refrigerant circuit ⇒ page 55 .
– Check the high-pressure safety valve.
If the high-pressure safety valve has blown off:
– Check activation of radiator fan. AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Check refrigerant pipes and refrigerant hoses for restrictions
ised b ara
nte
in cross-section at bends that have too tight radius. thor eo
au ra
s c
– Check refrigerant pipes and refrigerant hoses for external
s
ce
le
damage.
un
pt
an
d
itte
y li
– If no defects are found, blow through refrigerant circuit with
rm
ab
compressed air and nitrogen.
pe
ility
ot
wit
The pressure in the refrigerant circuit is equal to or greater than
, is n
h re
that in the table
hole
spec
– Start engine.
es, in part or in w
t to the co
– On vehicles with electrical air conditioner compressor, switch
off ignition.
Danger to life from high voltage rrectness of i
l purpos

electric shock.
nform
ercia

m
a
com
ti
voltage cables.
on in
r
te o
thi

s
iva
tools.
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.


93 ; General warning instructions for work on the high-voltage

system .
– Set air conditioning system for maximum cooling output.
. Volkswagen AG
gen AG does
swa
Note yV
olk not
gu
d b ara
ise nte
r
If when connected to the air conditioner service station
ut
h the low-
o eo
ra
pressure switch had been removed, bypass the electrical con‐
s a c
s
nections in the respective pressure measurement plug.
ce
e
nl
pt
du
an
itte
y li
• The air conditioner compressor is driven by the engine via the
erm
ab
ility
air conditioning system magnetic clutch - N25- .
ot p
wit
, is n
• The air conditioner compressor regulating valve - N280- is ac‐
h re
hole
tivated by the Climatronic control unit - J255- .
spec
es, in part or in w
⇒ Rep. gr. 87
t to the co
If the air conditioner compressor is not driven or the regulating
valve not activated when the engine is running:
rrectness of i
– Determine the cause, e.g. by reading the event memory for
l purpos
the air conditioning system, and rectify it.

– Observe the test prerequisites.
nform
ercia
– Check power supply for air conditioning system magnetic

m
at
clutch - N25- . If this is OK, repair magnetic clutch.
om
ion
c
in t
– Check actuation of air conditioner compressor regulating valve
or
his
e
- N280- .
at
do
priv
cum
⇒ Rep. gr. 87 .
for
en
ng
t.
yi
11.1.3 Continuation of checking pressures
Co
Cop py
ht. rig
rig ht
by
♦ Where vehicles have a restrictor and reservoir, check these copy Vo
by lksw
(with internally regulated air conditioning system compressor) cted agen
Prote AG.
⇒ page 159 .
♦ Where vehicles have an expansion valve and receiver, check
these (with internally regulated air conditioner compressor)
⇒ page 163 .
♦ Where vehicles have an expansion valve and receiver, check
these (without internally regulated air conditioner compressor)
⇒ page 167 .
♦ Where vehicles have a restrictor and reservoir and air condi‐
tioning system compressor regulating valve - N280- (external‐
ly regulated air conditioning system compressor)
⇒ page 168 .

11.2 Checking systems with a restrictor and

collector (with internally regulated air
conditioner compressor)
Note
♦ Connect the air conditioner service station ⇒ page 154 .

Volkswagen AG
♦ Observe the test prerequisites ⇒ page
swa 155 .
gen AG
.
does
not k
y gu Vol
d b ara
e
– Raise engine speed to 2000
horis rpm. nte
eo
ut ra
a
– Observe pressure gauge
ss of the air conditioner service station . c
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
♦ Switching pressures for refrigerant circuit switches are vehi‐
wit
is n
cle-specific.
h re
ole,
spec
♦ The connection with a valve for the low-pressure switch or on

the evaporator should only be used where the vehicle does
t to the co
not have a service connection on the low-pressure side and
access to the connection on the air conditioner compressor or
reservoir is not possible (measurement accuracy). This only
rrectne
applies to certain vehicles.
ss
⇒ Rep. gr. 87
o
cial p
f inform
11.2.1 Specifications:
mer
atio
m
High-pressure side:
o
n
c
i
or
n thi
e
Rising from starting pressure (when pressure gauge is connec‐

t
sd
va
ted) to maximum 20 bar.

i
o
pr
cum
r
fo
Low-pressure side:
en
ng
t.
yi Co
op py
Falling from starting pressure (when pressure gauge is connec‐ t. C rig
gh ht
ted) to diagram value. pyri by
Vo
co lksw
by
cted
A - High pressure (measured at the service connection) in bar
agen
Prote AG.
positive pressure.
B - Low pressure (measured at the connection with the valve at
the air conditioner compressor or at the reservoir) in bar positive
pressure.
C - Permitted tolerance range.
D - Low pressure (measured at the connection with the valve for
the low-pressure switch or at the service connection) in bar pos‐
itive pressure.
E - Permitted tolerance range.

Possible deviation from specification Possible cause of fault Rectifying fault

• High pressure remains constant or in‐ Too little refrigerant in circuit. – Look for leaks and rectify them.
creases only slightly (above the pres‐
sure measured when the engine is – Re-charge refrigerant circuit.
stopped).
• Low pressure falls quickly to the dia‐
gram value or lower,
• Required cooling output is not at‐
tained.
• High pressure normal

• Low pressure matches the diagram
value,
tained.

• Low pressure is too low (see dia‐
gram),
tained.
AG. Volkswagen AG d
agen oes
Volksw Note not
gu
by ara
d
rise nte
If no fault can beuthofound for this complaint, purge (clean) refrigerant
eo
ra
circuit with refrigerant
ss a R134a ⇒ page 65 . If this is not possible inc
your workshop, blow through refrigerant circuit with compressed
ce
le
un
pt
air and dry with nitrogen ⇒ page 63 .

an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re

ole,
spec
• High pressure only increases slightly The air conditioner compressor is de‐ – Flush refrigerant circuit
above pressure with engine stop‐ fective. ⇒ page 65 .

t to the co
ped,
– Renew the air condi‐
• Low pressure falls only slightly, tioner compressor.
rrectne

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


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

AG. Volkswagen AG d
agen oes the system does not
ksw
y Vol operate
not
gu correctly.
edb ara
ris nte
tho – Purge (clean) eo
r a refrig‐
s au erant circuit c
s
⇒ page 65 .
ce
le
un
pt
an
d
• High pressure and low pressure are Moisture in refrigerant circuit – Blowing through re‐
itte
y li
normal at first, but after a time, frigerant circuit with
rm
ab
pe
compressed air and
ility
• The high pressure increases beyond
ot
nitrogen.
wit
, is n
the specified value,
h re
hole
– Renew receiver.
spec
• The low pressure falls to the diagram
es, in part or in w
value or lower,
t to the co
• The cooling power called for is not the system does not
delivered. operate correctly.
rrectness of i
– Purge (clean) refrig‐
l purpos
erant circuit
⇒ page 65 .
nform
ercia
– Re-charge refriger‐
m
ant circuit.
a
com
– Repeat test. tion in

r
te o
thi
s
iva
• High pressure normal The air conditioner compressor is defec‐ – Purge (clean) refrig‐
do
r
rp
tive. erant circuit

um
fo
• Low pressure is too low (see dia‐ ⇒ page 65 .

en
ng
t.
yi
gram),
Co
Cop py
– Renew the air con‐
t. rig
• The cooling power required is deliv‐
gh ht
yri
ditioner compres‐
p by
ered.
o Vo
by c lksw
Prote
cted AG. sor. agen
Note
♦ If the fault is “high pressure normal, low pressure too low ”

please note the following:
♦ In this case, the evaporator may be iced up or the low-pressure
switch for air conditioning system - F73- has switched off the
air conditioning system compressor, although the correct
quantity of refrigerant is present in the refrigerant circuit.

Possible deviation from specifica‐ Possible cause of fault Rectifying fault

tion
• High pressure normal or too Too much refrigerant in circuit. – Extract some refrigerant from
high the refrigerant circuit.
• Low pressure too high (see dia‐ • If quantity of refrigerant extrac‐
gram), ted roughly corresponds to
• The air conditioner compressor specified capacity:
is noisy (especially immediately – Renew the air conditioner com‐
after being switched on), pressor.
• Required cooling output is not
attained. • The quantity of refrigerant ex‐
tracted is significantly greater
than the prescribed charge
quantity.
– Re-charge refrigerant circuit.
– Repeat test.
Possible deviation from specification G. Volkswage Possible cause of fault Rectifying fault
A n AG d
agen oes
• High pressure and lowypressure
Volksw Too much refrigerant
not oil in circuit.
gu – Drain refrigerant cir‐
normal ise
d b ara
n cuit.
r tee
ho
• Required cooling
au output is not at‐
t or
ac – Purge (clean) refrig‐
tained. ss
erant circuit
ce
e
nl
⇒ page 65 .
pt
du
an
itte
y li
• High pressure and low pressure

erm
ab
normal
ility
ot p
wit
, is n
• The air conditioner compressor is

h re
noisy (especially immediately af‐

hole
spec
ter being switched on),

es, in part or in w
t to the co
• The cooling power required is de‐

livered.
rrectness of i
l purpos
Note
nform
ercia
♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor
m
at
was renewed.
om
ion
c
in t
r
♦ If the air conditioner compressor is not to be replaced, drain

o
his
e
refrigerant oil from air conditioner compressor via the block

at
do
riv
connections. From the total amount of refrigerant oil, fill 50 g

p
cum
or
direct into air conditioner compressor and fill remainder in re‐

f
en
ng
t.
frigerant circuit according to ⇒ vehicle-specific workshop man‐
yi Co
op py
ual . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


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

♦ Observe the test prerequisites ⇒ page 155 .
– Raise engine speed to 2000 rpm.

