Air Conditioning Systems General Information
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Workshop Manual wage
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Air conditioning systems with refrigerant R1234yf -
General information
Edition 01.2018
Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
87 - Air conditioning system
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B80609EAF
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Contents
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00 - Technical bdata
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1.1 s au Safety precautions when working on air conditioning ac systems . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
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1.4 Safety measures when using air conditioner service stations . . . . . . . . . . . . . . . . . . . . . . 2
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1.5 Safety measures for working on vehicles with high-voltage system . . . . . . . . . . . . . . . . . . 3
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1.6 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 4
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1.7 Safety measures when working on pressurised tanks/containers . . . . . . . . . . . . . . . . . . . . 4
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urposes, in part or in wh
2 Legal texts and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Provisions and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Charging refrigerant circuit with different refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.3 Workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
s
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.2 Refrigerant circuit seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
inform
3.3 Refrigerant and refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.4 Handling pressurised tanks/containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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3.5 Handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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4.1 Notice for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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5.1 Refrigerant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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5.2 Refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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5.3 Safety data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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6 Basic technical and physical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Basics of air conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Physical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3 Product characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 Function and role of air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2 General description - components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Possible complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.4 Investigating leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.5 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.6 Cleaning refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.7 Checking pressures with pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Working with air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.1 Working with air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.2 Connecting air conditioner service station to refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . 126
2.3 Performing gas analysis of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.4 Emptying refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.5 Evacuating refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.6 Charging refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.7 Bringing air conditioning system into service after charging . . . . . . . . . . . . . . . . . . . . . . . . 144
2.8 Switching off air conditioner service station and separating from refrigerant circuit . . . . . . 146
2.9 Charging refrigerant in reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.10 Emptying air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Contents i
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
2.11 Cleaning electrical air conditioning compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.12 Cleaning refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal
. . . . . . . . . . . . . . . . .n.A.G.. V
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2.14 Checking pressures V olksw . . . . . . . . . . . . . . o.e.s n. o.t g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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3 Testing requipment
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3.2 Tools
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3.3 Tools that can be locally manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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ii Contents
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
00 – Technical data
1 Safety information
(VRL011332; Edition 01.2018)
⇒ “1.1 Safety precautions when working on air conditioning sys‐
tems”, page 1
⇒ “1.2 Safety precautions when handling refrigerants”,
page 1
⇒ “1.3 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.4 Safety measures when using air conditioner service sta‐
tions”, page 2
⇒ “1.5 Safety measures for working on vehicles with high-voltage
system”, page 3
⇒ “1.6 Safety precautions when working in the vicinity of high-
voltage components”, page 4
⇒ “1.7 Safety measures when working on pressurised tanks/con‐
tainers”, page 4
1.1 Safety precautions when working on air conditioning systems
Risk of fatal injury and explosion from sources of ignition
Risk of fatal injury and explosion from sources of ignition in the
vicinity of air conditioning systems and refrigerant tanks. Escap‐
ing refrigerant could ignite and cause an explosion. Risk of ex‐
plosion leading to loss of life or serious injuries.
– Never bring sources of ignition close to air conditioning sys‐
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– Avoid electrostatic discharge, sparks from tools
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Risk of damage to refrigerant lines
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– Never bend refrigerant lines to a radius less than 100 mm.
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1.2 Safety precautions when handling refrigerants
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Risk of suffocation and poisoning from refrigerant
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– Never inhale refrigerant vapours.
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– Only work on the refrigerant circuit and refrigerant tanks in well
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ventilated areas.
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– Never work in or near cellars or other low lying areas.
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– Switch on the extraction system.
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1. Safety information 1
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Risk of freezing injury from refrigerant
When working on the air conditioning system, there is a risk of
highly pressurised refrigerant escaping from the system. There is
a risk of injury to the skin and parts of the body due to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immediately
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 refrigerant
circuit from continued evaporation.
1.3 Safety measures when working on vehicles with a start/stop system
Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.4 Safety measures when using air condi‐
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• Once the purified refrigerant from the air conditioner service
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and charging system to moisture and do not use in a damp
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• Before performing any maintenance work on the air condition‐
er service station , disconnect the extracting and charging
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system from the power supply.
• To reduce the risk of fire, avoid using an extension cable. If
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• In case of fire, remove external cylinder.
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• If oil is drawn out of the air conditioning system by the suction
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2 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
• When the air conditioner service station is switched off, take
measures to prevent it from rolling away.
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• Only keep or use in areas with a sufficient flow of air (complete erm
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1.5 Safety measures for working on vehicles with high-voltage system
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Danger to life from high voltage
The high-voltage system is under high voltage. Severe or fatal
injury from electric shock.
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– Persons with life-preserving or other electronic medical devi‐
s
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s o
voltage system. Such medical devices include internal anal‐
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gesic pumps, implanted defibrillators, pacemakers, insulin
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Risk of injury due to unexpected motor start
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On electric and hybrid vehicles, it can easily be missed that the
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vehicle is in „ready“ mode. There is a risk of parts of the body
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becoming trapped or drawn in.
– Switch off ignition.
– Always store the ignition key outside the vehicle.
Risk of damage to high-voltage cables
Improper handling of high-voltage cables or high-voltage connec‐
tors can result in damage to their insulation.
– Never support body weight on high-voltage cables or high-
voltage connectors.
– Never support any tools on high-voltage cables or high-volt‐
age connectors.
– Never kink or severely bend high-voltage cables.
– Always observe the coding when connecting high-voltage con‐
nectors.
Risk of injury from activate stationary air conditioning
On electric and hybrid vehicles with active stationary air condi‐
tioning, the stationary air conditioning could switch on uninten‐
tionally. Risk of limbs becoming trapped or drawn in by the
radiator fan starting automatically.
1. Safety information 3
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Deactivate the stationary air conditioning.
1.6 Safety precautions when working in the vicinity of high-voltage components
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.
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1.7 Safety measures when working on pressurised tanks/containers
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Risk of fatal injury and explosion from sources of ignition
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Risk of fatal injury and explosion from sources of ignition in the
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vicinity of air conditioning systems and refrigerant tanks. Escap‐
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– Avoid electrostatic discharge, sparks from tools striking sur‐
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4 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
2 Legal texts and regulations
⇒ “2.1 Provisions and directives”, page 5
⇒ “2.2 Charging refrigerant circuit with different refrigerants”,
page 6
⇒ “2.3 Workplace safety”, page 7
2.1 Provisions and directives
Note
♦ The laws and regulations listed below are valid in Germany.
Other or additional laws and regulations may apply in other
countries.
♦ The effects concerning the changing climate can be seen
world-wide. Protection of the climate is therefore one of the
most important roles of the human race. This role is a huge
challenge for all concerned.
♦ The so called Kyoto Protocol defines, among other things,
world-wide targets to protect the climate. Aside from reduction
targets for carbon dioxide, this protocol defines reduction tar‐
gets for fluoride containing greenhouse gases e.g. for refrig‐
erant R134a owing to the high greenhouse potential.
♦ The cut-off date for bringing vehicles that were type approved
before 2011 into operation for the first time with R134a refrig‐
erant is 31.12.2016 (this applies to countries within the EU, gen AG
. Volkswagen AG
does
different regulations may apply in countries outside the VolkEU).
swa not
From 01.01.2017, vehicles must not be newly commissioned d by gu
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in countries of the EU unless their refrigerant circuit
thor is charged nte
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with refrigerant with a global warming potential
s au less than 150. ra
c
R1234yf refrigerant meets the requirements of Regulation
s
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(EC) No. 706/2007.
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Within Europe, for example, a large number of relevant statutes
ility
ot p
have been introduced for the motor industry. In Germany, for ex‐
wit
is n
ample, the climate protective regulation concerning chemicals
h re
ole,
came into force from the 1st of August 2008 in addition to Euro‐
spec
pean legislation.
urposes, in part or in wh
In the European Community, various regulations directives for t to the co
handling refrigerant have been introduced e.g.: rrectne
♦ Regulation (EC) No. 1005/2009
♦ Regulation (EC) No. 2037/2000
ss o
♦ Regulation EU No. 517/2014
cial p
f inform
♦ Regulation (EC) No. 706/2007
mer
atio
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♦ Regulation (EC) No. 307/2008
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♦ Directive 2006/40/EC
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In Germany, additional regulations concerning refrigerant have
p
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been introduced e.g.:
en
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♦ Climate Protection Regulation Concerning Chemicals (Chem‐ C py
t. rig
ikalien-Klimaschutzverordnung), Closed Substance Cycle
gh ht
pyri by
Waste Management Law (Kreislaufwirtschaftsgesetz, KrWG),
co Vo
by lksw
cted agen
Prote AG.
♦ Technical Regulations for Compressed Gases (Technische
Regeln Druckgase, TRG).
2. Legal texts and regulations 5
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
The R1234yf refrigerant is currently not referenced in the various
rules and regulations. Due to its chemical composition, however,
it can be assumed that it will be included the next time the relevant
rules and regulations are revised. The rules and regulations per‐
tinent to the R134a refrigerant are therefore to be observed and
adhered to when handling the R1234yf refrigerant.
Maintenance and repairs to refrigerant circuits for air conditioning
systems
Only persons who are deemed to be competent in accordance
with Regulation (EC) No. 307/2008 may carry out repairs and
service work on the refrigerant circuit of an air conditioning system
(applies to countries in which this regulation is valid - different
rules and regulations may apply in other countries).
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.
♦ Records must be kept about the quantity used during opera‐
tion and repair work so that, if necessary, a schedule of
application can be presented to the relevant authorities on re‐
quest. A record sheet need no longer be kept within the EU
due to respective European parliament legislation from 2005.
Other legislation may apply in countries not belonging to the
EU.
♦ Companies that sell materials and preparations listed in the
above mentioned legislation have a duty to accept returned
materials and preparations after they
n AG.have
Volkswbeen
agen Aused,
G do or to
wage
ensure that a specified third
y Vo party will accept them. s not g
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♦ Maintenance workhand ris decommissioning of products that con‐ntee
t o
tain refrigerant referred
u to in the above mentioned legislation. or ac
sa
The returned substances and preparations referred to in this
s
ce
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legislation may also only be accepted by persons who have
un
pt
an
the necessary specialist knowledge and technical equipment.
d
itte
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erm
ab
Closed Substance Cycle Waste Management Law (Kreislaufwirt‐
ility
ot p
schaftsgesetz, KrWG) as well as processing and disposing of
wit
is n
contaminated refrigerant and refrigerant oil
h re
ole,
spec
The respective rules and regulations of the country must be ob‐
urposes, in part or in wh
served here.
t to the co
2.2 Charging refrigerant circuit with different
refrigerants
rrectne
Air conditioning systems developed and designed for R1234yf
ss
refrigerant cannot simply be charged with a different refrigerant,
o
cial p
e.g. R134a.
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
According to current legislation, R134a refrigerant must not be
sd
iva
charged in vehicles that were type approved for R1234yf refrig‐
pr
cum
r
fo
erant.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
6
Prote AG.
Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
2.3 Workplace safety
♦ Regulations on general health and safety according to the
VBG (German organisation of trade associations (employers'
liability insurance association)) e.g. VGB 20 Accident preven‐
tion regulation (UVV) for “Refrigerant systems, heat pumps
and cooling equipment” and VGB 1 “General regulations and
obligations of the company” and “Obligations of the insured
party”.
♦ Observe the work instructions relevant to the place of work.
♦ Only persons who are deemed to be competent in accordance
with Regulation (EC) No. 307/2008 may carry out repairs and
service work on the refrigerant circuit of an air conditioning
system (applies to countries in which this regulation is valid -
different rules and regulations may apply in other countries).
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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nl
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du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Legal texts and regulations 7
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 8
⇒ “3.2 Refrigerant circuit seals”, page 8
⇒ “3.3 Refrigerant and refrigerant oil”, page 9 wage
n AG. Volkswagen AG do
es n
lks ot g
Vo
⇒ “3.4 Handling pressurised tanks/containers”, page d 11
by ua
ran
ir se tee
o
⇒ “3.5 Handling refrigerants”, page 12 auth or
ac
ss
3.1 Rules for cleanliness
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le
un
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itte
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Even small amounts of contamination/soiling can lead to defects.
rm
ab
Therefore, observe the following rules for cleanliness when work‐
pe
ility
ing on the air conditioning system:
ot
wit
, is n
h re
♦ Seal open pipes and connections immediately with clean
hole
spec
plugs, for example from the engine bung set - VAS 6122- .
es, in part or in w
t to the co
♦ Place removed parts on a clean surface. Cover with lint-free
cloths only.
♦ If repair work cannot be performed immediately, carefully cov‐
rrectness of i
er or seal components.
l purpos
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
nform
ercia
have been stored outside their packaging (e.g. in tool boxes).
m
♦ Do not work with compressed air when the system is open.
a
com
tion in
♦ Protect disconnected electrical connections from dirt and wa‐
r
te o
thi
ter and only reconnect in dry condition.
s
iva
do
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rp
c
3.2 Refrigerant circuit seals
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ng
t.
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♦ Renew seals after removal. C py
t. rig
gh ht
yri
♦ Moisten seals with refrigerant oil before installing.
p by
co Vo
by lksw
cted agen
♦ Ensure proper seating of seals on the pipe or in the groove.
Prote AG.
♦ Work in a completely clean environment. Even the smallest
contaminants, e.g. a hair, can cause leaks.
♦ Install only seals resistant to refrigerant R134a/R1234yf and
respective refrigerant oil ⇒ Electronic parts catalogue (ET‐
KA) .
The dimensions -a- and -b- depend on the fitting location of the
seal ⇒ Electronic parts catalogue (ETKA) .
8 Rep. gr.00 - Technical data
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
3.3 Refrigerant and refrigerant oil
. Volkswagen AG
a gen AG does
⇒ “3.3.1 Important repair instructions for refrigerantVol and refriger‐
ksw not
gu
ant oil”, page 9 ed by ara
nte
ris
ho eo
⇒ “3.3.2 Refrigerant oil”, page 9 aut ra
ss c
3.3.1 Important repair instructions for refriger‐
ce
e
nl
pt
du
an
ant and refrigerant oil
itte
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erm
ab
ility
• An air conditioner designed for R1234yf refrigerant must never
ot p
wit
be charged with R134a refrigerant. , is n
h re
hole
• An air conditioner designed for R134a refrigerant must never
spec
be charged with R1234yf refrigerant.
es, in part or in w
t to the co
• The refrigerant oils especially developed for refrigerant circuits
with R1234yf and R134a refrigerant may not be used in a re‐
frigerant circuit charged with a different refrigerant unless the
rrectness of i
relevant permissions have been granted ⇒ Electronic parts
l purpos
catalogue and ⇒ Heating, air conditioning system; Rep. gr.
00 ; Technical data; refrigerant oil .
nf
ercia
• Air conditioner service stations which come in contact with re‐
or
frigerant may only be used for the target refrigerant.
m
m
atio
m
• A label -A- is attached in the engine compartment to the lock
o
n in
or c
carrier or the plenum chamber to provide information on the
thi
e
refrigerant used.
t
sd
iva
o
r
rp
cu
• Different refrigerants must never be mixed.
o
m
f
en
ng
t.
yi Co
• Depending on the type and production period, it may also in‐ Cop py
dicate the GWP for the refrigerant used.
t. rig
gh ht
pyri by
Vo
o
• To ensure that only R1234yf refrigerant with a certain purity
by c lksw
cted agen
level is drawn into the air conditioner service station (R1234yf),
Prote AG.
a gas analysis must be performed before the refrigerant circuit
is emptied
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
Note
If, during the gas analysis, it is found that the R1234yf refrigerant
is contaminated with a different gas, it must be extracted from the
refrigerant circuit and analysed, processed or disposed of as gas
of unknown composition in accordance with the legal require‐
ments ⇒ VW / Audi ServiceNet ,
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 and
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for analy‐
sis, processing or disposal”, page 25 .
3.3.2 Refrigerant oil
CAUTION
Risk of chemical burns from atomised refrigerant oil. Eyes and
other parts of the body could be injured.
– Wear protective gloves.
– Wear protective goggles.
– Never inhale atomised refrigerant oil.
♦ Refrigerant oil mixes with the refrigerant (about 10 to 40%,
depending on compressor type and amount of refrigerant) and
circulates constantly in the system, lubricating the moving
parts.
3. Repair instructions 9
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Special synthetic refrigerant machine oils such as polyalky‐
lene glycol (PAG) oil with certain additives adapted to the
refrigerant oil are used in conjunction with R1234yf air condi‐
tioning systems. This is necessary because e.g. mineral oil
does not mix with R1234yf and, should the additives be miss‐
ing, undesired reactions with the refrigerant or components of
the refrigerant circuit could occur. In addition, the components
of the R1234yf air conditioning system could be attacked if the
mixture circulated within the refrigerant circuit under pressure
and at high temperatures, or the lubricant film in the air con‐
ditioner compressor broke down. The use of non-approved
oils can lead to failure of the air conditioning system. There‐
fore, use only approved refrigerant oils ⇒ Electronic parts
catalogue .
♦ Type of oil for R1234yf refrigerant in motor vehicles: PAG oil
with specific additives adapted to R1234yf refrigerant (polyal‐
kylene glycol with certain additives).
♦ The most important properties are high solubility with refriger‐
ant, good lubricating quality, absence of acid and low water
content. For this reason, only very specific oils may be used.
List of approved refrigerant oils and capacities ⇒ Electronic
parts catalogue and ⇒ Heating, air conditioning system; Rep.
gr. 00 ; Technical data (vehicle-specific workshop manual).
♦ The PAG oils suitable for refrigerant R1234yf are heavily hy‐
groscopic and cannot always be mixed with other oils. There‐
fore, only use approved refrigerant oils.
♦ Moisture and acids promote ageing of refrigerant oil, causing
it to become dark, viscous and aggressive towards metals.
Containers for refrigerant oil should therefore be kept closed
to prevent the ingress of moisture. When containers are
opened, they should be closed again immediately.
♦ Disposal of used oils: Volkswagen InfoNet; Operation; Hand‐ AG. Volkswagen AG d
books & dealer literature; Handbook Service; 15. Environmen‐ agen oes
olksw not
tal protection; under general instructions follow d by the link
V gu
ara
“Environmental protection in the dealership oris and in the work‐
e nte
eo
shop”; 4. Waste disposal; 6. Disposal channels;
aut
h
Disposal of ra
used oils; Refrigerant oils ss c
ce
e
nl
pt
♦ For refrigerant circuits with R1234yf refrigerant circuit, only
du
an
itte
approved oils may be used for this refrigerant and the air con‐
y li
erm
ab
ditioner compressor installed in the system ⇒ Electronic parts
ility
ot p
catalogue and ⇒ Heating, air conditioning system; Rep. gr.
wit
, is n
00 ; Technical data .
h re
hole
spec
♦ Refrigerant oil that was developed for R134a refrigerant is not
es, in part or in w
suitable for refrigerant circuits with R1234yf refrigerant (as it
t to the co
is missing specific additives). Therefore, ensure that the cor‐
rect type is used ⇒ Electronic parts catalogue and ⇒ Heating,
air conditioning system; Rep. gr. 00 ; Technical data; Refrig‐
rrectness of i
erant oil .
l purpos
♦ Refrigerant oil that was developed for R1234yf refrigerant
could also be suitable for use in refrigerant circuits with R134a
refrigerant. Observe notes ⇒ Electronic parts catalogue and
nf
ercia
⇒ Heating, air conditioning system; Rep. gr. 00 ; Technical
rm
m
data (vehicle-specific workshop manual).
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.
10 Rep. gr.00 - Technical data
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The cylinder in which the refrigerant oil is supplied has a label
from which the expiry date of the refrigerant oil can be gleaned.
♦ This expiry date is not critical if the cylinder is sealed tight.
♦ Refrigerant oil from a tightly sealed cylinder can also be used
after the expiry date specified on the cylinder.
Note
♦ Do not store refrigerant oils open to the atmosphere as they
are very hygroscopic (they readily absorb water).
♦ Always keep the refrigerant oil container and the refrigerant
circuit sealed.
♦ Do not use ester oils (POE oils) as these are currently only
compatible with larger systems under different operating con‐
ditions (not suitable for motor vehicle air conditioning sys‐
tems).
3.4 Handling pressurised tanks/containers
Keep containers tightly sealed inn a
wage
AGwell
. Volkventilated,
swagen AG cool location.
doe
ks s no
Vol t
Refrigerant is heavieredthanby air. Should gas escape from agsystem,
ua
ran
it collects at ground
thoris
level in particular. tee
or
au ac
Protect against
ss heat and direct sunlight, do not keep in areas with
ce
temperatures higher than 50°C.
e
nl
pt
du
an
itte
Do not keep in or near cellars or other low lying areas.
y li
erm
ab
ility
Only keep in areas with an adequate flow of air.
ot p
wit
, is n
Keep containers away from sources of ignition.
h re
hole
spec
Smoking is forbidden in areas in which R1234yf refrigerant is
es, in part or in w
kept. Also take measures to prevent electrostatic discharge.
t to the co
Secure containers to prevent them falling over.
rrectness of i
Secure upright cylinders to stop them falling over and cylinders
lying flat to stop them rolling away.
l purpos
Containers must never be thrown.
nf
ercia
If they should fall, the containers may become severely deformed
or
and break open. The refrigerant evaporates immediately, liberat‐
m
m
atio
ing considerable force. Flying fragments of cylinders can cause
om
n in
severe injuries.
or c
thi
e
To protect cylinder valves, cylinders are only to be transported
t
sd
iva
with a protective cap screwed on.
r
rp
cu
o
m
f
en
ng
Valves may break off if cylinders are not properly transported.
t.
yi Co
Cop py
Do not place near radiators!
t. rig
gh ht
pyri by
Vo
o
by c
High temperatures can occur near radiators. High temperatures
lksw
cted agen
are also associated with high pressures and the maximum per‐
Prote AG.
missible tank pressure may be exceeded.
Do not heat up above 50°C
To mitigate any risk, the pressure vessel regulations stipulate that
tanks/containers must not be heated up above 50°C.
3. Repair instructions 11
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Do not expose to uncontrolled heat
Do not heat with a naked flame under any circumstances. The
local overheating that will result can change the structure of the
container's materials, thereby reducing the safe maximum pres‐
sure limit of the container. There is also a danger of the refrigerant
decomposing due to localised overheating.
Seal empty tanks/containers
Empty refrigerant tanks/containers must always be closed to pre‐
vent the ingress of moisture. Moisture causes steel tanks/con‐
tainers to rust. Rust weakens the tank/container walls. In addition,
rust particles which ingress into refrigeration systems from tanks/
containers cause malfunctions.
3.5 Handling refrigerants
Note
♦ Refrigerant has no perceptible odour and usually remains un‐
noticed.
♦ Refrigerant gas is heavier than air. It collects in low lying areas,
such as inspection pits, cellars and troughs or hollows, where
it displaces the ambient air along with the oxygen. Spending
time in areas starved of oxygen can be fatal.
♦ If liquid refrigerant escapes e.g.
agen
from
AG. Vaolleak, itnvaporises
kswage AG d at an
ambient pressure of about olk1
swbar at approx. -29.4°C. oes
Ifnorefrig‐
t gu
yV
erant vaporises on the ed skin, the result will be frost bite or freeze
b ara
burns. Sensitive tbody
horis
parts, such as the cornea and mucous nte
eo
membranes, are s au especially at risk. Larger freeze burns could r ac
lead to loss ofs life.
ce
le
un
pt
♦ Refrigerant gas is inflammable: electrostatic discharge, sparks
an
d
itte
y li
from striking tools, hot surfaces and naked flames could ignite
rm
ab
a mixture of R1234yf refrigerant and ambient air. However,
pe
ility
ot
refrigerant only burns if supported by a flame, or if it is in the
wit
, is n
vicinity of a hot surface. It extinguishes when it is no longer
h re
hole
supported e.g. by a flame.
spec
es, in part or in w
♦ Refrigerant decomposes when exposed to a flame or in con‐
t to the co
tact with a hot surface. Danger of poisoning on inhaling poi‐
sonous decomposed products. A pungent odour indicates that
the products of decomposition are already present. Breathing
rrectness of i
in these substances must be avoided in all circumstances, or
the bronchial tubes, lungs and other organs could be injured.
l purpos
♦ The specific risks of refrigerant, material data etc. can be
gleaned from the safety data sheets. Safety data sheets about
nform
ercia
refrigerant, refrigerant oil etc. can be found on the ⇒ VW
m
ServiceNet .
com
tion in
r
te o
thi
• Do not weld, braze or soft-solder any parts of the charged air
s
iva
do
conditioning system. This also applies to welding and solder‐
r
rp
cum
ing work on the vehicle when the danger exists that parts of
fo
en
g
the air conditioning system may heat up. When spray painting
n
t.
yi Co
is carried out, temperatures of objects in the drying booth or Cop py
ht. rig
the preheating zone must not exceed 80°C. opy
rig by
Vo
ht
c lksw
Reason:
by
cted agen
Prote AG.
Heating causes great excess pressure to develop in the system,
which can cause the pressure release valve of the system to
open.
Remedy:
– Empty refrigerant circuit with air conditioner service station
⇒ page 124 .
12 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
Do not repair damaged or leaking parts of the air conditioner by
welding or soldering. These must 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.
Reason:
Refrigerant expands as it heats up.
Remedy:
– When charging and storing compressed AG. Vgas
olkswcontainers
agen AG (re‐
agen etc.), observe
turnable cylinders, recycling ocylinders dthe
oes ap‐
lksw not
plicable regulations, technical
db
y V rules and legislation. gu
ar
e an
ris tee
– Containers must never ut
ho be completely filled with liquid refrig‐ or
erant. Without sufficient
ss
a
expansion space (gas cushion), the ac
container will burst should the temperature rise with devastat‐
ce
e
nl
pt
ing consequences ⇒ “6.2 Physical properties”, page 19 .
du
an
itte
y li
erm
Under no circumstances may refrigerant be charged into systems
ab
ility
or vessels containing air.
ot p
wit
, is n
Remedy:
h re
hole
spec
– Evacuate systems and containers before charging with refrig‐
es, in part or in w
erant ⇒ page 124 .
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
n in
or c
thi
te
sd
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o
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Repair instructions 13
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
4 Identification
⇒ “4.1 Notice for refrigerant circuit”, page 14 AG. Volkswagen AG d
agen oes
lksw not
4.1 Notice for refrigerant circuit Vo gu
d by ara
ise nte
or eo
♦ The notice -A- provides details
aut about the type of refrigerant,
h
ra
the volume of refrigerant scharged in the system during pro‐
s c
ce
le
duction and which refrigerant oil is used.
un
pt
an
d
itte
♦ Symbols on the notice -A- indicate the risks that might be en‐
y li
rm
ab
countered when handling refrigerant and when working on the
pe
ility
refrigerant circuit.
ot
wit
, is n
h re
♦ In addition, it may specify standards, e.g. specific SAE stand‐
hole
spec
ards that are valid in the USA. SAE J639 describes the safety
es, in part or in w
instructions for air conditioning systems in passenger cars.
t to the co
SAE J842 describes that only components and materials ap‐
proved for R1234yf refrigerant may be used, while SAE J2845
indicates that only trained and certified persons may carry out
rrectness of i
repairs and service work on the refrigerant circuit of an air
conditioning system.
l purpos
♦ Depending on the type and production period, it may also in‐
dicate the GWP for the refrigerant used.
nform
ercia
♦ The capacities and type of refrigerant oil marked on the notice
m
a
com
t
-A- indicate the status during production of the vehicle. The
ion in
latest applicable values should always be gleaned from the
r
te o
thi
vehicle-specific workshop manual ⇒ Heating, air conditioning
s
iva
do
system; Rep. gr. 00 ; Technical data (vehicle-specific work‐
r
rp
c
shop manual).
um
fo
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
o
by c lksw
cted agen
The country-specific legislation, regulations and standards must Prote AG.
be obeyed independently of the details on the notice -A-. In the
area of the European Union, e.g. the applicable EC regulations
⇒ “2 Legal texts and regulations”, page 5
With details about the type of refrigerant and specified capacity
⇒ Heating, air conditioning system; Rep. gr. 00 ; Technical data
(vehicle-specific workshop manual).