– Observe pressure gauge set.
Note
Switching pressures and design of refrigerant circuit switches are

vehicle-specific.
Pressures must be measured at service connections; fitting loca‐

tions of these connections are vehicle-specific.
⇒ Rep. gr. 87
11.3.1 Specifications: lkswage

es n
ot g
o
byV ua
High-pressure side: ir se
d ran
tee
tho
or
Rising from starting pressure s(when
au pressure gauge is connec‐ ac
ted) to maximum 20 bar. s
ce
e
nl
pt
du
Low-pressure side: an
itte
y li
erm
ab
Falling from starting pressure (when pressure gauge is connec‐ ility
ot p
ted) to diagram value. wit

, is n
h re
A - High pressure in bar positive pressure.

hole
spec
B - Low pressure in bar positive pressure.

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.


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

tioning system is not OK when the test is repeated, purge refrig‐
erant circuit with refrigerant R134a (clean) ⇒ page 65 . If this is
not possible in your workshop, blow through refrigerant circuit with
compressed air and dry with nitrogen ⇒ page 63 . AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Possible deviation from specifica‐ Possible cause orisof fault
ed
Rectifying fault nte
tion aut
h eo
ra
ss c
• High pressure increases above ♦ Constriction or obstruction in re‐ – Run hand over refrigerant circuit ce
e
nl
specification frigerant circuit to check for differences in tem‐ pt

du
an
perature.
itte
y li
• Low pressure falls quickly to the ♦ Expansion valve defective
erm
ab
diagram value or lower,
ility
• At one component a tempera‐
ot p
wit
ture gradient will be detected:

, is n

h re
attained.
hole
– If a hose or pipe is kinked or

spec
crushed, renew it.

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

flush refrigerant circuit with com‐
rrectness of i
pressed air and nitrogen and re‐

place expansion valve.
l purpos
• If no fault can be detected:

nf
ercia
– Purge (clean) refrigerant circuit

orm
⇒ page 65 .
m
atio
om
n in
c
– Repeat test.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note
kswage es n
If the air conditioning system is still by Vnot operating correctly after t gua
ol o
the refrigerant circuit has been ir sepurged with compressed air and
d ran
tee
nitrogen, the expansion valveautho
must be renewed. or
ac
ss
ce
le
un
pt
an
d
itte
y li
• High and low pressure normal at ♦ Expansion valve defective – Examine expansion
erm
ab
first, valve for dirt or cor‐
ility
ot p
♦ Moisture in refrigerant circuit rosion and replace if
wit
is n
• After a while, the high pressure necessary
h re
ole,
increases beyond the specifica‐
spec
tion, and the low pressure falls to
– Blowing through re‐

the diagram value or lower,
t to the co
frigerant circuit with
• The cooling power called for is compressed air and
not delivered. nitrogen.
rrectne
– Renew receiver.
ss
o
cial p
f
the system does not
inform
operate correctly.
mer
atio
m

o
n
c
i
erant circuit
or
n thi
e
⇒ page 65 .
t
sd
iva
o
pr
cum
r
fo
en
ng
ant circuit.
t.
yi Co
Cop py
t. rig
gh
– Repeat test.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Always replace receiver if this fault occurs.


• High pressure normal or too high ♦ Too much refrigerant in circuit. – Extract some refrig‐
(see diagram), erant from the re‐
♦ Expansion valve or air conditioner com‐ frigerant circuit.
• Required cooling output is not at‐ pressor defective.
tained. • If quantity of refrig‐
• The air conditioner compressor is erant extracted
noisy (especially immediately af‐ roughly corre‐
ter being switched on), sponds to specified
capacity:
– Renew the expan‐
sion valve.
ant circuit.
– Repeat test.
• The quantity of re‐

frigerant extracted
is significantly
greater than the
prescribed charge
quantity.
ant circuit.
– Repeat test.
Note
. Volkswagen AG
gen AG does
swa
If the air conditioning system is still not operating correctly when yV
olk not
gu
the test is repeated, refit the expansion valve and purge the re‐ ised b ara
nte
frigerant circuit with compressed air and nitrogen. Then replace ut
hor eo
the air conditioner compressor and receiver. ss a ra
c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
• High pressure only increases ♦ The air conditioner compressor is defec‐ – Flush refrigerant cir‐
h re
slightly above pressure with en‐ tive. cuit ⇒ page 65 .
hole
spec
gine stopped,
es, in part or in w
– Replace the air con‐

t to the co
• Low pressure falls only slightly, ditioner compressor
• The required cooling power is not and receiver. rrectness of i
delivered.
l purpos
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ercia
Possible deviation Possible cause of fault Rectifying

from specification fault
m
at
om
ion
• High pressure ♦ Expansion valve or air – Renew

c
in t
or
normal conditioner compres‐ the expan‐

his
ate
sor defective. sion valve.

do
riv
• Low pressure is
p
cum
or
too low (see dia‐

f
– Re-
en
ng
t.
yi
gram),
Co
charge re‐ Cop py
frigerant ht. rig
• The cooling pow‐ rig ht
by
circuit.
py
er required is de‐
co Vo
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cted agen
livered. Prote AG.
– Repeat
test.

Note
♦ If repeated check results in air conditioning system still not

operating correctly, purge (clean) the refrigerant circuit
⇒ page 65 . Then replace the air conditioner compressor and
receiver.
♦ In this case, the evaporator may ice up although the correct

• High pressure and low pressure Too much refrigerant oil in circuit. – Drain refrigerant cir‐
normal cuit.
• Required cooling output is not at‐ – Purge (clean) refrig‐
tained. erant circuit
⇒ page 65 .
• High pressure and low pressure agen
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oes
normal Volksw not
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• The air conditioner compressor is orise nte
eo
h
noisy (especially immediately af‐ aut ra
c
ter being switched on), ss
ce
e
nl
pt
du
• The cooling power required is de‐
an
itte
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livered.
erm
ab
ility
ot p
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Note
hole
spec
es, in part or in w
t to the co
was renewed.
rrectness of i
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ercia

ual .
m
at
om
ion
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or
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ate
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riv

p
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for
en
g
valve and reservoir (without regulated

n
t.
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op py
air conditioner compressor)
t. C rig
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pyri by
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cted agen
Prote AG.
11.4.1 Conditions for testing

• Radiator and condenser clean (clean if necessary)
• The V-belt for air conditioner compressor and alternator is
correctly tensioned.
• All air ducts, covers and seals are OK and properly installed.
• The flaps reach their end positions.
• Engine warm.
• The evaporator and heating do not draw any uncooled air at
highest fresh air blower speed.

With the engine running and the air conditioning system set to full
power, check the following points:
• The fresh air blower is running.
• The radiator fan is running or is switched on.
• The fresh air and air recirculation flap is set to “recirculate”.
• Ambient temperature above 15°C.
• The temperature switch for evaporator
AG. Volkswag-eE33-
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agen
and its switching temperatures
Volksw are correct. oes
not
g
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11.4.2 tho
rise
Check tee
or
s au ac
Check pressures
s in refrigerant circuit with ignition switched off.
ce
le
un
pt
– Check pressures in refrigerant circuit (using air conditioning
an
d
itte
y li
service station ) ⇒ page 156 .
erm
ab
ility
ot p
Check pressures in refrigerant circuit with air conditioner com‐
wit
is n
pressor being driven.
h re
ole,
– Connect the air conditioner service station ⇒ page 154 .
spec
t to the co
– Start engine.
rrectne
– Observe pressure gauge of air conditioner service station .
– Check actual values against specifications ⇒ page 168 . ss o
cial p
11.4.3 Specified values

inform
mer
High-pressure side
atio
om
Pressure rising from initial pressure to 20 bar max.

c
i
or
n thi
te
sd
Low-pressure side
iva
o
pr
cum
r
Pressure falling from initial pressure to diagram value.

fo
en
ng
t.
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A - High pressure in bar positive pressure. Cop py
t. rig
gh ht
yri
B - Low pressure in bar positive pressure. p by
co Vo
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cted agen
C - Permitted tolerance range. Prote AG.
11.5 Checking systems with a restrictor and

reservoir and air conditioner compres‐
sor regulating valve - N280- (with exter‐
nally regulated air conditioner compres‐
sor)
Note