14 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
5 Technical data
⇒ “5.1 Refrigerant capacity”, page 15
⇒ “5.2 Refrigerant oil capacities”, page 15
⇒ “5.3 Safety data sheets”, page 15
5.1 Refrigerant capacity
The capacities of R1234yf refrigerant can be found in the vehicle-
specific workshop manual ⇒ Heating, air conditioning system;
Rep. gr. 00 ; Technical data; R1234yf refrigerant capacities .
5.2 Refrigerant oil capacities
The capacities of refrigerant oil can be found in the vehicle-spe‐
cific workshop manual ⇒ Heating, air conditioning system; Rep.
gr. 00 ; Technical data; Refrigerant oil .
5.3 Safety data sheets
Safety data sheets are currently available on the ⇒ VW / Audi
ServiceNet .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Technical data 15
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
6 Basic technical and physical proper‐
ties
⇒ “6.1 Basics of air conditioning technology”, page 16
⇒ “6.2 Physical properties”, page 19
⇒ “6.3 Product characteristics”, page 26
⇒ “6.4 Function and role of air conditioning system”, page 26
⇒ “6.5 Other reference material”, page 28
6.1 Basics of air conditioning technologywagen AG. Volkswagen AG doe
ks s no
Vol t gu
⇒ “6.1.1 Physical properties of air conditioning system”,
ed
by ara
page 16 horis nte
eo
t
au ra
⇒ “6.1.2 Pressure and boiling point of refrigerant”,
ss page 17 c
ce
le
un
pt
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17
an
d
itte
y li
⇒ “6.2 Physical properties”, page 19
erm
ab
ility
ot p
6.1.1 Physical properties of air conditioning
wit
is n
h re
system
ole,
spec
urposes, in part or in wh
The 4 familiar states of water apply to air conditioning refrigerants
t to the co
as well.
1- Gas (invisible)
rrectne
2- Vapour
s
3- Liquid
s o
cial p
f in
4- Solid
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 -A-, it
changes first to vapour -B-, then to water and finally to ice.
A - Heat absorption
B - Heat dissipation
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. As a result,
the molecular motion of the warmer substance slows down and
that of the colder substance is accelerated. 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.
16 Rep. gr.00 - Technical data
AG. Volkswagen AG d
agen Arteon 2018 ➤ , oAtlas
es n 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
olksw ot g
dAir
by Vconditioning systems with refrigerant ua
ran
R1234yf - General information - Edition 01.2018
e
oris tee
th or
6.1.2 ss
au Pressure and boiling point of refrigerant ac
ce
le
un
The boiling point given in tables for a liquid is always referenced
pt
an
d
to atmospheric pressure (1 bar absolute pressure). If the pressure
itte
y li
rm
over a fluid changes, its boiling point changes as well.
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Pressure is indicated in various units: 1 MPa (Mega-Pascal) is
t to the co
equal to 10 bar or 145 psi; 1 bar absolute pressure is equal to
0 bar, which is about the same as ambient pressure (atmospheric
pressure).
rrectness of i
l purpos
It is well known that e.g. the lower the pressure, the lower the
temperature at which water boils.
nform
ercia
The vapour pressure curves for water and for R1234yf refrigerant
show that at constant pressure and falling temperature the vapour
m
a
com
t
becomes liquid (in the condenser), and that when pressure drops,
ion in
for example, the refrigerant changes from liquid into the vaporous
r
te o
thi
state (in the evaporator).
s
iva
do
r
rp
c
Vapour curve, water
um
fo
en
ng
t.
yi
A - Liquid
Co
Cop py
ht. rig
B - Gaseous rig ht
py by
co Vo
by lksw
C - Vapour curve, water
cted agen
Prote AG.
1 - Pressure on the liquid in bar (absolute)
2 - Temperature in °C
Vapour pressure curve for refrigerant R1234yf
A - Liquid
B - Gaseous
D - Vapour pressure curve for refrigerant R1234yf
1 - Pressure on the liquid in bar (absolute)
2 - Temperature in °C
Note
The vapour pressure curves of both refrigerants, R1234yf and
R134a, are very similar across a broad temperature range. The
pressure difference between the two refrigerants in a temperature
range of 0 C to +50°C is only about 0.2 bar, for example, which
is why it is not possible to differentiate between the two refriger‐
ants ⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17
and ⇒ Air conditioning system with R134a refrigerant; Rep. gr.
87 ; General information about the air conditioning system and
refrigerant circuit . It is only possible to determine a difference
using relevant sensors, which can analyse the chemical structure
of the refrigerant
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24 .
6.1.3 Vapour pressure table for refrigerant
The vapour pressure table for every refrigerant is published in
literature for refrigeration system engineers. This table makes it
6. Basic technical and physical properties 17
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
possible to determine the vapour pressure acting on the column
of liquid in a vessel if the temperature of the vessel is known.
Since its own characteristic vapour pressure table is known for
each refrigerant, it is possible to establish the type of refrigerant
by measuring the pressure and temperature of refrigerants whose
vapour pressure changes over a certain temperature range (does
not apply when differentiating between R1234yf and R134a as
the vapour pressures are too close
⇒ “6.1.2 Pressure and boiling point of refrigerant”, page 17 ).
Note
♦ The means of differentiation are only given for pure refriger‐
ants whose vapour pressures differ sufficiently. If different
refrigerants are mixed for form a new refrigerant (e.g. 3 differ‐
ent refrigerants to form R407C refrigerant), a vapour pressure n AG. Volkswagen AG do
will be created in accordance with the vapour pressures of the lkswage es n
ot g
individual refrigerants and their percentage in the mixture. d by V
o
ua
r e an
ris tee
♦ Absolute pressure means that “0 bar” corresponds to anutab‐
ho or
solute vacuum. The normal ambient pressure correspondsss
a
to ac
“1 bar” absolute pressure. On most pressure gauges, a read‐
ce
e
nl
pt
ing of “0 bar” corresponds to an absolute pressure of one bar
du
an
itte
(which is confirmed by the existence of a “-1 bar” marking be‐
y li
erm
ab
neath the “0” scale marking).
ility
ot p
wit
♦ Pressure is indicated in various units: 1 MPa (Mega-Pascal)
, is n
h re
is equal to 10 bar or 145 psi; 1 bar absolute pressure is equal
hole
spec
to 0 bar, which is about the same as ambient pressure (at‐
es, in part or in w
mospheric pressure).
t to the co
♦ The vapour pressures of the two refrigerants, R1234yf and
R134a, are very similar across a broad temperature range,
rrectness of i
which is why no difference can be established between them
⇒ Air conditioning system with R134a refrigerant, General in‐
l purpos
formation about the air conditioning system . It is only possible
to determine a difference using relevant sensors, which can
analyse the chemical structure of the refrigerant
nform
ercia
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24 .
m
at
om
ion
c
Temperature in °C Pressure in bar (positive pres‐
in t
or
sure) R1234yf
his
ate
do
riv
-40 -0.40
p
cum
for
en
g
-30 -0.01
n
t.
yi Co
op py
-25 0.12 t. C rig
gh ht
yri by
-20 0.50 cop Vo
by lksw
cted agen
-15 0.83
Prote AG.
-10 1.21
-5 1.65
0 2.15
5 2.72
10 3.36
15 4.09
20 4.90
25 5.81
30 6.82
35 7.93
40 9.17
45 10.52
18 Rep. gr.00 - Technical data
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Temperature in °C Pressure in bar (positive pres‐
sure) R1234yf
50 12.01
55 13.64
60 15.41
65 17.35
70 19.46
75 21.75
80 24.24
85 26.94
90 29.09
6.2 Physical properties
⇒ “6.2.1 R1234yf refrigerant”, page 19
⇒ “6.2.2 Potential risks with R1234yf refrigerant”, page 20
⇒ “6.2.3 Physical and chemical properties of R1234yf refrigerant”,
page 20
⇒ “6.2.4 Critical point”, page 20
⇒ “6.2.5 Environmental aspects of refrigerant R1234yf”,
page 21
⇒ “6.2.6 Trade names and designations of R1234yf refrigerant”,
page 21
. Volkswagen AG
wa gen AG does
⇒ “6.2.7 Colour and odour of R1234yf refrigerant”, page V22
olks not
gu
y
db ara
⇒ “6.2.8 Vapour pressure of R1234yf refrigerant”, page
or
ise 22 nte
eo
h
ut ra
⇒ “6.2.9 Physical properties of R1234yf refrigerant”,
ss
a
page 22 c
ce
le
un
⇒ “6.2.10 How R1234yf refrigerant reacts to metals and plastics”,
pt
an
d
page 22
itte
y li
erm
ab
⇒ “6.2.11 Critical temperature / critical pressure of R1234yf re‐
ility
ot p
frigerant”, page 23
wit
is n
h re
ole,
⇒ “6.2.12 Water content of R1234yf refrigerant”, page 23
spec
urposes, in part or in wh
⇒ “6.2.13 Flammability / decomposition of R1234yf refrigerant”,
t to the co
page 23
⇒ “6.2.14 Charge factor of refrigerant R1234yf”, page 23
rrectne
⇒ “6.2.15 Evidence of leaks in a refrigerant circuit with R1234yf
refrigerant”, page 24
ss o
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24
cial p
f inform
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for analy‐
mer
sis, processing or disposal”, page 25
atio
om
n
c
6.2.1 R1234yf refrigerant
or
n thi
te
sd
iva
♦ Air conditioners in vehicles employ the evaporation and con‐
pr
cum
r
fo
densation process. A substance (the refrigerant) is moved
en
ng
t.
about a circuit within an enclosed system.
yi Co
Cop py
t. rig
♦ The substance is one that has a low boiling point, in this in‐
gh ht
yri by
stance R1234yf refrigerant. cop Vo
by lksw
cted agen
Prote AG.
♦ The R1234yf refrigerant is marketed under various names
(e.g. HFO 1234yf, Opteon 1234yf etc.).
6. Basic technical and physical properties 19
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ For the air conditioning system, only approved refrigerant with
the requisite level of purity may be used
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24 .
♦ R1234yf refrigerant is a halogenated hydrocarbon compound
with the chemical designation “2,3,3,3-tetrafluoroprop-1-ene”
which boils at -29.4°C at a vapour pressure of “1 bar” (equiv‐
alent to ambient pressure).
6.2.2 Potential risks with R1234yf refrigerant
♦ The refrigerant is flammable with ambient air in a certain mix‐
ture ratio
⇒ “6.2.3 Physical and chemical properties of R1234yf refrig‐
erant”, page 20 and
⇒ “6.2.13 Flammability / decomposition of R1234yf refriger‐
ant”, page 23 .
♦ Rapid vaporisation of the liquid can cause freezing injuries
♦ High vapour concentrations can cause headaches, dizziness,
drowsiness and nausea and even loss of consciousness.
6.2.3 Physical and chemical properties of
R1234yf refrigerant
The following is a list of the main properties and safety information
for R1234yf refrigerant. The complete details can
n AG. V be
olkswagfound
en AG in the
respective safety data sheets on the s ageVW
w⇒ / Audi ServiceNet
does .
olk no t gu
V
by ara
ed
Chemical formula ris CF3CF=CH2 nte
tho eo
u
Chemical designationss a 2,3,3,3-tetrafluoroprop-1-ene, ra
c
HFO-1234yf
ce
e
nl
pt
du
Boiling point at 1 bar -29.4 °C
an
itte
y li
erm
Solidification point -152.2 °C
ab
ility
ot p
Critical temperature 94.7 °C
wit
, is n
h re
Critical pressure 32.82 bar (positive pressure)
hole
spec
33.82 bar (absolute pressure)
es, in part or in w
Self combustion temperature 405°C at 1.02 bar (absolute
t to the co
pressure)
Flammability Flammable gas
rrectness of i
♦ Lower explosion threshold
6.2% (volume)
l purpos
♦ Upper explosion threshold
12.3% (volume)
nf
ercia
orm
m
Form Compressed, liquefied gas
atio
om
n in
c
Colour Colourless
or
thi
e
Odour Weak odour
t
sd
iva
o
r
rp
cu
o
6.2.4 Critical point
f
en
ng
t.
yi Co
op py
The critical point (critical temperature and critical pressure) t. C rig
gh ht
means the point above which there is no longer a surface of sep‐ pyri by
Vo
co
aration between liquid and gas.
by lksw
cted agen
Prote AG.
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 vessel exhibit a liquid phase and a
gas phase, i.e. 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
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17 .
20 Rep. gr.00 - Technical data
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Air conditioning systems with refrigerant R1234yf
en AG. V
olksw-agGeneral
en AG information - Edition 01.2018
ag does
ksw not
y Vol gu
b ara
ed nte
ris
Note tho eo
au ra
c
ss
ce
e
♦ Refrigerants used in motor vehicles must not be mixed to‐
nl
pt
du
gether. Only the refrigerant prescribed for the respective air
an
itte
y li
conditioning system may be used.
erm
ab
ility
ot p
♦ The vapour pressures of the two refrigerants, R1234yf and
wit
R134a, are very similar across a broad temperature range, , is n
h re
which is why no difference can be established between them
hole
spec
⇒ Air conditioning system with R134a refrigerant, General in‐
es, in part or in w
formation about the air conditioning system . It is only possible
t to the co
to determine a difference using relevant sensors, which can
analyse the chemical structure of the refrigerant
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24 .
rrectness of i
l purpos
6.2.5 Environmental aspects of refrigerant
R1234yf
nf
ercia
orm
♦ R1234yf is a fluorocarbon (FC) and contains no chlorine.
m
atio
om
♦ R1234yf has a shorter atmospheric life than R12 and R134a
n in
or c
refrigerant and therefore has a less significant greenhouse ef‐
thi
te
sd
a
fect (lower global warming potential).
iv
o
r
rp
cu
o
m
♦ R1234yf does not damage the ozone layer, the potential to
f
en
ng
t.
reduce the amount of ozone is zero (as is the case with
yi Co
op
R134a).
C py
t. rig
gh ht
yri by
♦ The global warming potential (GWP) of R1234yf is 4 (the GWP
op Vo
by c lksw
cted
for carbon dioxide is 1).
agen
Prote AG.
♦ The contribution of R1234yf towards global warming is lower
than the R134a refrigerant by a factor of “350” (GWP of R134a
is about 1400).
Note
♦ The global warming effect of substances is calculated accord‐
ing to various methods based on their effect over a period of
100 years, which is why the results differ (e.g. R134a has a
GWP between 1300 and 1450).
♦ In order to compare the impact of various greenhouse gases
on the earth atmosphere, a calculation is carried out using the
carbon dioxide equivalent. The refrigerant R1234yf has a
GWP of 4, i.e. 1 kg of this refrigerant has the same impact on
the earth atmosphere as 4 kg of carbon dioxide (“CO2”).
6.2.6 Trade names and designations of
R1234yf refrigerant
Refrigerant R1234yf is currently available under the following
trade names:
♦ H-FKW 1234yf
♦ HFO 1234yf
♦ “Opteon yf” or“ Solstice yf” (examples of company names)
6. Basic technical and physical properties 21
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
AG. Volkswagen AG d
agen
♦ Different trade names may be used in other countries. Volksw
oes
not
by gu
ara
Of the wide range of refrigerants available, this is the only is one
d
♦ or
e nte
which may be used for vehicles. The names Frigen and aut Freon
h eo
ra
are trade names. These also apply to refrigerants swhich are
s c
not to be used in vehicles.
ce
le
un
pt
an
d
itte
y li
rm
6.2.7 Colour and odour of R1234yf refrigerant
ab
pe
ility
ot
wit
♦ Like water, refrigerants are colourless in both vapour and liq‐
, is n
h re
uid form. Gas is invisible. Only the boundary layer between hole
spec
gas and liquid is visible (liquid level in indicator tube of charg‐
es, in part or in w
ing cylinder or bubbles in sight glass). Liquid refrigerant
t to the co
R1234yf may have a coloured (milky) appearance in a sight
glass. This cloudiness is caused by partially dissolved refrig‐
erant oil and does not indicate a fault.
rrectness of i
♦ Refrigerant is almost odourless. Should R1234yf refrigerant
l purpos
escape, it may be possible to detect a slight smell of ether
depending on the ambient conditions.
nform
ercia
6.2.8 Vapour pressure of R1234yf refrigerant
m
a
com
ti
In an enclosed container that is not completely full, refrigerant
on in
evaporates at the surface in a quantity sufficient to form an equi‐
r
te o
thi
librium between vapour and liquid. This state of equilibrium occurs
s
iva
do
under the influence of pressure and is often called vapour pres‐
r
rp
cum
sure. The vapour pressure is temperature-dependant
fo
en
ng
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17 .
t.
yi Co
Cop py
t. rig
6.2.9 Physical properties of R1234yf refriger‐
gh ht
pyri by
Vo
o
by c
ant
lksw
cted agen
Prote AG.
♦ The vapour pressure curves of the two refrigerants, R1234yf
and R134a, are very similar across a broad temperature
range, which is why no difference can be established between
them
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17 and
⇒ Air conditioning system with R134a refrigerant, General in‐
formation about the air conditioning system . It is only possible
to determine a difference using relevant sensors, which can
analyse the chemical structure of the refrigerant
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24 .
♦ Lubrication of the air conditioner compressor with R1234yf is
by special synthetic refrigerant oils, e.g. PAG oils (polyalky‐
lene glycol oils) with certain additives adapted to the R1234yf
refrigerant oil, the air conditioner compressor and the operat‐
ing conditions.
6.2.10 How R1234yf refrigerant reacts to met‐
als and plastics
♦ In its pure state, R1234yf refrigerant is chemically stable and
has no corrosive effect on e.g. iron, aluminium and specially
developed plastics that are suitable for this purpose.
♦ Contaminants in the refrigerant, however, cause components
of the refrigerant circuit to become corroded and damaged
beyond repair.
♦ Unsuitable materials (e.g. seals and hoses that were not de‐
veloped for the R1234yf refrigerant and the associated refrig‐
erant oil) can also be corroded and damaged by pure R1234yf
refrigerant and refrigerant oil.
22 Rep. gr.00 - Technical data
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♦ If the refrigerant is contaminated, e.g. with chlorine com‐
pounds or by the influence of UV light, metals and also plastics
developed and tested for this refrigerant and refrigerant oil can
be corroded. This can lead to blockages, leaks and deposits
on the air conditioner compressor piston.
♦ Certain metals can be corroded by R1234yf refrigerant (e.g.
finely distributed aluminium, zinc, magnesium)
6.2.11 Critical temperature / critical pressure of
R1234yf refrigerant
Up to a gas pressure of 32.82 bar (which is equivalent to a tem‐
perature of 94.7°C), refrigerant evaporates at the surface in a
quantity that, combined with particles of vapour, returns it to liquid
again. Above this temperature / pressure there is no longer a sur‐
face separating the liquid and gas.
6.2.12 Water content of R1234yf refrigerant
♦ Only very small amounts of water are soluble in liquid refrig‐
erant. On the other hand, a n AG. Volkswavapour
gerefrigerant
gen AG
dand
oes water vapour
sw
mix in any ratio.by Volk not
gu
a d ran
se
♦ Any water thinori the refrigerant circuit will be entrained in droplet
tee
or
form once
ss
au
the dryer in the receiver or reservoir is full (once acit
has absorbed approx. 7 g of water). This water flows as far as ce
e
nl
the expansion valve nozzle or the restrictor and turns to ice.
pt
du
an
The air conditioner no longer provides cooling.
itte
y li
erm
ab
♦ If the existing water at the regulating valve of the air conditioner
ility
ot p
compressor turns to ice, a variety of complaints may be made
wit
, is n
depending on the design of the air conditioner compressor
h re
hole
(either the air conditioning system stops cooling or the air con‐
spec
ditioning system cools to such a degree that the evaporator
es, in part or in w
t to the co
ices over).
♦ Water destroys the air conditioner because at high pressures
and temperatures it can combine with other impurities to form
rrectness of i
acids.
l purpos
6.2.13 Flammability / decomposition of
R1234yf refrigerant
nform
mercia
♦ In certain concentrations in the ambient air, R1234yf refriger‐
at
om
io
ant is flammable.
n
c
in t
or
his
e
♦ R1234yf begins to decompose when exposed to flames and
at
do
riv
glowing or hot surfaces. Even UV light causes refrigerant to
p
cum
break up (UV light is part of normal sunlight, it is also encoun‐
for
en
g
tered e.g. during electrical welding), which releases poisonous
n
t.
yi Co
op
fission products that must not be inhaled. However, these C py
t. rig
chemicals irritate the mucous membranes, giving adequate
gh ht
yri by
warning of their presence. cop Vo
by lksw
cted agen
Prote AG.
♦ During decomposition, certain hazardous products such as
carbon monoxide, hydrogen fluoride and / or hydrogen halide
can be released.
6.2.14 Charge factor of refrigerant R1234yf
♦ When charging compressed gas containers (returnable cylin‐
ders, recycling cylinders etc.), observe the applicable regula‐
tions, technical rules and legislation.
♦ Never overcharge compressed gas containers (returnable cyl‐
inders, recycling cylinders etc.). The gas cushion (expansion
space) of overcharged compressed gas containers is too
small to accommodate expansion of the fluid caused by a rise
in temperature. Risk of bursting.
6. Basic technical and physical properties 23
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ To ensure safety, only use compressed gas containers fitted
with a safety valve.
♦ Returnable and recycling cylinders must be weighed on suit‐
able scales during charging, or a method of charging by vol‐
ume must be employed to ensure that the permissible weight
of the filling specified on the tank/container is not exceeded.
The maximum permissible filling volume is 80% of the maxi‐
mum refrigerant volume of the filling weight specified on the
returnable and recycling cylinder or 70% of the maximum filling
volume (charge factor, the smaller of the values always ap‐
plies respectively). Reason: There is no way of absolutely
ruling out refrigerant oil being filled into the returnable and re‐
cycling cylinder along with the refrigerant.
♦ 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 tem‐
perature 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 rup‐
ture the vessel. To prevent containers from being over‐
charged, regulations governing the storage of compressed
gases specify how many kilograms may be charged into a
container for every litre of container volume. This charge factor
multiplied by the internal volume gives the permissible charge
quantity. The charge factor for refrigerant used in vehicles is
1.15 kg/litre.
♦ Since contaminated refrigerant could have a different density
than pure R1234yf refrigerant, the maximum permissible
charge factor must always be observed.
. Volkswagen AG
gen AG
6.2.15 Evidence of leaks in a refrigerant circuit
wa does
olks not
yV gu
with R1234yf refrigerant d b ara
ise nte
or h eo
ut ra
♦ The refrigerant circuit could develop
ss
a
leaks, for example, from c
the use of unsuitable or contaminated refrigerant or untested
ce
e
nl
pt
materials in unsuitable components.
du
an
itte
y li
erm
♦ Since a small leak will involve only small quantities of refrig‐
ab
ility
erant, evidence of leaks should be sought using an electronic
ot p
wit
leak detector or by introducing a leak detection additive to the
, is n
h re
refrigerant circuit. Electronic leak detectors can detect leakage
hole
spec
rates of less than 5 grams loss of refrigerant per year.
es, in part or in w
t to the co
Note
rrectness of i
Use must however be made of leak detectors designed for the
composition of the respective refrigerant. For example, leak de‐
l purpos
tectors for R12 refrigerant are not suitable for R1234yf refrigerant
as these leak detectors do not always respond. Even leak detec‐
nform
ercia
tors that are designed just for R134a refrigerant are not suitable
for R1234yf refrigerant because R1234yf refrigerant has a differ‐
m
at
om
ent chemical structure than R134a. Subsequently, these leak
ion
c
detectors only respond to high concentrations of refrigerant in the
in t
or
air or not at all ⇒ Electronic parts catalogue .
his
ate
do
priv
cum
or
6.2.16 Analysis of refrigerant R1234yf
f
en
ng
t.
yi Co
op py
For operation of the air conditioning system, it is important that
. C rig
ht ht
rig
the refrigerant used has a certain degree of purity. py by
co Vo
by lksw
cted agen
Prote AG.
24 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ A faulty gas analysis is possible from air in the refrigerant ho‐
ses or non-observance of the procedure for gas analysis as
detailed in the operating instructions.
♦ Carefully follow the operating instructions of the gas analysis
device / air conditioner service station .
♦ Evacuate refrigerant hoses of the air conditioner service sta‐
tion before connecting the service couplings to the refrigerant
circuit / gas cylinder with R1234yf refrigerant hose (see oper‐
ating instructions of gas analysis device / air conditioner serv‐
ice station
⇒ “2.3 Performing gas analysis of refrigerant”,
wage
n AG. Volpage
kswage129
n AG.d
oe
olks s no
yV t gu
db ara
Contamination with other refrigerants
orise or gases can cause dam‐ nte
eo
age and thereby failure ofathe
ut air conditioning system and air
h
ra
conditioner service station
s .
s c
ce
le
un
pt
Contaminated refrigerant must be analysed and then processed
an
d
itte
(or disposed of) as gas of unknown composition in accordance
y li
erm
ab
with the relevant legal requirements
ility
ot p
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
wit
is n
h re
ole,
spec
Note
urposes, in part or in wh
t to the co
Return contaminated R1234yf refrigerant to your refrigerant sup‐
plier for analysis. If, owing to refrigerant circuit damage that has
already occurred or is expected, it is necessary for you to know
rrectne
exactly which impurities the refrigerant is contaminated with, sub‐
mit an application and request analysis results
ss
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for analy‐
o
cial p
f
sis, processing or disposal”, page 25 .
inform
mer
atio
The following thresholds apply for clean R1234yf refrigerant dur‐
om
ing the gas analysis:
n
c
i
or
n thi
e
♦ The extracted refrigerant gas consists of at least 95% R1234yf
t
sd
va
refrigerant.
i
o
pr
cum
r
fo
en
ng
♦ The percentage of impurities (oxygen, nitrogen, vapour, other
t.
yi Co
refrigerants) is less than 5%. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Note
agen
Prote AG.
To prevent liquid components (e.g. droplets of refrigerant oil) in
the extracted refrigerant gas from falsifying the result of the gas
analysis, separators (filters) are installed in the gas analysis de‐
vice that separate these droplets of liquid. Renew filters in ac‐
cordance with the specifications in the operating instructions
accompanying the gas analysis device and air conditioner service
station ⇒ Operating instructions of gas analysis device or ⇒ Op‐
erating instructions of air conditioner service station .
6.2.17 Returning contaminated R1234yf refrig‐
erant for analysis, processing or dispos‐
al
♦ When returning contaminated refrigerant for analysis, pro‐
cessing/recycling or disposing of refrigerant that is no longer
usable, the legal requirements must be observed
⇒ “2 Legal texts and regulations”, page 5 and ⇒ VW / Audi
ServiceNet .