– Observe pressure gauge of the air conditioner service station .
Note
Switching pressures for the air conditioner compressor regulating

valve - N280- and the radiator fan - V7- are vehicle-specific.
⇒ Rep. gr. 87
High-pressure side:
ted) to 20 bar.
AG. Volkswagen AG d
agen oes
olksw not
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pt
an
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ab
pe
ility
ot
wit
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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
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Low-pressure side:
Falling from starting pressure (when pressure gauge is connec‐
ted) to diagram value.
n AG. Volkswagen A
A - Low pressure (measured at the
olks
wagservice
e
connection) in
G do
esbar
not ab‐
solute pressure. d by V gu
ar
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ris tee
B - Control current forthothe air conditioner compressor regulating or
au
valve - N280- . s s ac
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e
nl
pt
du
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erm
ab
ility
ot p
Note
wit
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h re
♦ Under unfavourable conditions (very high ambient tempera‐
hole
spec
tures, high atmospheric humidity), the pressure on the high
es, in part or in w
pressure side can increase to a maximum of 29 bar.
t to the co
♦ The control current -B- is indicated in the measured values
block.
rrectness of i
♦ The high pressure is indicated in the measured values block
l purpos
⇒ Rep. gr. 87 .
♦ The low pressure is adjusted to within tolerances within the
nform
ercia
output range for the air conditioner compressor depending on

the control current for the air conditioner compressor regulat‐
m
at
om
ing valve - N280- .
ion
c
in t
or
♦ Under unfavourable conditions (very high ambient tempera‐ his

ate
tures, high humidity), the output may not always be sufficient

do
priv
to attain the specified value.

um
for
en
ng
t.
♦ The set working current for the regulating valve must be great‐
yi Co
op py
er than 0.3 A to ensure that the regulating valve is reliably
. C rig
ht ht
activated.
rig by
copy Vo
by lksw
cted
♦ At the setting for “maximum cooling power”, the control current
agen
Prote AG.
should be approx. 0.8 A (indicated in the measured values
block) ⇒ Rep. gr. 87 .
bar absolute. On the scales of most pressure gauges, 0 bar
corresponds to an absolute pressure of 1 bar (indicated by -1
bar mark below 0).

Possible deviation Possible cause of fault Rectifying fault

from specification
• High pressure ♦ Actuation of air con‐ – Check ac‐
remains con‐ ditioner compressor tuation of air
stant or increa‐ regulating valve - conditioner
ses only slightly N280- is defective. compressor
(above the pres‐ regulating
sure measured ♦ Too little refrigerant valve -
when the engine in circuit. N280- .
is stopped).
– Locate leak
• Low pressure with leak de‐
falls quickly to tector and
the diagram val‐ eliminate.
ue or lower,
• Required cooling – Re-charge
output is not at‐ refrigerant
tained. agen AG. Volkswagen AG d
oes circuit.
lksw
o no t gu
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db ara
• Highopressure
ris
e nte
eo
normal
aut
h
ra
ss c
• Low pressure ce
le
un
pt
matches the dia‐ an
d
itte
gram value,
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erm
ab
ility
ot p
wit
output is not at‐

is n
h re
tained.
ole,
spec
• High pressure
t to the co
normal
• Low pressure is
rrectne
too low (see dia‐

gram),
ss
o
cial p
output is not at‐

inform
tained.
mer
atio
• High pressure
om
normal
c
i
or
n thi
te
sd
• Low pressure is
iva
o
r
too low (see dia‐

p
cum
r
fo
gram),
en
ng
t.
yi Co
op
• Required cooling C py
t. rig
gh
output is not at‐
ht
pyri by
tained.
o Vo
by c lksw
cted agen
Prote AG.
Note
If no fault can be found for this complaint, purge (clean) refrigerant

circuit with refrigerant R134a ⇒ page 65 . If this is not possible in
your workshop, blow through refrigerant circuit with compressed
air and dry with nitrogen ⇒ page 63 .


tion
• High pressure only increases ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
slightly above pressure with en‐ ulating valve - N280- is defective. air conditioner com‐
gine stopped, pressor regulating
♦ The air conditioner compressor is defective. valve - N280- .
• Low pressure falls only slightly,
• Required cooling output is not – Purge (clean) refrig‐
attained. erant circuit
⇒ page 65 .

ditioner compres‐
sor.
• High pressure increases above ♦ Constriction or obstruction in refrigerant cir‐ – Run hand over re‐
specification cuit frigerant circuit to
• Low pressure falls only slightly, ces in temperature.
attained. • At one component a
temperature gradi‐
kinked or crushed,
renew it.
circuit with com‐
trogen in the event
of an obstruction.
• If no fault is found:
erant circuit
⇒ page 65 .
n AG. Volkswagen A
• High pressure and low pressure olks
wag♦
e
Moisture in refrigerant
G do
es n
ot g
circuit – Blowing through re‐
are normal at first, but after
by a
V u ara frigerant circuit with
ed
while, the high pressure
oris increa‐ nte
eo compressed air and
ses beyond the specification,
au
th ra nitrogen.
ss c
• The low pressure falls to the di‐
ce
e
– Renew reservoir.
nl
pt
agram value or lower,

du
an
itte
y li

erm
• The cooling power called for is

ab
the system does not

ility
not delivered.
ot p
operate correctly.
wit
, is n
h re
hole

spec
erant circuit
es, in part or in w
t to the co
⇒ page 65 .
ant circuit.
rrectness of i
l purpos
– Repeat test.
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
172
cted agen
Prote AG.

tion
• High pressure normal ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
ulating valve - N280- is defective. air conditioner com‐
• Low pressure is too low (see di‐ pressor regulating
agram), ♦ The air conditioner compressor is defective. valve - N280- .
• The cooling power required is
delivered. – Purge (clean) refrig‐
erant circuit
⇒ page 65 .
AG. Volkswagen AG d – Renew the air con‐

agen oes ditioner compres‐
olksw not
ara sor.
V gu
d by
e nte
ris
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
♦ If the fault is “high pressure normal, low pressure too low ” note
ot
wit
, is n
the following: if faulty the evaporator could ice up or the re‐
h re
quired cooling output is not delivered.
hole
spec
es, in part or in w
t to the co
♦ Check the measured value of the evaporator output tempera‐
rrectness of i
ture sender - G263- or evaporator temperature sensor -
G308- .
l purpos
♦ Check the actuation of the air conditioner compressor regu‐

lating valve - N280- .
nform
mercia
⇒ Rep. gr. 87
a
com
tion in
r
Possible deviation from specifi‐ Possible cause of fault Rectifying fault

te o
thi
cation
s
iva
do
r
rp
cum
• High pressure normal or too ♦ Too much refrigerant in circuit. – Extract some refrig‐
fo
en
g
high erant from the refrig‐

n
t.
yi Co
op
erant circuit.
C py
• Low pressure too high (see di‐
t. rig
gh ht
yri
agram),
by
op Vo
by c lksw
frigerant extracted is
cted agen
• The air conditioner compres‐
Prote AG.
sor is noisy (especially imme‐ about equal to the

diately after being switched prescribed charge
on), quantity:
• Required cooling output is not – Renew the air condi‐

attained. tioner compressor.
significantly greater
than the prescribed
charge quantity:
ant circuit.
– Repeat test.
• High pressure and low pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
sure normal cuit.
• Required cooling output is not – Purge (clean) refrig‐
attained. erant circuit
⇒ page 65 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo ut 2017 ➤ , Arteon 2018 ➤ , Atlas 2 ...
ho eo
ra
a
ss R134a - General information - Edition 08.2019 c
ce
e
nl
pt
du
an
itte
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erm
cation
ab
ility
ot p
• High pressure and low pres‐
wit
, is n
sure normal
h re
hole
spec
• The air conditioner compres‐
es, in part or in w
sor is noisy (especially imme‐
t to the co
diately after being switched
on),
rrectness of i
delivered. l purpos
nform
ercia
Note
m
at
om
ion
c
in t
or
his
ate
was renewed.
do
priv
cum
or

f
en
ng
t.
yi
Co
op py
connections. From the total amount of refrigerant oil, fill 50 g t. C rig
gh ht
direct into air conditioner compressor and fill remainder in re‐ pyri by
Vo
o
by c
lksw
cted agen
Prote
ual .
AG.

valve, receiver and air conditioner com‐
pressor regulating valve - N280- (with
externally regulated air conditioner com‐
pressor)
Note


– Observe pressure gauge of the air conditioner service station .
Note
♦ Switching pressures for the air conditioner compressor regu‐

lating valve - N280- and the radiator fan - V7- are vehicle-
specific.
♦ Pressures should be measured at the service connections; the
location of these connections is vehicle-specific ⇒ Rep. gr.
87 .
High-pressure side:
ted) to 20 bar.