6. Basic technical and physical properties 25
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ When disposing of refrigerant oil that is no longer usable, the
legal requirements must be observed
⇒ “2 Legal texts and regulations”, page 5 and ⇒ VW / Audi gen AG
. Volkswagen AG
does
swa
ServiceNet . yV
olk not
gu b ara
ed nte
♦ To protect the environment, no refrigerant should bethoreleased
ris e or
into the atmosphere au ac
ss
⇒ “2 Legal texts and regulations”, page 5 .
ce
e
nl
pt
du
♦ If, during the gas analysis, it is found that the R1234yf refrig‐
an
itte
y li
erant is contaminated with a different gas, it must be extracted
erm
ab
from the refrigerant circuit and returned to your gas supplier to
ility
ot p
be analysed, processed or disposed of as gas of unknown
wit
, is n
composition in accordance with the legal requirements ⇒ VW /
h re
Audi ServiceNet and hole
spec
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder
es, in part or in w
t to the co
for analysis, processing or disposal”, page 156 .
rrectness of i
Note
l purpos
Return contaminated R1234yf refrigerant to your refrigerant sup‐
plier for analysis. If, owing to refrigerant circuit damage that has
already occurred or is expected, it is necessary for you to know
nform
ercia
exactly which impurities the refrigerant is contaminated with, sub‐
m
at
mit an application by requesting analysis results
om
io
⇒ “2.4 Emptying refrigerant circuit”, page 132 .
n
c
in t
or
his
ate
do
riv
6.3 Product characteristics
p
cum
for
en
ng
R1234yf refrigerant used in motor vehicle air conditioning sys‐
t.
yi Co
op
tems belongs to the new generation of refrigerants based on C py
ht. rig
chlorine-free, partially fluorinated hydrocarbons. rig ht
py by
co Vo
by lksw
With regard to their physical properties, these are refrigerants cted agen
Prote AG.
which have been liquefied under pressure. These 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 Safety information”, page 1 .
6.4 Function and role of air conditioning sys‐
tem
⇒ “6.4.1 Principle of operation”, page 26
⇒ “6.4.2 Comfort”, page 27
⇒ “6.4.3 Environmental aspects”, page 27
6.4.1 Principle of operation
♦ The temperature in the passenger compartment depends on
the amount of heat radiated through the windows and con‐
ducted by the metal parts of the body. In order to maintain
comfortable temperatures for the occupants on very warm
days, part of the prevailing heat must be pumped away.
♦ Since heat spreads towards cooler bodies, a unit that can cre‐
ate low temperatures is fitted in the vehicle interior. Within this,
refrigerant is continually evaporated. The heat required to do
this is extracted from the air flowing through the evaporator.
♦ The refrigerant carries the heat with it as it is pumped away by
the air conditioner compressor. The work performed by the air
conditioner compressor on the refrigerant increases its heat
content and its temperature. This is now substantially higher
than that of the surrounding air.
26 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with
AGrefrigerant
. VolkswagenR1234yf
A
- General information - Edition 01.2018
n G do
wage es n
Volks ot g
♦ The hot refrigerant flowsedwith
by its heat content to the condenser. ua
ra
Here, the refrigeranthodissipates
ris its heat to the surrounding air ntee
via the condensers audue to the temperature gradient between
t or
ac
the refrigerant and the surrounding air.
s
ce
e
nl
pt
du
♦ The refrigerant thus acts as a heat transfer medium. As it is to
an
itte
y li
be re-used, the refrigerant is returned to the evaporator.
erm
ab
ility
ot p
♦ For this reason all air conditioning systems are based on the
wit
, is n
refrigerant circulation principle. There are however differences
h re
in the composition of the units
hole
spec
⇒ “1.1 System overview - refrigerant circuit”, page 30 .
es, in part or in w
t to the co
6.4.2 Comfort
♦ A basic requirement for concentration and safe driving is a
rrectness of i
feeling of comfort in the passenger compartment. This comfort
is only reached by using an air conditioning system, particu‐
l purpos
larly when it is hot and humid. Of course, open windows, an
open sunroof or increased air ventilation can contribute to
nform
ercia
comfort, but they all have certain disadvantages within the ve‐
hicle interior, such as additional noise, draughts, exhaust
m
at
gases, unhindered entry of pollen (unpleasant for allergy suf‐
om
io
ferers).
n
c
in t
or
his
e
♦ A well regulated air conditioning system in conjunction with a
at
do
riv
well thought-out heating and ventilation system can create a
p
cum
or
feeling of well-being and comfort by regulating the interior
f
en
ng
t.
temperature, humidity and rate of air change, regardless of the
yi Co
op
external conditions. This must be available whether the vehi‐
C py
ht. rig
cle is moving or not.
rig ht
py by
co Vo
by lksw
cted
Other important advantages of air conditioning are:
agen
Prote AG.
♦ Drying of the air in the passenger compartment (humidity in
the air condenses on the cold evaporator and is drained away
as condensate, the air is heated up again on the heat ex‐
changer for heater to a preset temperature, which reduces the
water content in the air and the absolute and relative humidity
is reduced).
♦ Additional cleansing of the air directed into the passenger
compartment (dust and pollen that have made their way
passed the dust and pollen filter, for example, are washed out
by the moist fins of the evaporator and carried off with the
condensation 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
6.4.3 Environmental aspects
♦ Until about 1992, air conditioning systems were equipped with
refrigerant R12. Due to its chlorine atoms, this CFC had a high
potential for destroying ozone and, in addition, a very high po‐
tential for increasing the greenhouse effect.
♦ From 1992, the air conditioning systems of newly manufac‐
tured cars have been successively changed from R12 refrig‐
erant to R134a refrigerant. This refrigerant contains no
chlorine and therefore does no damage to the ozone layer.
Due to the high global warming potential of approx. 1400
(GWP), it may no longer be used in vehicles that are newly
type approved from 2011. The cut-off date for bringing vehi‐
6. Basic technical and physical properties 27
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
cles that were type approved before 2011 into operation for
the first time with R134a refrigerant is 31.12.2016 (this applies
to countries within the EU, different regulations may apply in
countries outside the EU).
♦ After 01.01.2011, vehicles will only be given a new type ap‐
proval if the refrigerant used in the refrigerant circuit of their
air conditioning system has a GWP of less than 150. R1234yf
refrigerant has a GWP of approx. 4 and is therefore markedly
below the prescribed level.
♦ From 2011, the air conditioning systems of newly manufac‐
tured cars have been successively changed from R134a re‐
frigerant to R1234yf refrigerant. This refrigerant has a global
warming potential of approx. 4. The GWP of carbon dioxide =
1 (global warming potential) and has much less of an impact
on the earth’s atmosphere than R134a refrigerant.
♦ Conversion programmes have been developed for old sys‐
tems filled with the ozone-depleting substance R12 ⇒ Work‐
shop manual for air conditioners with R12 refrigerant (this
workshop manual is available in paper form only).
♦ According to current legislation, R134a refrigerant may still be
charged in vehicles that were type approved for use with
R134a refrigerant (or in vehicles converted from R12 refriger‐
ant to R134a refrigerant) until these vehicles are decommis‐
sioned. No provision has currently been made, therefore, to
convert air conditioning systems from R134a refrigerant to
R1234yf refrigerant ⇒ Air conditioning systems with R134a
refrigerant; Rep. gr. 87 ; Capacities for R134a refrigerant, re‐
frigerant oil and approved refrigerant oils .
♦ To protect the environment, no refrigerant should be released
into the atmosphere
⇒ “2 Legal texts and regulations”, page 5 .
♦ R1234yf refrigerant is chemically stable in an enclosed sys‐
tem. In the earth’s atmosphere, however, it decomposes n AG. Vowith‐
lkswagen AG
wage does
in a short space of time (within approx. 14 Vdays)
olks by the not
gu
y
influence of UV light into compounds that ed do not harm the
b ara
nte
is
earth’s atmosphere (hence the GWP thor of 4). eo
u ra
sa c
6.5 Other reference material
s
ce
e
nl
pt
du
an
♦ Workshop manual for model-specific maintenance work ⇒
itte
y li
Heating, air conditioning system; Rep. gr. 87 ; Overview of
erm
ab
ility
fitting locations - air conditioning system (vehicle-specific
ot p
wit
workshop manual) and ⇒ Current flow diagrams, Electrical
, is n
h re
fault finding and Fitting locations
hole
spec
♦ Technical Service Handbook with measures for rectifying lat‐
es, in part or in w
t to the co
est malfunctions
♦ Self-study Programmes, videos for workshop training and VW/
Audi TV episodes on the air conditioning system.
rrectness of i
♦ The specific risks of refrigerant, material data etc. can be
l purpos
gleaned from the safety data sheets. Safety data sheets about
refrigerant, refrigerant oil etc. ⇒ VW / Audi ServiceNet .
nform
ercia
♦ List of relevant special tools and workshop equipment for re‐
m
pairs to air conditioning systems ⇒ Electronic parts catalogue
at
om
(Tools; Workshop equipment/tools; Heating, air conditioning
on
c
in t
system).
or
his
ate
do
riv
♦ Information about the disposal of refrigerant oil and contami‐
p
nated refrigerant can be found on ⇒ VW / Audi ServiceNet .
um
for
en
ng
t.
yi
♦ For vehicles whose refrigerant circuit is charged with R134a
Co
Cop py
refrigerant (vehicles that were type approved before ht. rig
rig ht
31.12.2010 and have been or are to be commissioned for the py by
co Vo
by lksw
cted agen
Prote AG.
28 Rep. gr.00 - Technical data
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
first time by 31.12.2016
⇒ “2 Legal texts and regulations”, page 5 .
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Basic technical and physical properties 29
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
87 – Air conditioning system
1 Refrigerant circuit
⇒ “1.1 System overview - refrigerant circuit”, page 30
⇒ “1.2 General description - components of refrigerant circuit”,
page 36
⇒ “1.3 Possible complaints”, page 64
⇒ “1.4 Investigating leaks”, page 68
⇒ “1.5 Renewing components”, page 79
⇒ “1.6 Cleaning refrigerant circuit”, page 92
⇒ “1.7 Checking pressures with pressure gauge”, page 121
1.1 System overview - refrigerant circuit
⇒ “1.1.1 System overview - refrigerant circuit with expansion valve
and receiver”, page 30
⇒ “1.1.2 System overview - refrigerant circuit with restrictor and
reservoir”, page 32
⇒ “1.1.3 System overview - refrigerant circuit with electrically driv‐
en air conditioner compressor (with and without battery cooling
module)”, page 33
1.1.1 System overview - refrigerant circuit
with expansion valve and receiver
AG. Volkswagen AG d
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agen oes
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♦ The arrows indicatehorthe
is direction of coolant flow.
e nte
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ut ra
♦ The following diagram shows an example of a refrigerant cir‐
s a c
s
cuit with 2 evaporators and one internal heat exchanger.
ce
e
nl
pt
du
an
♦ The layout of the refrigerant circuit is specific to the vehicle ⇒
itte
y li
erm
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
ab
ility
cuit (vehicle-specific workshop manual).
ot p
wit
, is n
h re
hole
HD = High-pressure side
spec
es, in part or in w
ND = Low-pressure side
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.
30 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1 - Air conditioner compressor
regulating valve - N280-
2 - Air conditioner compressor
n AG. Volkswagen AG do
ks wage es n
3 - Pulley Vol ot g
d by ua
ran
❑ Depending on the ver‐ or
ise tee
sion, an air conditioning auth or
ac
system magnetic clutchss
ce
le
- N25- is installed in the
un
pt
belt pulley ⇒ Heating,
an
d
itte
y li
air conditioning system;
rm
ab
Rep. gr. 87 ; Refrigerant
pe
ility
ot
circuit (vehicle-specific
wit
, is n
workshop manual).
h re
hole
spec
❑ Depending on the ver‐
es, in part or in w
sion there may be a
t to the co
drive unit instead of the
belt pulley ⇒ Heating,
air conditioning system;
rrectness of i
Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific
l purpos
workshop manual).
4 - High-pressure safety valve
nform
ercia
5 - Refrigerant pressure send‐
m
a
com
t
er
ion in
r
❑ Vehicle-specific ver‐
te o
thi
sions ⇒ Heating, air
s
iva
do
conditioning system;
r
rp
cum
fo
Rep. gr. 87 ; Refrigerant
en
ng
t.
circuit .
yi Co
Cop py
t. rig
6 - Condenser (with receiver)
gh ht
pyri by
Vo
co lksw
by
7 - Receiver Prote
cted AG.
agen
❑ Installed on, at or in the
condenser ⇒ Heating,
air conditioning system;
Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual).
❑ With desiccant cartridge
8 - Service connection, high-pressure side
❑ With sealing cap
9 - Refrigerant line with internal heat exchanger
10 - Front expansion valve
11 - Front evaporator
❑ Evaporator in front heater and air conditioning unit (installed under dash panel)
12 - Service connection, low-pressure side
❑ With sealing cap
13 - Rear expansion valve
❑ Only on vehicles with rear air conditioning unit (extra equipment)
14 - Rear evaporator
❑ Only on vehicles with rear air conditioning unit (extra equipment)
1. Refrigerant circuit 31
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.1.2 System overview - refrigerant circuit
with restrictor and reservoir
Note
♦ The arrows indicate the direction of coolant flow.
♦ The following diagram shows an example of a refrigerant cir‐
cuit with one evaporator.
♦ This refrigerant circuit layout is currently not planned for VW/
Audi vehicles.
♦ The layout of the refrigerant circuit is specific to the vehicle ⇒
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
cuit (vehicle-specific workshop manual).
HD = High-pressure side
ND = Low-pressure side
1 - Air conditioner compressor
regulating valve - N280-
2 - Air conditioner compressor
3 - Pulley
❑ Depending on the ver‐
sion, an air conditioning
system magnetic clutch
- N25- is installed in the
belt pulley ⇒ Heating,
air conditioning system;
Rep. gr. 87 ; Refrigerant AG. Volkswagen AG d
agen oes
ksw
circuit (vehicle-specific byV
ol not
gu
ara
workshop manual). rised
nte
ho eo
❑ Depending on the ver‐ aut ra
c
s
sion there may be a s
ce
e
drive unit instead of the
nl
pt
du
an
belt pulley ⇒ Heating,
itte
y li
air conditioning system;
erm
ab
Rep. gr. 87 ; Refrigerant
ility
ot p
circuit (vehicle-specific
wit
, is n
workshop manual).
h re
hole
spec
4 - High-pressure safety valve
es, in part or in w
t to the co
5 - Condenser
6 - Refrigerant pressure send‐
rrectness of i
er
❑ Vehicle-specific ver‐
l purpos
sions ⇒ Heating, air
conditioning system;
nf
ercia
Rep. gr. 87 ; Refrigerant
or
circuit (vehicle-specific
m
m
atio
workshop manual).
om
n in
or c
7 - Service connection, high-
thi
te
pressure side
sd
iva
o
r
rp
cu
❑ With sealing cap
o
m
f
en
ng
t.
yi
8 - Restrictor
Co
Cop py
ht. rig
9 - Evaporator rig ht
py by
co Vo
lksw
❑ Evaporator in front heater and air conditioning unit (installed under dash panel)
by
cted agen
Prote AG.