Low-pressure side:
Falling from starting pressure (when pressure gauge is connec‐
ted) to diagram value.
A - Low pressure (measuredgeatn Athe
G. Vservice
olkswageconnection)
n AG d in bar ab‐
a
solute pressure. Volksw
oes
not
g
y ua
db r
B - Control current
ris for the air conditioner compressor regulating
e an
tee
ho
valve - N280-au.
t or
a
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
hole
tures, high atmospheric humidity), the pressure on the high
spec
pressure side can increase to a maximum of 29 bar.
es, in part or in w
t to the co
♦ The control current -B- is indicated in the measured values
block.
rrectness of i
♦ The high-pressure value measured by the high-pressure
sender - G65- is indicated in the measured values block ⇒
l purpos
Rep. gr. 87 .
♦ The low pressure is adjusted to within tolerances within the
nform
ercia
output range for the air conditioner compressor depending on

m
the control current for the air conditioner compressor regulat‐
a
com
tio
ing valve - N280- .
n in
r
te o
thi
s
iva
do
tures, high humidity), the output may not always be sufficient

r
rp
cum
to attain the specified value.

fo
en
ng
t.
yi
♦ The set working current for the regulating valve must be great‐
Co
Cop py
er than 0.3 A to ensure that the regulating valve is reliably
t. rig
gh ht
yri
activated.
p by
o Vo
by c lksw
cted agen
♦ At the setting “maximum cooling power”, the control current
Prote AG.
should be approx. 0.65 A to 0.8 A (vehicle-specific, indicated

in the measured values block) ⇒ Rep. gr. 87 .
bar absolute. On the scales of most pressure gauges, 0 bar
corresponds to an absolute pressure of 1 bar (indicated by -1
bar mark below 0).


from specification
• High pressure ♦ Actuation of air con‐ – Check ac‐
remains con‐ ditioner compressor tuation of air
stant or increa‐ regulating valve - conditioner
ses only slightly N280- is defective. compressor
(above the pres‐ regulating
sure measured ♦ Too little refrigerant valve -
when the engine in circuit. N280- .
is stopped).
– Locate leak
• Low pressure with leak de‐
falls quickly to tector and
the diagram val‐ eliminate.
ue or lower.
• Required cool‐ – Re-charge
ing output is not refrigerant
attained. circuit.
• High pressure
normal.
• Low pressure
matches the di‐
agram value. AG. Volkswagen AG d
agen oes
• Required cool‐ olksw not
y V gu
b
ing output is not rise
d ara
nte
attained. utho eo
ra
s a c
s
• High pressure • Too little refrigerant – Extract some
ce
le
un
pt
normal. in circuit. refrigerant
an
d
itte
y li
from the re‐
erm
ab
• Low pressure is frigerant cir‐
ility
ot p
too low (see dia‐ cuit.
wit
gram).
is n
h re
ole,
• Required cool‐ • The quantity
spec
of refrigerant
ing output is not

extracted is
t to the co
attained.
significantly
less than the
prescribed
rrectne
charge
quantity.
ss o
– Locate leak
cial p
with leak de‐ f inform

mer
tector, elimi‐
atio
nate.
om
n
c
i
or
– Re-charge
thi
te
sd
a
refrigerant
iv
o
pr
circuit.
um
r
fo
en
ng
t.
yi
– Repeat test.
Co
Cop py
t. rig
gh ht
yri
• If quantity of p by
co Vo
by lksw
refrigerant Prote
cted agen
extracted
AG.
roughly cor‐
responds to
specified ca‐
pacity:


from specification
• Expansion valve de‐ – Renew the
fective expansion
valve.
– Re-charge
refrigerant
circuit.
– Repeat test.
Note
♦ If no fault can be found for this complaint, purge (clean) re‐

frigerant circuit with refrigerant R134a ⇒ page 65 . If this is not
possible in your workshop, blow through refrigerant circuit with
compressed air and dry with nitrogen ⇒ page 63 .
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- or evaporator temperature sensor -
G308- and actuation of the air conditioner compressor
regulating valve - N280- . If the measured value of the evap‐
orator output temperature sender - G263- or the evaporator
temperature sender - G308- is faulty, the evaporator may ice
up or the cooling output will not be achieved.
♦ If a repeat test after the expansion valve has been renewed
indicates that the air conditioning system is still not operating
correctly, refit the expansion valve and flush the refrigerant
circuit with compressed air and nitrogen. Then replace the air
conditioner compressor and receiver.
♦ If the expansion valve is defective (always closed or not open‐
n AG. Volkswagen A
ing wide enough) the air conditioner compressorolks
wage regulating G does no
valve - N280- will be set to maximum d b power and the low-pres‐
y V t gu
ara
sure value will fall to the diagram orise value or less (the air condi‐ nte
eo
tioner compressor is drawing aut the refrigerant out of the low-
h
ra
pressure side). However, since
ss no refrigerant can flow through c
ce
le
the expansion valve, the required cooling power is not deliv‐

un
pt
ered, and it can be that the high-pressure value does not rise
an
d
itte
y li
at all or not enough, since no energy exchange is occurring.

erm
ab
ility
ot p
wit
is n
h re

ole,
spec
tion
t to the co
• High pressure only increases ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
slightly above pressure with en‐ ulating valve - N280- is defective. air conditioner com‐
gine stopped. pressor regulating
valve - N280- .
rrectne
• Low pressure falls only slightly.

ss
attained.
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.


tion
♦ The air conditioner compressor is defective. – Extract refrigerant.

erant circuit
⇒ page 65 .

ditioner compres‐
sor.
ant circuit.
• High pressure increases above ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
specification. ulating valve - N280- is defective. air conditioner com‐
pressor regulating
• Low pressure falls quickly to the valve - N280- .
diagram value or lower.
AG. Volkswagen AG d
• Required cooling output
wageis not
n oes
olks not
attained. db
y V gu
ara
e nte
ris
ho eo
au
t
♦ Constriction or obstructionra
c
in refrigerant cir‐ – Run hand over re‐
ss cuit frigerant circuit to
ce
le

un
pt
an
ces in temperature.
d
itte
y li
rm
ab
pe
• At one component a
ility
ot
temperature gradi‐
wit
, is n

h re
hole
spec
es, in part or in w
kinked or crushed,
t to the co
renew it.
rrectness of i
circuit with com‐

l purpos

trogen in the event
of an obstruction.
nform
ercia
m
a
com
ant circuit.
ion in
r
te o
thi
– Repeat test.
s
iva
do
r
rp
cum
• If no fault is found:
fo
en
ng
t.
yi
Co
Cop py
erant circuit
ht. rig
rig ht
⇒ page 65 .
py by
co Vo
by lksw
cted agen
Prote AG.
ant circuit.

the system does not
operate correctly.
♦ Expansion valve defective – Extract refrigerant.

sion valve and re‐
ceiver.
ant circuit.

Note

ing wide enough) the air conditioner compressor regulating
valve - N280- will be set to maximum power and the low-pres‐
sure value will fall to the diagram value or less (the air condi‐
tioner compressor is drawing the refrigerant out of the low-
pressure side). However, since no refrigerant can flow through AG. Volkswagen AG d
the expansion valve, the required cooling power is not agen
deliv‐ oes
olksw not
ered, and it can be that the high-pressure valueeddoesby
V
not rise gu
ara
at all or not enough, since no energy exchange ho
ris is occurring. nte
e t or
au ac
ss
ce
le
un
pt
tion
an
d
itte
y li
erm
• High pressure and low pressure ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
ab
ility
are normal at first, but after a ulating valve - N280- is defective. air conditioner com‐
ot p
wit
while, the high pressure increa‐ pressor regulating
is n
h re
ses beyond the specification. valve - N280- .
ole,
spec
• After a time, the low pressure
t to the co
falls to the diagram value or low‐
er.
• The cooling power called for is
rrectne
not delivered.
ss
• High pressure and low pressure ♦ Moisture in refrigerant circuit – Extract refrigerant.
o
cial p
f
are normal at first, but after a
inform
longer drive, the low pressure – Blowing through re‐
mer
falls to below the specification frigerant circuit with
atio
m
(evaporator iced up). compressed air and

o
n
c
nitrogen.
i
or
n thi
te
sd
va
– Renew receiver to‐

i
o
pr
cum
r
gether with dryer.

fo
en
ng
t.
yi Co
op
– Evacuate refriger‐
C py
t. rig
ant circuit for at
gh ht
yri by
least 3 hours.
op Vo
by c lksw
cted agen
Prote AG.
ant circuit.

the system does not
operate correctly.

erant circuit
⇒ page 65 .
ant circuit.
– Repeat test.

Note
♦ If this complaint occurs after a longer period of operation or

only occasionally (the low pressure falls below the specifica‐
tion and the evaporator ices up) it is sufficient only to renew
the dryer (fitted within the receiver). Check the quantity of re‐
frigerant oil. Refrigerant circuit is then to be evacuated for at
least 3 hours.
♦ In case of this complaint, it is not initially necessary to purge
the refrigerant circuit with compressed air and nitrogen, since
as a rule only a small quantity of moisture will have accumu‐
lated in the system, which can be removed by a longer evac‐
uation period.

tion
G. Volkswagen
• High pressure normal, low pres‐ ♦ Actuation of air conditionerlkscompressor
wage
nA reg‐ – AGCheck
does actuation of
not
sure too low (see diagram), and ulating valve - N280- is by defective.
Vo
air conditioner
gu
ara com‐
d
the cooling performance is at‐ oris
e pressor regulating
nte
tained. au
th valve - N280- e.or a
ss c
ce
e
♦ Expansion valve defective – Extract refrigerant.

nl
pt
du
an
itte
y li
erm
ab
erant circuit
ility
ot p
⇒ page 65 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
ceiver.
rrectness of i
ant circuit.
l purpos

the system does not
operate correctly.
nform
ercia

m
at
om
ditioner compres‐ ion

c
in t
sor.
or
his
ate
♦ The air conditioner compressor is defective. – Extract refrigerant.

do
priv
cum
for

en
ng
t.
yi
erant circuit
Co
Cop py
⇒ page 65 .
t. rig
gh ht
pyri by
Vo
co lksw
by
Prote
cted – Renew the air con‐
AG.
agen
ditioner compres‐
sor.
ant circuit.
– Repeat test.

Note
♦ If the fault is “high pressure normal, low pressure too low ” note
the following: if faulty the evaporator could ice up or the re‐
quired cooling output is not delivered.
♦ In this case, the evaporator may ice up Aalthough
G. Volkswathe
gen correct
quantity of refrigerant is present lkinswthe
agenrefrigerant circuit.
AG do
es n
o Vo t gu
by
♦ Check the measured values
ris
ed of the evaporator output temper‐
ara
nte
ature sender - G263- orut evaporator temperature sensor -
ho eo
ra
G308- and actuationss of the air conditioner compressor
a c
regulating valve - N280- . If the measured value at the high-
ce
le
un
pt
pressure sender - G65- is faulty, the evaporator can ice up or
an
d
itte
the required cooling power is not delivered.
y li
rm
ab
pe
ility
♦ If the defect is in the air conditioner compressor regulating
ot
valve - N280- (the regulating valve is not activated, but the air
wit
, is n
h re
conditioner compressor still runs), it is not necessary to blow
hole
through the refrigerant circuit. If this fault occurs, it is sufficient
spec
to renew the air conditioner compressor (check the refrigerant
es, in part or in w
t to the co
oil quantity in the air conditioner compressor).
rrectness of i
l purpos
pressure side). However, since no refrigerant can flow through
nform
ercia

m
a
com
ti
on in
r
te o
thi
s
⇒ Rep. gr. 87
iva
do
r
rp
cum
fo

en
ng
t.
yi
cation
Co
Cop py
t. rig
• High pressure normal or too ♦ Actuation of air conditioner compressor reg‐ – Check actuation of
gh ht
pyri by
high. ulating valve - N280- is defective. air conditioner com‐
co Vo
by lksw
cted
pressor regulating
agen
Prote AG.
• Low pressure too high (see di‐ ♦ Too much refrigerant in circuit. valve - N280- .
agram).
• The air conditioner compres‐ – Extract some refrig‐
sor is noisy (especially imme‐ erant from the refrig‐
diately after being switched erant circuit.
on).
• Required cooling output is not frigerant extracted is
attained. about equal to the
prescribed charge
quantity:
tioner compressor.
than the prescribed
charge quantity:
ant circuit.
– Repeat test.


cation
♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
cuit.
• If quantity of refriger‐
ant extracted roughly
corresponds to
specified capacity:
AG. Volkswagen AG d – Purge (clean) refrig‐
agen oes
ksw not
byV
ol
gu
ara
erant circuit
rised
nte ⇒ page 65 .
ho eo
ut ra
ss a c – Re-charge refriger‐
ant circuit.
ce
le
un
pt
an
d
itte
– Repeat test.
y li
erm
ab
ility
♦ Expansion valve defective – Drain refrigerant cir‐
ot p
cuit.
wit
is n
h re
ole,
spec
t to the co
ceiver.
rrectne
ant circuit.
ss
the system does not
o
cial p
f
operate correctly.
inform
mer
atio
m
tioner compressor.
o
n
c
i
or
n thi
♦ The air conditioner compressor is defective. – Drain refrigerant cir‐
te
sd
a
cuit.
iv
o
pr
cum
r
fo
en
ng

t.
yi Co
. Cop py erant circuit
⇒ page 65 .
ht rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
tioner compressor.

than the prescribed
charge quantity.
ant circuit.
– Repeat test.

Note
♦ If the defect is in the air conditioner compressor regulating

valve - N280- (the regulating valve is not activated, but the air
conditioner compressor still runs), it is not necessary to blow
through the refrigerant circuit. If this fault occurs, it is sufficient
to renew the air conditioner compressor (check the refrigerant
oil quantity in the air conditioner compressor).
was renewed.
ual .
pressure side). However, since no refrigerant can flow through

cation
AG. Volkswagen AG d
agen oes
• High pressure and low pres‐ ♦ Actuation olkswof air conditioner compressor not reg‐ – Check actuation of
yV gu
sure are normal. ulating
ed b valve - N280- is defective. ara
nte
air conditioner com‐
oris e o pressor regulating
• Required cooling output is not ♦ au Too much refrigerant oil in circuit.
th
r a valve - N280- .
attained. ss c
ce
e
nl

pt
du
an
erant circuit
itte
y li
erm
⇒ page 65 .
ab
ility
ot p
• High pressure and low pres‐ ♦ Too much refrigerant oil in circuit. – Drain refrigerant cir‐
wit
, is n
sure are normal. cuit.

h re
hole
spec
• The air conditioner compres‐ – Purge (clean) refrig‐

es, in part or in w
sor is noisy (especially imme‐ erant circuit

t to the co
diately after being switched ⇒ page 65 .

on).
rrectness of i

delivered. ant circuit.
l purpos
– Repeat test.
♦ Expansion valve defective – Renew the expan‐
nform
ercia
sion valve.
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.

Note

was renewed.
ual .
♦ If the expansion valve is defective (always open) the evapo‐
rator temperature will no longer be regulated so that only
gaseous refrigerant exits the evaporator. It is then possible
that under certain operating conditions, drops of liquid will be
drawn into the air conditioner compressor, which will hen
cause noise (because liquid is incompressible).
11.7 With expansion valve, receiver and

electrical air conditioner compressor
Note
The electrical air conditioner compressor does not have an air

conditioner compressor regulating valve - N280- . Regulation
takes place via the speed of the air conditioner compressor. The
air conditioner compressor contains the control electronics and a
G-supercharger that impels the refrigerant.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
184
cop Vo
by lksw
Rep. gr.00 - Technical data Prote
cted AG.
agen
12 Renewing components
• All components of the refrigerant circuit submitted for quality
monitoring must always be sealed (use the original sealing
caps from the genuine part).
• The genuine parts of air conditioner compressor, reservoir,
receiver, evaporator and condenser are charged with nitrogen
before shipment. This filling is being gradually discontinued,
or the pressure of the nitrogen filling is so low that escaping
gas is no longer perceptible when the part is initially opened.
• Where vehicles are fitted with an air conditioner compressor
without a magnetic clutch, the engine should be started only
when the refrigerant circuit has been fully assembled (since
the air conditioner compressor will always run when the engine
is running) ⇒ page 13 .
• The air conditioner compressor with air conditioner compres‐
sor regulating valve - N280- (without magnetic clutch) has an
internal oil circuit to ensure that the air conditioner compressor
is not damaged when the refrigerant circuit is empty. This
means that approx. 40 to 50 cm3 of refrigerant oil
ag
AG. Volksin
enremain
wagen AG
does
ksw
the air conditioner compressor ⇒ page b13 yV
o.l not
gu
ara
ed nte
oris e
th or
au ac
Note ss
ce
e
nl
pt
du
♦ Since genuine parts are sometimes stored for long periods in
an
itte
y li
various places, it can well be that gas will escape from some
erm
ab
parts when first opened but not from others (even among those
ility
ot p
having the same part number). Therefore, be careful when
wit
, is n
unscrewing the sealing caps from the genuine part connec‐
h re
hole
tions and allow the nitrogen gas to escape slowly.
spec
es, in part or in w
♦ Either a restrictor with a reservoir or an expansion valve with
t to the co
a receiver is built into the refrigerant circuit.
♦ Seal open connections and pipes (to prevent absorption of
rrectness of i
moisture).
l purpos
♦ Always renew the restrictor.

nf
ercia
The reservoir / receiver or desiccant bag / cartridge need not be

or
renewed under the following circumstances.

m
m
atio
m
• After an accident in which there was no damage to the reser‐

o
n in
or c
voir or receiver.
thi
te
sd
iva
• Repairs are performed quickly (no more delay than during a

o
r
rp
cu
normal repair time) and there was no moisture intrusion. The

o
m
f
en
ng
vehicle is no more than 5 years old.

t.
yi Co
Cop py
The reservoir or receiver or dryer cartridge should be renewed
t. rig
gh ht
yri by
under the following circumstances> cop Vo
by lksw
cted agen
Prote
• The refrigerant circuit was opened and the vehicle is more than
AG.
5 years old.
• The refrigerant circuit has been opened for in indeterminate
period (seepage leak).
• Repairs take longer than a normal repair time and there has
been moisture intrusion.
• Always renew collector/reservoir or dryer cartridge after blow‐
ing through with compressed air or purging with refrigerant
R134a. Keep genuine parts sealed for as long as possible to
keep the ingress of moisture as low as possible.
• The air conditioner compressor seizes.
12. Renewing components 185

• The reservoir or receiver is damaged (e.g. in an accident).
CAUTION
Risk of chemical burns from atomised refrigerant oil. Eyes and
other parts of the body could be injured.
– Never inhale atomised refrigerant oil.
12.1 In the event of leaking or damaged com‐

ponents (apart from the air conditioner
compressor, receiver or reservoir)
12.1.1 If the refrigerant circuit was completely

empty
– Remove defective part.
– Remove air conditioner compressor.* ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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.