32 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
10 - Service connection, low-pressure side
❑ With sealing cap
11 - Reservoir
❑ With desiccant cartridge
1.1.3 System overview - refrigerant circuit
with electrically driven air conditioner
compressor (with and without battery
cooling module)
Note
♦ The arrows indicate the direction of coolant flow.
♦ The following diagram shows an example of a refrigerant cir‐
cuit with expansion valve and second evaporator for battery
cooling and one internal heat exchanger.
♦ The layout of the refrigerant circuit is specific to the vehicle ⇒
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
cuit (vehicle-specific workshop manual).
HD = High-pressure side
ND = Low-pressure side
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
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orm
m
atio
om
n in
or c
thi
te
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o
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o
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en
ng
t.
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Prote AG.
1. Refrigerant circuit 33
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ed ran
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 horis ➤ , Crafter 201 ... tee
t or
Air conditioning systems with refrigerant R1234yf -s General
au information - Edition 01.2018 ac
s
ce
le
un
1 - Electrical air conditioner
pt
an
d
itte
compressor
y li
erm
ab
❑ With control unit for air
ility
ot p
conditioner compressor
wit
is n
- J842- and electrical air
h re
ole,
conditioner compressor
spec
urposes, in part or in wh
- V470- ⇒ Heating, air
conditioning system;
t to the co
Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific
workshop manual).
rrectne
2 - High-pressure safety valve
ss
3 - Condenser
o
cial p
f in
❑ With receiver and desic‐
form
mer
cant cartridge.
atio
4 - Receiver om
n
c
i
or
n thi
❑ Part of condenser in this
te
sd
va
case.
i
o
pr
cum
r
fo
5 - Refrigerant pressure send‐
en
ng
t.
yi
er
Co
Cop py
t. rig
❑ Vehicle-specific ver‐
gh ht
yri by
sions ⇒ Heating, air cop Vo
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cted
conditioning system;
agen
Prote AG.
Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific
workshop manual).
6 - Service connection, high-
pressure side
❑ With sealing cap.
7 - Refrigerant line with internal
heat exchanger
8 - Refrigerant shut-off valve
❑ Different designations
⇒ Heating, air condi‐
tioning system; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-
Note
The refrigerant shut-off valve is ac‐
tuated e.g. if battery cooling is nec‐
essary and no cooling of the pas‐
senger compartment is required
(open when not actuated).
9 - Expansion valve
❑ On evaporator in heater and air conditioning unit
10 - Front evaporator
❑ Evaporator in heater and air conditioning unit
11 - -Expansion valve with shut-off valve-
❑ Different designations ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
❑ On evaporator in battery cooling module
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-
34 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
The -expansion valve with shut-off
valve- is actuated if battery cooling
is necessary (closed when not actu‐
ated).
12 - Evaporator
❑ Evaporator in battery cooling module
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-
13 - Service connection, low-pressure side
❑ With sealing cap
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pt
an
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.
1. Refrigerant circuit 35
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2 General description - components of re‐
frigerant circuit
⇒ “1.2.1 Layout and function of refrigerant circuit”, page 36
⇒ “1.2.2 Mechanical air conditioner compressor”, page 38
⇒ “1.2.3 Electrical air conditioner compressor for hybrid vehicles”,
page 40
⇒ “1.2.4 Condenser”, page 43
⇒ “1.2.5 Evaporator”, page 43
⇒ “1.2.6 Reservoir”, page 44
⇒ “1.2.7 Heat exchanger for heat pump mode”, page 45
⇒ “1.2.8 Liquid receiver”, page 45
⇒ “1.2.9 Restrictor”, page 46
⇒ “1.2.10 Receiver”, page 47
⇒ “1.2.11 Expansion valve (with and without shut-off valve)”, page
48
⇒ “1.2.12 Refrigerant shut-off valves”, page 50
⇒ “1.2.13 Refrigerant line with internal heat exchanger”,
page 51
⇒ “1.2.14 Quick release couplings of refrigerant lines”,
page 51
⇒ “1.2.15 Seals”, page 52
⇒ “1.2.16 Pipes and hoses in refrigerant circuit”, page 52
⇒ “1.2.17 High-pressure safety valve”, page 53
n AG. Volkswagen AG do
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⇒ “1.2.18 Non-return valves”, page 54 yV
olks ot g
ua
b
ed ran
⇒ “1.2.19 Quick-release coupling connections in refrigeranthocir‐
ris tee
cuit”, page 55 aut or
ac
ss
⇒ “1.2.20 Connections with valve for switches in refrigerant circuit
ce
e
nl
pt
du
”, page 59
an
itte
y li
erm
ab
⇒ “1.2.21 Pressure senders and switches in refrigerant circuit”,
ility
ot p
page 59
wit
, is n
⇒ “1.2.22 Refrigerant pressure and temperature sender”, h re
hole
page 60
spec
es, in part or in w
t to the co
⇒ “1.2.23 Air conditioner compressor regulating valve N280 ”,
page 63
⇒ “1.2.24 Refrigerant temperature sender”, page 63
rrectness of i
1.2.1 Layout and function of refrigerant circuit
l purpos
♦ Located on the high-pressure side are the condenser, receiver
nf
ercia
and restrictor or expansion valve to separate the high-pres‐
or
sure side (HD) and low-pressure side (ND).
m
m
atio
m
♦ High pressure is created by the restrictor or expansion valve
o
n in
or c
forming a constriction and causing the refrigerant to build up,
thi
te
thus leading to increased pressure and temperature.
sd
iva
o
r
rp
cu
♦ Excessive pressure results if the circuit is filled with too much
o
m
f
en
ng
refrigerant or refrigerant oil, or the condenser is dirty, the ra‐
t.
yi Co
op
diator fan is defective, there is a blockage in the system or C py
t. rig
there is moisture in the refrigerant circuit (causing the restrictor
gh ht
pyri by
or expansion valve to ice up).
co Vo
by lksw
cted agen
Prote AG.
36 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Located on the low-pressure side are the evaporator, the tem‐
perature sensor for the evaporator and the air conditioner
compressor that acts as the separation between the high-
pressure (HD) and low-pressure (ND) gas sides.
♦ A loss of pressure in the system can be due to loss of refrig‐
erant, restrictor or expansion valve defective or blocked, de‐
fective air conditioner compressor or an iced-up evaporator.
n AG. Volkswagen AG do
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d ran
ir se tee
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u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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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
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t.
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t. rig
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pyri by
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by
37
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1. Refrigerant circuit
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.2 Mechanical air conditioner compressor
The air conditioner compressor is driven by a poly V-belt -B- or a
shaft by the engine.
Air conditioner compressor with air conditioning system magnetic
clutch - N25- :
An electromagnetic clutch -A- attached to the air conditioner com‐
pressor provides power transfer between pulley -B- and com‐
pressor crankshaft when the air conditioning is switched on.
An overload protection device attached to the clutch plate or fitted
in the solenoid of the air conditioner compressor triggers if there
is resistance in the air conditioner compressor (sluggish move‐
ment), protecting the belt drive or the drive unit against overload.
Note
♦ To ensure that the air conditioner compressor is not damaged
if the refrigerant circuit is empty, the air conditioner compres‐
sor regulating valve - N280- and, under certain circumstances,
the air conditioning system magnetic clutch - N25- are no lon‐
ger actuated (the air conditioner compressor only runs at idle
with the engine if -N25- is actuated).
♦ An air conditioner compressor with -N25- (without -N280- ) is AG. Volkswagen AG d
not actuated if the refrigerant circuit is empty and is therefore olkswagen oes
not
not driven. db
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Air conditioner compressor without air conditioning system
ss
a mag‐
u ra
c
netic clutch - N25- :
ce
e
nl
pt
du
an
♦ An overload protection device attached to the pulley -B- or fit‐
itte
y li
ted in the drive unit of the air conditioner compressor triggers
erm
ab
if there is resistance in the air conditioner compressor (slug‐
ility
ot p
gish movement), protecting the belt drive or the drive unit
wit
, is n
against overload.
h re
hole
spec
♦ An air conditioner compressor with air conditioner compressor
es, in part or in w
regulating valve - N280- (without -N25- ) is switched over to
t to the co
internal lubrication via a valve if the refrigerant circuit is empty.
rrectness of i
Note
l purpos
♦ On air conditioner compressors without air conditioning sys‐
tem magnetic clutch - N25- , the engine may only be started
nf
ercia
following complete assembly of the refrigerant circuit.
rm
m
atio
m
♦ To ensure that the air conditioner compressor suffers no dam‐
o
n in
c
age if the refrigerant circuit is empty, the air conditioner com‐
or
thi
pressor regulating valve - N280- is no longer activated (the air
te
sd
iva
conditioner compressor idles with the engine).
o
r
rp
cu
o
m
f
en
ng
t.
yi
All air conditioner compressors
Co
Cop py
t. rig
The air conditioner compressor draws refrigerant gas from the
gh ht
pyri by
evaporator, compresses it and sends it to the condenser.
co Vo
by lksw
cted agen
Prote AG.
38 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The air conditioner compressor contains refrigerant oil, which
can be mixed with R1234yf refrigerant at any temperature.
♦ The identification plate states the refrigerant for which the air
conditioner compressor is suitable. A valve regulates the pres‐
sure on the low-pressure side within the specified range (con‐
trol characteristic) ⇒ Heating, air conditioning system; Rep.
gr. 87 ; Refrigerant circuit .
♦ Depending on the version of air conditioner compressor, dif‐
ferent refrigerant oils are filled in the air conditioner compres‐
sor. Refrigerant oils that were developed for R134a refrigerant
oil only, must not be used for R1234yf refrigerant ⇒ Heating,
air conditioning system; Rep. gr. 00 ; Technical data; Refrig‐
erant oil .
♦ Air conditioner compressors with or without air conditioning en AG. V
olkswagen AG
system magnetic clutch - N25- are currently actuated via an Vol
ksw
ag does
not
air conditioner compressor regulating valve - N280- -C-edexter‐
by gu
ara
nally ⇒ Heating, air conditioning system; Rep. gr. th87
or ; Re‐
is nte
eo
frigerant circuit . s au ra
c
s
♦ The identification plate states the refrigerant for which the air
ce
le
un
pt
conditioner compressor is suitable. An air conditioner com‐
an
d
itte
y li
pressor regulating valve - N280- regulates the pressure on the
erm
ab
low-pressure side within the specified range (control charac‐
ility
ot p
teristic) ⇒ Heating, air conditioning system; Rep. gr. 87 ;
wit
is n
Refrigerant circuit .
h re
ole,
spec
♦ The air conditioner compressor regulating valve - N280- is ac‐
urposes, in part or in wh
tuated externally ⇒ Vehicle diagnostic tester in “Guided Fault
t to the co
Finding” in air conditioning system.
♦ The engine must not be started in a vehicle with air conditioner
rrectne
compressor but no air conditioner compressor magnetic clutch
- N25- if there is negative pressure in the refrigerant circuit
(e.g. during evacuation) ⇒ page 124 .
ss o
cial p
f
♦ The engine may only be started in a vehicle with air conditioner
inform
compressor but no air conditioner compressor magnetic clutch
mer
- N25- when the refrigerant circuit has been completely as‐
atio
m
sembled.
o
n
c
i
or
n thi
♦ To ensure that the air conditioner compressor suffers no dam‐
te
sd
a
age if the refrigerant circuit is empty, the air conditioner com‐
iv
o
pr
c
pressor regulating valve - N280- is no longer activated (the air
um
r
fo
en
conditioner compressor idles with the engine) if the pressure
ng
t.
yi Co
in the refrigerant circuit is too low (lower than approx. 2 bar). ht. Cop py
rig
rig ht
♦ An air conditioner compressor with air conditioner compressor py by
co Vo
regulating valve - N280- is switched over to internal lubrication
by lksw
cted agen
Prote
via a valve if the refrigerant circuit is empty.
AG.
♦ Depending on the version of air conditioner compressor, a
valve may be installed on the high-pressure side that prevents
liquefied refrigerant flowing back into the air conditioner com‐
pressor after the air conditioning system is switched off. If an
air conditioner compressor with this valve is installed in a ve‐
hicle with a refrigerant circuit with expansion valve, it could
take some time before the pressure on the high-pressure side
drops (the expansion valve is cold and the pressure on the
low-pressure side rises quickly after switching off, the expan‐
sion valve closes and refrigerant only flows slowly on the low-
pressure side). If the air conditioner compressor is switched
on, the pressure on the low-pressure side drops, the expan‐
sion valve opens and refrigerant can flow on the low-pressure
side.
1. Refrigerant circuit 39
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ On an air conditioner compressor with electromagnetic clutch
-A- and regulating valve -C-, the electromagnetic clutch -A- is
usually only actuated if the regulating valve -C- is also actu‐
ated ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrig‐
erant circuit .
1.2.3 Electrical air conditioner compressor for
hybrid vehicles
Vehicles with high-voltage system (hybrid vehicles)
If repair work in the vicinity of high-voltage components and ca‐
bles is necessary, inspect high-voltage components and cables
for damage ⇒ page 4 ⇒ Electrical system; Rep. gr. 93 ; General
warning instructions for work on the high-voltage system .
If work on the components of the high-voltage system is neces‐
sary, ensure that the high-voltage system is de-energised ⇒ Rep.
gr. 93 ; De-energising high-voltage system .