– Unscrew oil drain plug -B- / -D- from air conditioner compres‐
sor -A-.*
Note
♦ The design of the oil drain plug -B- / -D- and seal -C- / -E- may
vary (depending on the manufacturer of the air conditioner
compressor) ⇒ Heating, air conditioning; Rep. gr. 87 ; Airagen AG. Volkswagen AG do
conditioner compressor (vehicle-specific workshop ymanual).
Vol
ksw es n
ot g
b ua
ed ran
♦ When installing the oil drain plug -B-/-D-, observe
ho
ris the corre‐ tee
sponding torque specification (depending on authe manufacturer
t or
ac
of the air conditioner compressor and the design
ss of the oil drain
ce
le
plug). Please note that the oil drain plug of air conditioner
un
pt
compressors manufactured by “Denso” and “Delphi” is equip‐
an
d
itte
y li
ped with an oil seal ⇒ Heating, Air conditioning; Rep. gr. 87 ;
erm
ab
Air conditioning compressor, Assembly overview - drive unit
ility
ot p
of air conditioner compressor (currently valid specified torque:
wit
is n
30 Nm for “Denso” and 15 Nm for “Delphi” compressors). The
h re
ole,
oil drain plug of air conditioner compressors manufactured by
spec
“Sanden” and “Zexel- / Valeo” may be equipped with an O-ring
t to the co
or an oil seal (depending on the vehicle equipment; currently
valid specified torque: 10 Nm, respectively).
♦ On the Denso air conditioner compressor, for example, the oil
rrectne
drain plug -D- has an oil seal -E-; renew ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
s
specific workshop manual) and ⇒ Electronic parts catalogue .
s o
cial p
f in
♦ On the Sanden air conditioner compressor, for example, the
form
mer
oil drain plug -B- has a seal -C-; renew ⇒ Heating, air condi‐
atio
tioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
om
specific workshop manual) and ⇒ Electronic parts catalogue .
n
c
i
or
n thi
e
♦ If a seal (oil seal or O-ring) fitted to the oil drain plug is not
t
sd
iva
o
available as a replacement part, the removed old part can be
pr
cum
r
fo
reused (as an exception to the general rule of using new seals
en
ng
t.
only). The old seal, however, must always be checked for
yi Co
op
damage prior to installation. If any damage or deformation is
C py
t. rig
gh
detected on the old seal, it must be renewed with a commer‐
ht
pyri by
Vo
o
cially available new part.
c by lksw
cted agen
Prote AG.
♦ After filling the refrigerant circuit, check the installed oil drain
plug for leaks using e.g. an electronic leak detector.
♦ To speed up draining of the refrigerant oil, rotate the shaft of
the air conditioner compressor e.g. using the belt pulley or the
magnetic clutch pulley.

Note
♦ To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor by hand using the poly V-
belt pulley or the magnetic clutch.
♦ Pour old refrigerant oil out of air conditioner compressor, han‐
dling refrigerant oil ⇒ Volkswagen ServiceNet; Service hand‐
oils .
♦ Then fill the air conditioner compressor with the quantity of
new refrigerant oil corresponding to the quantity in a genuine
air conditioner compressor ⇒ Rep. gr. 87 .
♦ Different types and quantities of refrigerant oils are required
for different air conditioner compressors ⇒ Rep. gr. 87 .
♦ To ensure proper lubrication of the air conditioner compressor
when it runs for the first time, the air conditioner compressor
must be filled with at least 80 cm3 of refrigerant oil; the re‐
mainder can be poured into the new reservoir or receiver ⇒
Rep. gr. 87 . n AG. Volkswagen A ge G do
swa es n
♦ If dirt enters the air conditioner compressor
by
Vol whilst the refrig‐
k ot g
ua
erant circuit is open (e.g. after an accident),
ris
ed the air conditioner ran
tee
compressor should be renewed. ut ho
or
sa ac
♦ Blow through refrigerant circuits with compressed air and re‐
ce
le
move moisture with nitrogen ⇒ page 63 .

un
pt
an
d
itte
y li
erm
ab
– Replace receiver or reservoir and restrictor.
ility
ot p
wit
– Assemble the refrigerant circuit, evacuate it and charge it.
is n
h re
ole,
spec
12.1.2 If there is still refrigerant in the refriger‐ t to the co

ant circuit
– Drain refrigerant circuit.
rrectne
– Remove the defective part, blow through with compressed air

and collect any escaping refrigerant oil.
ss o
cial p
– The refrigerant oil that is blown out (plus 20 cm3 for the evap‐
inform
orator, plus 10 cm3 for the condenser, refrigerant lines and

mer
refrigerant hoses) should be poured into the new component

atio
m
as fresh refrigerant oil.

o
n
c
i
or
n thi
e
– Replace restrictor. Depending on vehicle.

t
sd
iva
o
pr
– Assemble, evacuate and charge refrigerant circuit.

um
r
fo
en
ng
t.
yi
12.2 Renew the air conditioner compressor
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.
On vehicles equipped with an electrical air conditioner compres‐

sor, de-energise the high-voltage system before removing the air
conditioner compressor. ⇒ Electric drive; Rep. gr. 93 ; Electric
drive; De-energising high-voltage system
12.2.1 Without needing to flush refrigerant cir‐

cuit of contaminants (cleaning), e.g. in

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo 2017 ra ➤
, Arteon 2018 ➤ , Atlas 2 ...
s c
s
ce
le
un
pt
an
d
itte
cases of external damage after an acci‐
y li
rm
ab
dent
pe
ility
ot
wit
, is n
h re
hole
spec
– Remove air conditioner compressor.
es, in part or in w
t to the co
Note
rrectness of i
If a different air conditioner compressor with other refrigerant oil
l purpos
is fitted, purge the refrigerant circuit with R134a refrigerant

⇒ page 65 .
nform
ercia
Electrical air conditioner compressor

m
a
com
tio
If an electrical air conditioner compressor is renewed without hav‐
n in
r
te o
ing a mechanical fault (e.g. defective printed circuit board), the
thi
s
amount of refrigerant oil from this electrical air conditioner com‐
iva
do
r
pressor must be determined.

rp
cum
fo
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
♦ The air conditioner compressor must be purged in order to
cted agen
Prote AG.
extract the refrigerant oil which needs to be determined.
♦ Purge the air conditioner compressor in normal direction of
flow (from low-pressure inlet to high-pressure outlet).
♦ In order to purge as much refrigerant oil from the air condi‐
tioner compressor as possible make sure that the high-pres‐
sure outlet of the air conditioner compressor is in the lowest
position possible.
♦ If an air conditioning service station without purging pro‐
gramme is used, the sequence has to be carried out manually
(evacuate, purge 3 times with at least 2 kg of refrigerant each
time and extract refrigerant again, evacuate).
Determined amount e.g. 50 cm³

Then, remove as much refrigerant oil from the new air conditioner
compressor as is necessary to ensure that only the same amount
of refrigerant oil which has been purged from the old air condi‐
tioner compressor remains in the new one (plus 10 cm 3). If, for
example, the new original air conditioner compressor is filled with
e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐
oils .
Note
If the amount of refrigerant oil which can be removed from the

new air conditioner compressor is not sufficient, the new air con‐
ditioner compressor must be purged. After the new air conditioner
compressor has been purged, fill the amount of refrigerant oil
which has been determined when purging the old air conditioner
compressor.
Mechanically driven air conditioner compressor: Drain refrigerant

oil via block connections.

– To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor using the magnetic clutch
poly V-belt pulley. Not applicable for electrical air conditioner
compressor.
AG . Volkswage
– Pour old refrigerant oil out of air conditioner
agen compressor. Han‐
n AG d
oes
lksw not
dling refrigerant ⇒ Volkswagen by ServiceNet; Service hand‐
Vo gu
ara
book; Environmental protection;
ris
ed
Waste disposal; Current nte
situation; Disposal channels;
autho
Disposal of used oils; Refrigerant eo
ra
oils . ss c
ce
le
un
– Only refill with fresh refrigerant oil equivalent to volume of oil
pt
an
d
itte
that was removed (from defective air conditioner compressor).
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
♦ If for instance 70 cm3 refrigerant oil was poured out of the de‐
t to the co
fective air conditioner compressor, and 220 cm3 oil was pour‐
ed out of the genuine air conditioner compressor (a small
quantity of refrigerant oil remains in the air conditioner com‐
rrectne
pressor), pour 70 cm3 refrigerant oil into the genuine air con‐
ditioner compressor (the refrigerant oil previously poured out
of the genuine air conditioner compressor part may be used).
ss o
cial p
f
♦ Different air conditioner compressors require different types
inform
and quantities of refrigerant oils ⇒ Rep. gr. 87 .
mer
atio
m
♦ If a large quantity of refrigerant oil (more than about 80 cm3)

o
n
c
was poured from the defective air conditioner compressor, the
i
or
n thi
remaining refrigerant oil can also be poured into the evapora‐
te
sd
va
tor or the reservoir or receiver ⇒ Rep. gr. 87 .

i
o
pr
cum
r
fo
en
ng
t.
yi
– Replace restrictor. Depending on vehicle.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
12.2.2 Leaks or internal damage (e.g. noises or
cted agen
Prote AG.
lack of power)
Note
♦ For internal damage or leak (in or from air conditioner com‐

pressor), flush refrigerant circuit with refrigerant R134a
⇒ page 65 .
♦ If a different air conditioner compressor with other refrigerant
oil is fitted, purge the refrigerant circuit with R134a refrigerant
⇒ page 65 .
12.3 Replace receiver or reservoir and re‐

strictor
12.3.1 After flushing contaminants from refrig‐

erant circuit, e.g. due to moisture intru‐
sion (because refrigerant circuit was

open for a longer period of time) or due

to soiling
The reservoir/receiver or desiccant bag/cartridge need not be re‐
newed under the following circumstances:
• After an accident in which there was no damage to the reser‐
voir or receiver.
• Repairs are performed quickly (no more delay than during a
normal repair time) and there was no moisture intrusion. The
vehicle is no more than 5 years old.
The reservoir or receiver or dryer cartridge should be renewed
under the following circumstances>
• The refrigerant circuit was opened and the vehicle is more than
5 years old.
• The refrigerant circuit has been opened for in indeterminate
period (seepage leak).
• Repairs take longer than a normal repair time and there has
been moisture intrusion.
• Always renew collector/reservoir or dryer cartridge after blow‐ gen AG
. Volkswagen AG
does
swa
ing through with compressed air or purging with refrigerant
yV
olk not
gu
R134a. Keep genuine parts sealed for as long as risepossible
d b
to ara
nte
keep the ingress of moisture as low as possible.
ut
ho eo
r a ac
ss
• The air conditioner compressor seizes.
ce
e
nl
pt
du
• The reservoir or receiver is damaged (e.g. in an accident).
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Rectify cause of fault.
spec
es, in part or in w
– Renew the expansion valve.
t to the co
– Drain refrigerant oil from air conditioner compressor via block
connections.
rrectness of i
– To speed up the draining of the refrigerant oil, rotate the shaft
l purpos
of the air conditioner compressor using the magnetic clutch

poly V-belt pulley.
nf
ercia

dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐ orm
m
atio
m

o
n in
c

or
thi
e
oils .
t
sd
iva
o
r
rp
cu
– Then fill the air conditioner compressor with a quantity of new

o
m
f
refrigerant oil equal to the quantity in a genuine air conditioner

en
ng
t.
yi Co
compressor ⇒ Rep. gr. 87 . . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

lkswage es n
o ot g
yV
Note d b ua
ran
ir se tee
tho
u or
♦ Types and quantities of refrigerant
ss oils which should be used
a ac
for different air conditioner compressors ⇒ Rep. gr. 87 .
ce
e
nl
pt
du
an
♦ To ensure proper lubrication of the air conditioner compressor
itte
y li
when it runs for the first time, the air conditioner compressor
erm
ab
ility
must be filled with at least 80 cm3 of refrigerant oil; the re‐
ot p
wit
mainder can be poured into the new reservoir or receiver ⇒
, is n
h re
Rep. gr. 87 .
hole
spec
♦ If dirt enters the air conditioner compressor whilst the refrig‐
es, in part or in w
t to the co
erant circuit is open (e.g. after an accident), the air conditioner
compressor should be renewed.
rrectness of i
– Replace receiver or reservoir and restrictor.
l purpos
12.3.2 Without needing to flush contaminants
nform
ercia
from refrigerant circuit (e.g. damage in

m
at
om
i
an accident); no refrigerant has escaped
on
c
in t
or
and no moisture or dirt has entered re‐
his
ate
do
riv
frigerant circuit
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Replace restrictor. Depending on vehicle. gh ht
pyri by
Vo
co lksw
by
– Remove receiver or reservoir. Prote
cted AG.
agen
– Clean any dirt out of receiver or reservoir.

– Weigh removed receiver or reservoir.
Note
♦ Fill enough refrigerant oil into the new reservoir or collector so

that it has the same weight as the container which was re‐
moved.
♦ Install new receiver or reservoir.

13 Testing equipment and tools
13.1 List of test equipment, tools and materi‐

als
Note
This list is an overview of the test equipment, tools and materials

necessary for professional repairs to the refrigerant circuit.
13.1.1 Tools and materials available from re‐

gional sales centre or importer
Overview Page
Air conditioner service station ⇒ page 195
Leak detector - V.A.G 1796- ⇒ page 196
Leak detecting system - VAS 6196- ⇒ page 196
Leak detection additive - VAS 6196/1- Not illustrated
Leak detecting system - VAS 6201- or later ⇒ page 197
model
Air conditioner service station with purging Not illustrated
device or air conditioner service station with
purging device - VAS 6337- (latest available
air conditioner service stations ⇒ V.A.G
workshop equipment catalogue ).
♦ With integrated program for purging re‐
frigerant circuit using refrigerant R134a.
Purging device for refrigerant circuits - VAS ⇒ page 196

6337/1- , (other available wrefrigerant
agen AG
. Volkcircuit
swagen AG
does n
purging devices ⇒ V.A.G Vol workshop equip‐
ks ot g
by ua
ment catalogue .ise d ran
♦ For purging ut
horefrigerant
r
circuit using re‐ tee
or
frigerantss R134a. May also be used on
a ac
older air conditioner service stations
ce
e
nl
pt
(purging procedure must then be carried

du
an
itte
out manually) with a reservoir volume of

y li
erm
ab
at least 10 kg refrigerant R134a.

ility
ot p
wit
, is n
Purging device for refrigerant circuits - VAS ⇒ page 196

h re
6336/1- , (other available refrigerant circuit

hole
spec
purging devices ⇒ V.A.G workshop equip‐

es, in part or in w
ment catalogue .
t to the co
♦ For purging refrigerant circuit using re‐

frigerant R134a. May also be used on
older air conditioner service stations
rrectness of i
(purging procedure must then be carried

out manually) with a reservoir volume of
l purpos
at least 10 kg refrigerant R134a.

nform
ercia
Adapter case VW/Audi passenger vehicle Not illustrated

set VAS 631 for refrigerant circuits with re‐
m
at
om
frigerant R134a.
ion
c
♦ For connection of air conditioner service

in t
or
his
e
station to refrigerant circuit and to bridge

at
do
riv
certain components during purging with

p
cum
refrigerant R134a or blowing through with

for
en
g
compressed air or nitrogen.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
193
Prote AG.
13. Testing equipment and tools
Overview Page
Adapter case commercial vehicle set - Not illustrated
VAS 6338/50- for refrigerant circuits with re‐
frigerant R134a.
♦ For connection of air conditioner service
station to refrigerant circuit and to bridge
certain components during purging or
blowing through.
Ultrasonic air conditioner cleaning unit - VAS Not illustrated

6189A-
♦ To remove unpleasant odours originating
from air conditioning system.
Suction feed spray-gun - V.A.G 1538- Not illustrated

♦ V.A.G 1538/5, probe for evaporator
cleaning, short agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ V.A.G 1538/6, probe efor
d b evaporator
yV ua
ran
cleaning, long ho
ris tee
t or
au ac
♦ V.A.G 1538/7, sprobe
s for evaporator
cleaning, 700 mm (CV)
ce
e
nl
pt
du
an
itte
♦ Cleaner D 600 100 A1
y li
erm
ab
ility
♦ Cleaning solution for evaporator D 600
ot p
100 A2
wit
, is n
h re
hole
♦ To remove unpleasant odours from evap‐

spec
orator
es, in part or in w
t to the co
Release tools case - VAS 6127- ⇒ page 197
♦ To open refrigerant pipes.
rrectness of i
Release tools - VAS 6127/1-3- ⇒ page 197

l purpos
♦ To open refrigerant pipes.

nf
Counter-hold tool - V.A.G 1616- ⇒ page 198

ercia
♦ For coupling plate (air conditioner com‐

rm
m
atio
pressor made by “Sanden”).

om
n in
or c
Puller - V.A.G 1616/1- for magnetic clutch ⇒ page 198

thi
te
sd
a
(Sanden air conditioner compressor).

iv
o
r
rp
cu
Magnetic clutch puller - V.A.G 1719- (Zexel ⇒ page 198

o
m
f
en
ng
air conditioner compressor).

t.
yi Co
Cop py
Adapter set for refrigerant circuit - V.A.G ⇒ page 198
t. rig
gh ht
yri
1785/1-10- R134a.
p by
co Vo
by lksw
cted agen
Combination fine filter unit for compressed Prote Not illustrated
AG.
air systems; oil, dirt and water separator as
used for paint gun systems ⇒ Workshop
equipment catalogue .
O-ring ⇒ Parts catalogue . Not illustrated
Refrigerant oil ⇒ Parts catalogue . Not illustrated
Socket insert - T10364- for valves of service ⇒ page 199
connections on HP/LP side of refrigerant cir‐
cuit.
13.1.2 Tools and materials commercially available

Overview Page
Fin comb ⇒ page 199
Charging hoses 5/8"-18 UNF with valve opener ⇒ page 200
Connector piece for pressure bottles for refrigerant and sealing ring with quick- ⇒ page 200
release coupling or threaded connector 5/8"-18 UNF