De-energise the high-voltage system and restarting the high-volt‐
age system ⇒ Rep. gr. 93 ; De-energising high-voltage system
en AG starts when . Volkswage
– To minimise the number of automatic ksw
agengine
n AG d
the
oes
not
l
vehicle's drive system is active by (READY)
Vo during test and gu
ara
measurement work, charge risethe vehicle batteries e.g. with the
d
nte
battery charger 60 A - VAS
autho
5904- in battery standby mode ⇒ eo
ra
Electrical system - General
ss information; Rep. gr. 27 ; Charging c
battery and ⇒ Electrical system; Rep. gr. 93 ; General warning ce
le
un
instructions for work on the high-voltage system . pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
40 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– For testing and measuring work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake, and arrange the tools needed so that they can‐
not come into contact with moving components of the engine
and so that they cannot even come near to components that
turn when the engine is running.
Electrical air conditioner compressor
NOTICE
Risk of irreparable damage to electrical air conditioner com‐
pressor from short circuit.
olkswagen AG
– Never touch theksair en AG. V
wagconditioner compressor
does when switching
l not
on the ignition
by V or starting the drive machines.
o gu
a
ed ran
oris tee
th or
♦ Thessair
au conditioner compressor draws refrigerant gas from ac the
evaporator, compresses it and sends it to the condenser.
ce
e
nl
pt
du
an
♦ The electric motor of the air conditioner compressor is sup‐
itte
y li
plied with power e.g. from the power and control electronics
erm
ab
for electric drive - JX1- ⇒ Current flow diagrams, Electrical fault
ility
ot p
finding and Fitting locations.
wit
, is n
h re
♦ The control unit for air conditioner compressor - J842- inte‐
hole
spec
grated in the air conditioner compressor regulates the speed
es, in part or in w
and thereby the performance of the air conditioner compressor
( electrical air conditioner compressor - V470- ) according to t to the co
the request received via the data bus ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” function of air conditioning
rrectness of i
system and battery control system
l purpos
♦ There is no air conditioner compressor regulating valve -
N280- in the electrical air conditioner compressor.
nf
ercia
♦ The bolting points of the air conditioner compressor and the
rm
m
bracket must be checked prior to installation. The contact sur‐
atio
m
faces must be free of dirt, rust and grease. Otherwise, repair
o
n in
or c
contact surfaces using contact surface cleaning set - VAS
thi
e
6410- ⇒ Electrical system; General information; Rep. gr. 97 ;
t
sd
iva
Wiring harness and connector repair .
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.
1. Refrigerant circuit 41
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If the air conditioner compressor control unit - J842- is defec‐
tive, the amount of refrigerant oil in the new air conditioner
compressor must be adjusted. The refrigerant circuit must not
be cleaned (flushed) with R1234yf. wage
n AG. Volkswagen AG do
e ks s no
Vol t
♦ The control unit for air conditioner
ed
by compressor - J842- and theguara
electrical air conditionerho compressor - V470- are one compo‐
ris nte
eo
nent and can currently
s aut not be separated. ra
c
s
♦ There is no -N280- installed in the electrical air conditioner
ce
le
un
pt
compressor. The power of the air conditioner compressor is
an
d
itte
y li
regulated externally by the speed of the air conditioner com‐
erm
ab
pressor ⇒ Current flow diagrams, Electrical fault finding and
ility
ot p
Fitting locations and ⇒ Vehicle diagnostic tester in “Guided
wit
is n
Fault Finding” mode - air conditioning system and battery reg‐
h re
ole,
ulation.
spec
urposes, in part or in wh
♦ The electrical air conditioner compressor currently works in
t to the co
the same way as a spiral or scroll-type charger (similar to a G-
Lader).
rrectne
♦ The air conditioner compressor contains refrigerant oil, which
can be mixed with R1234yf refrigerant at any temperature.
ss
♦ The identification plate states the refrigerant for which the air
o
cial p
f
conditioner compressor is suitable.
inform
mer
♦ The integrated electronics regulate the performance of the air
atio
conditioner compressor via the speed (and thereby the pres‐
om
sure on the low-pressure side) within the specific target range n
c
i
or
n thi
(control characteristic).
te
sd
iva
o
r
♦ The engine should be started only when the refrigerant circuit
p
cum
r
fo
has been fully assembled.
en
ng
t.
yi Co
op
♦ The air conditioner compressor has an internal oil circuit to
C py
ht. rig
ensure that the air conditioner compressor is not damaged rig ht
py by
when the refrigerant circuit is empty. This means that approx.
co Vo
by lksw
cted agen
40 to 50 cm3 of refrigerant oil remain in the air conditioner
Prote AG.
compressor.
♦ Just like the mechanical air conditioner compressor, the elec‐
trical air conditioner compressor has a pressure relief valve.
♦ On vehicles with battery cooling, electric and hybrid operation
is only possible with the air conditioning system charged and
no faults stored in connection with the air conditioning system
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system and battery regulation.
♦ First bring the electrical air conditioner compressor into oper‐
ation after installing the air conditioner compressor and charg‐
ing the refrigerant circuit via the “Compressor run-in” function
in basic settings. Should there be an accumulation of refriger‐
ant oil in the compression chamber of the air conditioner
compressor before installation owing to unfavourable storage,
damage could be caused to the air conditioner compressor
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system and battery regulation.
♦ An electrically driven air conditioner compressor may only be
activated when the refrigerant circuit is charged. Running the
air conditioner compressor with the refrigerant circuit empty
could lead to compressor damage ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode.
42 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.4 Condenser
♦ The condenser -A- transfers heat from the compressed refrig‐
erant gas into the surrounding air.
♦ When this happens, the refrigerant gas condenses to liquid.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
♦ Depending on the design of sthe refrigerant circuit, the receiver
s a c
may be attached to the condenser or integrated in the con‐
ce
e
nl
pt
du
denser ⇒ Heating, air conditioning system; Rep. gr. 87 ;
an
itte
Refrigerant circuit (vehicle-specific workshop manual) and ⇒
y li
erm
ab
Electronic parts catalogue .
ility
ot p
wit
♦ There are different versions of the condenser; from the outside
, is n
h re
these versions can only be identified by their part number.
hole
spec
Version -1- of the condenser is split into two sections (“two-
es, in part or in w
pass condenser”). Version -2- of the condenser is split into four
t to the co
sections (“four-pass condenser”).
♦ This illustration shows a condenser with the receiver -C- at‐
rrectness of i
tached.
l purpos
♦ The gaseous refrigerant enters the condenser at connection
-A-; the refrigerant is then cooled down in the condenser and
turns into liquid.
nf
ercia
♦ The liquid refrigerant accumulates in receiver -C- (with dryer) orm
m
atio
and flows through the bottom cooling section to connection
om
n in
-B-.
or c
thi
e
♦ The refrigerant capacity in a refrigerant circuit may differ de‐
t
sd
iva
pending on the design of the condenser (internal volume, flow,
r
rp
cu
o
etc.). Therefore, always ensure the version and allocation of
f
en
ng
t.
the condenser are correct ⇒ Heating, air conditioning system;
yi Co
op py
Rep. gr. 00 ; Technical data (vehicle-specific workshop man‐ . C rig
ht ht
ual) and ⇒ Electronic parts catalogue .
rig by
copy Vo
by lksw
cted agen
Prote AG.
1.2.5 Evaporator
There are different types of evaporator. Depending on the design
and function, the thermal energy that is needed to evaporate the
refrigerant is drawn from the air flowing through the system (e.g.
with the evaporator in heater and air conditioning unit or in the
battery cooling module) or the coolant flowing through the system
(e.g. with the heat exchanger for the high-voltage battery) ⇒
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit (vehicle-specific workshop
manual).
Note
The following describes 2 versions of the evaporator.
1. Refrigerant circuit 43
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Evaporator in heating and air conditioning system (or in the bat‐
tery cooling module)
♦ The liquid refrigerant evaporates in the pipelines of the evap‐
orator -A-. The heat required to do this is drawn from the air
flowing over the evaporator fins -B-. 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 defined quantity of refrigerant is fed to the evaporator
through an expansion valve (restrictor). In systems with an
expansion valve the flow rate is regulated such that only gas‐
eous refrigerant emerges at the evaporator outlet.
♦ When R1234yf refrigerant was introduced, the evaporators
were adapted to the refrigerant, hence the need to observe the
correct version ⇒ Electronic parts catalogue .
Evaporator / heat exchanger for high-voltage battery (chiller)
The liquid refrigerant evaporates in the evaporator (heat ex‐
changer). The heat required to do this is drawn from the coolant
that flows through the evaporator. The coolant cools. The refrig‐
erant evaporates and is drawn into the air conditioner
wage
ncompressor
AG. Volkswagen AG d
oes
carrying with it the heat it has absorbed. y Volks not
gu b ara
ed
A defined quantity of refrigerant is fedhoto
ris the evaporator through nte
e
a restrictor (or an expansion valve)s aand
ut a shut-off valve. The flow or
ac
rate of the coolant (or refrigerant) sis regulated in such a way that
ce
le
only gaseous refrigerant escapes at the evaporator outlet ⇒
un
pt
an
d
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
itte
y li
overview - refrigerant circuit (vehicle-specific workshop manual).
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
1.2.6 Reservoir
urposes, in part or in wh
t to the co
Note rrectne
This type of air conditioning system is currently only installed in
systems with a restrictor.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
44 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 agen ➤ , Caddy 2016
AG. Volkswagen AG d ➤ , Crafter 201 ...
oes
ksw not
Air conditioning systems with refrigerant R1234yf
by Vol
- General information - Edition
gu 01.2018
a
ed ran
oris tee
♦ The reservoir collects the vaporised and gaseous
au
th
mixture or
ac
coming from the evaporator to ensure the air
ss conditioner com‐
ce
le
pressor receives only gaseous refrigerant. The vapour be‐
un
pt
comes gaseous refrigerant.
an
d
itte
y li
rm
ab
♦ Refrigerant oil flowing in the circuit does not remain in the res‐
pe
ility
ervoir because an oil extraction hole has been provided.
ot
wit
, is n
h re
♦ Any moisture ingress into the refrigerant circuit during assem‐
hole
spec
bly is trapped by a filter (desiccant bag) in the reservoir.
es, in part or in w
t to the co
♦ Gaseous refrigerant with oil is drawn in by the air conditioner
compressor.
rrectness of i
Note
l purpos
♦ Renew the reservoir if the refrigerant circuit has been open for
nform
ercia
an extended period of time and moisture has entered or if re‐
quired to do so owing to a specific complaint ⇒ page 79 .
m
a
com
tio
♦ Do not remove sealing plugs -A- and -B- until just before in‐
n in
stallation.
r
te o
thi
s
iva
do
♦ A dryer kept in an unsealed reservoir is saturated with mois‐
r
rp
cum
ture after a short time and cannot be used.
fo
en
ng
t.
yi
♦ When installing, observe arrow indicating direction of flow if
Co
Cop py
applicable.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2.7 Heat exchanger for heat pump mode
The gaseous or vaporous refrigerant compressed by the air con‐
ditioning compressor is liquefied in the heat exchanger -A-. The
heat that is given off in the process is picked-up by the coolant
flowing through the system ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - refrigerant circuit .
1.2.8 Liquid receiver
In certain operating conditions (e.g. in heat pump mode), the re‐
ceiver (e.g. on the condenser) is not integrated in the refrigerant
circuit. The receiver -B- collects the refrigerant, temporarily stores
any excess should a certain amount of refrigerant not be required
and then feeds it in a steady flow to the expansion valve (in front
of the evaporator in the heater and air conditioning unit) or to the
heat exchanger in the coolant circuit of the high voltage system
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Sys‐
tem overview - refrigerant circuit .
1. Refrigerant circuit 45
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.9 Restrictor
Restrictor in front of evaporator
Note
Currently, there is no air conditioning system with a restrictor in‐
stalled in front of the evaporator.
♦ The restrictor creates a constriction. This restriction limits the
flow, separating the high pressure and low pressure sides in
the refrigerant circuit. Upstream of the restrictor, the refriger‐
ant is warm due to the high pressure. Downstream of the
restrictor, the refrigerant is cold due to the low pressure. Up‐
stream of the constriction is a strainer to catch dirt and down‐
stream of the constriction is a strainer to atomise the
refrigerant before it enters the evaporator.
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
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ara
ed
ris nte
o eo
♦ Arrow -A- on autthe restrictor points to the evaporator.
h
ra
ss c
♦ Renew every time the refrigerant circuit is opened.
ce
e
nl
pt
du
an
♦ Note different versions; refer to the various customer service
itte
y li
erm
information ⇒ Electronic parts catalogue .
ab
ility
ot p
wit
, is n
Restrictor in front of heat exchanger for high-voltage battery (chill‐
h re
er)
hole
spec
es, in part or in w
t to the co
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
rrectness of i
due to the high pressure. Downstream of the restrictor, the refrig‐
erant is cold due to the low pressure.
l purpos
Note
nform
mercia
at
♦ The illustration shows a refrigerant line -A- with a permanently
om
ion
installed restrictor -B- (without strainer).
c
in t
or
his
te
♦ The diameter of the shown restrictor hole -B- is
a
do
riv
approx. 0.7 mm. Depending on the refrigerant line version, this
p
cum
or
restrictor is permanently installed or it can be removed. For the
f
en
ng
t.
removable version a strainer may be fitted to prevent the re‐
yi Co
op py
strictor hole from being blocked by suspended particles.
. C rig
ht ht
rig by
py
♦ Check for soiling before installing and clean or renew as nec‐
co Vo
by lksw
cted
essary.
agen
Prote AG.
♦ Observe different versions.
46 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.10 Receiver
♦ The receiver -B- collects the liquid droplets and directs them
in a continuous stream to the expansion valve. Any moisture
that has entered the refrigerant circuit during assembly is col‐
lected by a dryer -D- in the receiver -B-.
♦ Depending on the layout of the refrigerant circuit and the ver‐
sion of condenser -A-, the receiver -B- may be installed on the
condenser -A- or (integrated) in the condenser -A- ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐
cific workshop manual) and ⇒ Electronic parts catalogue .