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
is Amarok 2011 ➤ , Amarok 2017 ➤ , Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2 ...
ed
r nte
o e
Air
aut conditioning systems with refrigerant R134a - oGeneral
h
ra information - Edition 08.2019
ss c
ce
e
nl
Overview Page
pt
du
an
itte
y li
Valve caps 5/8" -18 UNF ⇒ page 200
erm
ab
ility
ot p
Manifold gauge with pressure limiter for nitrogen ⇒ page 200
wit
, is n
Quick connector adapter for service connections, 2 × included with the air ⇒ page 201
h re
hole
conditioner service station .
spec
es, in part or in w
Open ring spanners of widths matching those of the threaded connections on Not illustrated
t to the co
the refrigerant pipes.
Valve opener for charging hoses Not illustrated
rrectness of i
Connection nipple for tapered seal 5/8"-18 UNF Not illustrated
l purpos
Compressed air gun with rubber nozzle Not illustrated

Hand shut-off valve 5/8" - 18 UNF Not illustrated
nf
ercia
Recycling bottle for refrigerant R134a Not illustrated
orm
m
Digital thermometer
atio
Not illustrated
om
n in
c
Safety gloves Not illustrated

or
thi
te
Safety glasses Not illustrated
sd
iva
o
r
rp
cu
Refrigerant R134a with pressure bottle (contents as required) Not illustrated
o
m
f
en
ng
t.
Nitrogen in pressure bottle Not illustrated
yi Co
Cop py
.
Strap wrench (oil filter) as counterhold for poly V-belt pulley Not illustrated
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
13.1.3 Tools to be made locally

Overview Page
Charging hose with connection to workshop ⇒ page 201
compressed air system
13.1.4 Tools and materials available from re‐

gional sales centre or importer
Air conditioner service station
♦ The procedures for testing, extracting (recycling), evacuating
and charging should be carried out in accordance with the re‐
spective user's manual.
♦ The installed filter and dryer must be renewed at the latest at
the end of the period of use specified in the operating instruc‐
tions and every time that the station is emptied (keep replace‐
ment filter on hand. They can be ordered from the manufac‐
turer of the device, see user's manual.
♦ Air conditioner service stations or purging devices approved
by VW but not shown here may also be used.
Note
♦ This air conditioner service station incorporates the following

familiar individual devices: charging cylinder, manifold gauge,
vacuum pump, shut-off valves and charging hoses.
♦ This air conditioner service station includes one of each type
of quick-release connector (for high-pressure and low-pres‐
sure side service connections).
13. Testing equipment and tools 195

Purging device for refrigerant circuits - VAS 6337/1- from “Behr”

or later model.
Note
♦ With filter -1- and two large cylindrical sight glasses

♦ The filter in the purging device for refrigerant circuits should
be changed after about 2 purging cycles (depending on the
level of contamination from the purged refrigerant circuits). If
a heavily contaminated refrigerant circuit is purged (the refrig‐
erant oil from the refrigerant circuit is black and viscous or
there are large amounts of shavings in the refrigerant circuit)
renew filter after purging
swa
gerefrigerant circuit.
n AG. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
Purging device uth for refrigerant circuits - VAS 6336/1- from “Waeco”
o eo
ra
or later model.
ss
a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ With filter -1- and one sight glass
wit
, is n
h re
♦ The filter in the purging device for refrigerant circuits should
hole
spec
be changed after about 2 purging cycles (depending on the
es, in part or in w
level of contamination from the purged refrigerant circuits). If t to the co

a heavily contaminated refrigerant circuit is purged (the refrig‐
erant oil from the refrigerant circuit is black and viscous or
there are large amounts of shavings in the refrigerant circuit)
rrectness of i
renew filter after purging refrigerant circuit.

l purpos
Leak detector - V.A.G 1796-

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.
Leak detecting system - VAS 6196-

Leak detecting system - VAS 6201- or later model
Release tool - VAS 6127- case comprising release tool - VAS

6127/1- release tool - VAS 6127/2- and release tool - VAS 6127/3-
Release tool - VAS 6127/1- release tool - VAS 6127/2-

♦ Blue 1/2 inch
♦ Black 5/8 inch
♦ Red 3/8 inch
♦ White 3/4 inch
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
Release tool - VAS 6127/3-

y li
rm
ab
pe
ility
♦ Green NW 8 for high-pressure line
ot
wit
, is n
♦ Black NW 13 for low-pressure line

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Counterhold - V.A.G 1616- for clutch pulley (for “Sanden” air con‐
ditioner compressors)
Puller - V.A.G 1616/1- for clutch pulley (for “Sanden” air condi‐
tioner compressors)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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
Magnetic clutch puller - V.A.G 1719- (for “Zexel” air conditioner
t to the co
compressors)
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
Adapter set for refrigerant circuit - V.A.G 1785/1-10-

ng
t.
yi Co
op py
♦ Adapter to clean refrigerant circuit (flushing with refrigerant t. C rig
gh ht
R134a) ⇒ page 65 or blowing through with compressed air or pyri by
Vo
o
by c
nitrogen ⇒ page 63
lksw
cted agen
Prote AG.
A - 5/8"-18 UNF thread for conical surface seal
B - Cap nuts (for connection with O-ring) with thread
♦ M 18x1.5 V.A.G 1785/1
♦ M 20x1.5 V.A.G 1785/2
♦ M 24x1.5 V.A.G 1785/3
♦ M 28x1.5 V.A.G 1785/4
B - Threaded union for O-ring

♦ M 18x1.5 V.A.G 1785/5

♦ M 20x1.5 V.A.G 1785/6
♦ M 24x1.5 V.A.G 1785/7
♦ M 28x1.5 V.A.G 1785/8
Valve adapter
B - Internal thread with valve opener M 10x1.25 V.A.G 1785/9 (for
connections with valves on the high-pressure side) M 12x1.5
V.A.G 1785/10 (for connections on the low-pressure side)
Note
♦ There is a Schrader valve screwed into connection -A-.

♦ A valve opener must be fitted into the charging hose connec‐
tion.
Socket insert - T10364- for valves of service connections

AG. Volkswagenon
AG dHP/
agen
LP side of refrigerant circuit Volksw
oes
not
by gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
13.1.5 Tools and materials commercially avail‐

able
rrectness of i
l purpos
Fin comb
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.

Charging hoses
5/8"-18 UNF thread
Note
♦ Use charging hoses in different colours, 1800 mm long.

♦ Maintain a stock of valve openers and spare seals.
Connector piece for pressure bottles for refrigerant with sealing

ring, quick-release coupling or threaded connector g5/8"-18
en AG. V UNF
olkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
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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
Valve caps with replacement seals (for 5/8''-18 UNF threads)
Seals can also be used for charging hoses.
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
Manifold gauge with pressure reducer for nitrogen (maximum re‐
Co
op py
duction pressure: 15 bar)
. C rig
ht ht
rig by
py
1- Manifold gauge with pressure reducer
co Vo
by lksw
cted agen
Prote AG.
2- Pressure hose (internal diameter 5 mm, length 2 m) with
hose junctions
3- Nitrogen bottle
4- Hose fitting
Note
Hose junctions for connection to the adapter set for refrigerant

circuit - V.A.G 1785- with 5/8"-18 UNF threads or quick-release
coupling adapter for service connections to refrigerant circuit.

Quick-release coupling adapter for service connections

♦ High-pressure side with nominal diameter of 16 mm
♦ Low-pressure side with nominal diameter 13 mm
Note
These quick-release couplings are supplied with the air condi‐

tioner service station .
13.1.6 Tools to be made locally

Charging hose with connection to workshop compressed air sys‐
tem
A - Charging hose 5/8" - 18 UNF** (version with largewinternal
gen AG
. Volkswagen AG
does
s a
diameter) yV
olk not
gu b ara
ed
B - Connector for workshop compressed air tho
rsystem**
is (use only nte
e or
with filter and dryer for compressed air) s au ac
s
ce
e
** Tools and materials commercially available

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

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Service Department. Technical Information

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Passat 2015s au➤

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Passat Variant 2015 ➤ , Phaeton 2003 ➤ ,

Polo 2018 ➤ , Polo Classic 1996 ➤ ,

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up! 2012 ➤ , up! 2017 ➤

Air conditioning systems with refrigerant R134a -

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8027068B

2.5 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Legal texts and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.2 Recycling and refuse law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.4 Maintaining records on refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.3 Flushing refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

12 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

receiver or reservoir) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

12.2 Renew the air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

12.3 Replace receiver or reservoir and restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

13 Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

1.1 Other reference material

♦ Workshop manual for air conditioning system with R12 refrig‐

1.2.1 Physical principles: sd

The four familiar states of water apply to air conditioning refriger‐

When water is heated in a vessel (heat absorption), water vapour

1. General information on air conditioning 1

1.2.2 Heat always flows from a warmer to a

1.2.3 Pressure and boiling point

Vapour curve, water

Vapour pressure curve for refrigerant R134a

D - Vapour pressure curve for refrigerant R134a

1.3 Vapour pressure table for refrigerant

2 Rep. gr.00 - Technical data

Absolute pressure means that 0 bar correspondsswtoagan en Aabsolute

1.4 Refrigerant R134a

1.4.1 Physical data of refrigerant R134a