♦ Installed in the receiver -B- is a dryer (e.g. desiccant bag -D-)
and strainer -F- (that filters out smaller contaminants).
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
♦ The receiver -B- comes in different versions and different de‐
s a c
s
signs ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
ce
e
nl
pt
du
circuit (vehicle-specific workshop manual) and ⇒ Electronic
an
itte
parts catalogue .
y li
erm
ab
ility
♦ Renew the receiver -B- and plastic bolt (with seals) -C-, des‐
ot p
wit
iccant cartridge -D-, filter carrier -E- and strainer -F- if the
, is n
h re
refrigerant circuit was open for an extended period of time and
hole
spec
moisture has been absorbed, or if required to do so owing to
es, in part or in w
a specific complaint ⇒ page 79 .
t to the co
♦ Do not remove the sealing plugs of a receiver until immediately
prior to installation as a desiccant bag in a non-sealed reser‐
rrectness of i
voir will become saturated with moisture and become unusa‐
ble.
l purpos
♦ The desiccant cartridge comes in an air-tight transport bag,
which should remain sealed for as long as possible. Do not
nform
ercia
open the transport bag until immediately prior to inserting the
desiccant cartridge -D- in the receiver -B- of the condenser.
m
at
om
After the transport bag has been opened, the desiccant car‐
ion
c
tridge will become saturated with moisture within a short time in t
or
his
and is then unusable.
ate
do
priv
♦ When installing, observe arrow indicating direction of flow if
um
for
applicable.
en
ng
t.
yi Co
op py
♦ The procedure to adopt in the event of a complaint differs de‐
. C rig
ht ht
pending on the type of receiver/desiccant cartridge. If the
rig by
opy Vo
receiver is installed on the condenser, for example, it can be
by c lksw
cted agen
renewed completely with the desiccant cartridge. If the receiv‐
Prote AG.
er is integrated in the condenser, for example, the desiccant
cartridge and an additional filter element (if one is fitted) can
be replaced individually on most versions. If the receiver is
integrated in the condenser and it is not possible to replace
the receiver/desiccant cartridge separately, it may be neces‐
sary to replace the entire condenser ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
manual) and ⇒ Electronic parts catalogue .
♦ Depending on the layout of the refrigerant circuit (with desic‐
cant bag or desiccant cartridge), the receiver may also be
integrated in the refrigerant circuit (it need not always be in‐
stalled on or in the condenser) ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
manual) and ⇒ Electronic parts catalogue .
1. Refrigerant circuit 47
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.11 Expansion valve (with and without shut-
off valve)
Expansion valve without shut-off function
The expansion valve -A- atomises incoming refrigerant and reg‐
ulates the flow so that, depending on the heat transport, the
vapour does not become a gas until it areaches
gen AG the outlet ofdothe
. Volkswagen AG
evaporator. Volksw es n
ot g
by ua
ed ran
oris tee
th or
Note au ac
ss
ce
le
un
pt
♦ When R1234yf refrigerant was introduced, the expansion
an
d
itte
valves were adapted to the refrigerant (different characteris‐
y li
erm
ab
tics), hence the need to observe the correct version ⇒ Elec‐
ility
ot p
tronic parts catalogue .
wit
is n
h re
♦ Different versions of expansion valve due to different charac‐
ole,
spec
teristics that are matched to the relevant refrigerant circuit ⇒
urposes, in part or in wh
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
t to the co
hicle-specific workshop manual) and ⇒ Electronic parts cata‐
logue .
rrectne
♦ When renewing the expansion valve, make sure that the part
number is correct ⇒ Electronic parts catalogue .
s
♦ Depending on the version of air conditioner compressor, a
s o
cial p
f
valve may be installed on the high-pressure side that prevents
inform
liquefied refrigerant flowing back into the air conditioner com‐
mer
pressor after the air conditioning system is switched off. If an
atio
m
air conditioner compressor with this valve is installed in a ve‐
o
n
c
hicle with a refrigerant circuit with expansion valve, it could
i
or
n thi
take some time before the pressure on the high-pressure side
te
sd
va
drops (the expansion valve is cold and the pressure on the
i
o
pr
cum
low-pressure side rises quickly after switching off, the expan‐
r
fo
en
ng
sion valve closes and refrigerant only flows slowly on the low-
t.
yi Co
op
pressure side). If the air conditioner compressor is switched C py
ht. rig
on, the pressure on the low-pressure side drops, the expan‐ rig ht
py by
sion valve opens and refrigerant can flow on the low-pressure co Vo
by lksw
side.
cted agen
Prote AG.
Expansion valve with refrigerant shut-off valve
Note
Shut-off valves come in different versions, with different functions
and different designations ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
48 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ The expansion valve -A- with shut-off valve -B- atomises the
incoming refrigerant and regulates the flow rate of the refrig‐
erant to the evaporator in the battery cooling module of the
hybrid battery unit - AX1- in such a way that, depending on the
heat transport, the vapour does not become a gas until it rea‐
ches the outlet of the evaporator.
♦ If the shut-off valve -B- is actuated by the electronics, it is open
and allows refrigerant to flow through to the expansion valve
-A-.
♦ If the shut-off valve -B- is open, the expansion valve -A- allows
refrigerant to flow through to the evaporator or heat exchanger
based on its control characteristic ⇒ Heating, air conditioning; Volkswa
Rep. gr. 87 ; Refrigerant circuit . swa
gen AG
. gen AG
does
k not
y Vol gu
♦ The solenoid -B- attached to the expansion valve d b-A- is actu‐ ara
ise nte
ated by different control units depending on the h vehicle ⇒ Cur‐
or eo
ut
rent flow diagrams, Electrical fault finding sand
s a Fitting locations
ra
c
and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
ce
le
un
mode.
pt
an
d
itte
y li
♦ If, on a vehicle with 2 evaporators (one in the heater and air
erm
ab
conditioner unit and one in the battery cooling module, e.g. the
ility
ot p
Audi Q5 Hybrid), the temperature measured at one evaporator
wit
is n
meets the specification or falls below the specification, while
h re
ole,
on the other evaporator however the requisite specification is
spec
urposes, in part or in wh
not reached, regulation works as follows: the battery regula‐
t to the co
tion control unit - J840- makes the electrical air conditioner
compressor run at a higher speed via the power and control
electronics for electric drive - JX1- and the control unit for air
rrectne
conditioning compressor - J842- (which results in the cooling
output of the air conditioning system rising and pressure on
the low pressure side falling along with the evaporator tem‐
ss
perature). If, as a result, the temperature at one evaporator
o
cial p
f
falls below the specified level, -J840- actuates refrigerant shut-
inform
off valve 1 for hybrid battery - N516- or refrigerant shut-off
mer
valve 2 for hybrid battery - N517- in such a way that the evap‐
atio
m
orator - which is too cold - no longer has refrigerant flowing
o
n
c
i
through it ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
or
n thi
e
mode.
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Refrigerant circuit 49
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.12 Refrigerant shut-off valves
Shut-off valves with 2 switch statuses (open or closed)
♦ Shut-off valves come in different versions, with different func‐
tions and different designations ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit .
♦ If the shut-off valve -A- is not actuated by the electronics, it is
open and allows refrigerant to flow through.
♦ The shut-off valve -A- is installed on vehicles with high-voltage
system, for example. It is actuated when no climate control is
wanted for the passenger compartmentAbut obattery
lkswagencooling is
required for the hybrid battery unit w- en G..V
agAX1- AG do
e
lks s n o ot g
yV ua
♦ Note the arrow -B- on the iseshut-off valve -A-, which shows the
db ran
tee
or (from condenser to evaporator in
direction of refrigerantuthflow or
the heater and air conditioning
ss
a unit). ac
ce
le
♦ The solenoid -C- attached to the shut-off valve -A- is actuated
un
pt
an
d
by different control units depending on the vehicle ⇒ Current
itte
y li
flow diagrams, Electrical fault finding and Fitting locations and
erm
ab
ility
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
ot p
wit
air conditioning system and battery regulation.
is n
h re
ole,
♦ If, on a vehicle with 2 evaporators (one in the heater and air
spec
urposes, in part or in wh
conditioner unit and one in the battery cooling module, e.g. the
t to the co
Audi Q5 Hybrid), the temperature measured at one evaporator
meets the specification or falls below the specification, while
on the other evaporator however the requisite specification is
not reached, regulation works as follows: the respective con‐
rrectne
trol unit makes the electrical air conditioner compressor run at
a higher speed (which results in the cooling output of the air
ss
conditioning system rising and pressure on the low pressure o
cial p
f
side falling along with the evaporator temperature). If the tem‐
inform
perature at an evaporator then falls below the specified level,
mer
the respective control unit actuates the shut-off valve in such
atio
m
a way that the evaporator that is too cold no longer has refrig‐
o
n
c
erant flowing through it ⇒ Heating, air conditioning; Rep. gr.
i
or
n thi
e
87 ; Refrigerant circuit and ⇒ Vehicle diagnostic tester in “Gui‐
t
sd
va
ded Fault Finding” mode.
i
o
pr
cum
r
fo
en
ng
Shut-off valves regulated via characteristic curves yi
t.
Co
Cop py
t. rig
gh
♦ The shut-off valve -A- is actuated via an incremental motor
ht
pyri by
Vo
-B- by the respective control unit with characteristic curves
co lksw
by
cted agen
(open or closed). Prote AG.
♦ If the shut-off valve acts as a control valve (e.g. refrigerant
expansion valve 1 - N636- as is the case with the Audi Q7), it
is only opened enough to allow the temperature set for the heat
exchanger to be reached ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit .
♦ Shut-off valves actuated via incremental motors do not have
a defined rest position. For this reason, they have to be set to
a certain position (open or closed) before work on the refrig‐
erant circuit is performed ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit .
♦ Depending on layout of the refrigerant circuit there could be a
cluster of shut-off valves forming a valve block (e.g. on the e-
Golf or Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit .
♦ The incremental motor is programmed and actuated via data
lines (LIN-Bus) by the respective control unit in relation to its
installation location ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit and ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
50 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.13 Refrigerant line with internal heat ex‐
changer
♦ In this refrigerant line, the warm liquid refrigerant flowing on
the high pressure side supplies energy to the cold refrigerant
gas or vapour flowing on the low pressure side, thus enhanc‐
ing the efficiency of the air conditioner.
Note
AG. Volkswagen AG d
agen oes
olksw not
This illustration shows a refrigerant line with inner
d b heat exchanger
y V gu
ara
as fitted e.g. on the Golf 7, Audi A4 2008 h>oriand
se Audi A5 Coupé nte
eo
2008 > ⇒ Heating, air conditioning; Rep. a gr. 87 ; Refrigerant
ut ra
circuit . ss c
ce
le
un
pt
an
d
itte
A - Refrigerant line with internal heat exchanger
y li
erm
ab
ility
B - Channels in the refrigerant line along which hot liquid refrig‐
ot p
erant flows to the evaporator (high pressure side of refrigerant
wit
is n
h re
circuit).
ole,
spec
urposes, in part or in wh
C - Channel in the refrigerant line through which the cold gaseous
or vaporous refrigerant flows to the air conditioner compressor
t to the co
(low pressure side of refrigerant circuit).
rrectne
1.2.14 Quick release couplings of refrigerant
lines
ss o
cial p
f inform
mer
Note
atio
om
n
♦ This illustration shows the quick-release couplings with a re‐
c
i
or
n thi
frigerant line with internal heat exchanger as fitted e.g. on the
te
sd
a
Audi A4 2008 > and the Audi A5 Coupé 2008 > ⇒ Heating, air
iv
o
pr
c
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
um
r
fo
workshop manual). en
ng
t.
yi Co
op py
♦ Removal of the refrigerant line -D- involves opening the re‐
t. C rig
gh ht
taining ring -A- e.g. with the refrigerant line release tool ( re‐ pyri by
Vo
co
lease tool - T40149- or removal tool - T40232- ) ⇒ Heating,
by lksw
cted agen
Prote
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐
AG.
cific workshop manual).
♦ After removing the respective refrigerant line, the quick re‐
lease couplings -B- and -G- are to be renewed along with the
associated support ring -E- or -H- and the associated seal
-F- or -J- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual) and ⇒ Electronic
parts catalogue .
A - Retaining ring (in quick release coupling on high pressure
side)
B - Quick release coupling with retaining ring “high pressure side”
C - Refrigerant line with internal heat exchanger
D - Refrigerant line “high pressure side”
E - Support ring “high pressure side”
F - Seal “high pressure side”
G - Quick release coupling with retaining ring “low pressure side”
H - Support ring “low pressure side”
J - Seal “low pressure side”
1. Refrigerant circuit 51
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The quick release couplings come in different versions -A- and
-D-. On both versions of these quick release couplings, the
refrigerant lines -C- can be released and removed in the same
way, e.g. with refrigerant line release tool -T40149/1- ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
♦ For quick release coupling version -A-, the control pins -B- be‐
come visible after installing the refrigerant line -C- once the
engaged refrigerant line -C- is pulled in the direction of arrow.
♦ For quick release coupling version -D-, the refrigerant line
-C- is installed in the same way as quick release coupling
-A-. When the refrigerant line -C- on this version is pulled in
the direction of arrow following assembly, the snap ring -E-
protrudes from the quick release coupling -D-, thereby indi‐
cating that the retaining ring -F- is completely engaged with
the refrigerant line -C-. The snap ring -E- must then be re‐
moved from the refrigerant line -C-.
1.2.15 Seals
. Volkswagen AG
gen AG does
♦ These seals seal the connection points between the individual Vol
ksw
a
not
components of the refrigerant circuit ed
by gu
ara
⇒ “3.2 Refrigerant circuit seals”, page 8 . thoris nte
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
1.2.16 Pipes and hoses in refrigerant circuit
rrectness of i
♦ In its pure state, R1234yf refrigerant is chemically stable and
l purpos
has no corrosive effect on e.g. iron, aluminium and specially
developed plastics that are suitable for this purpose. A mixture
of refrigerant oil and R1234yf refrigerant can affect certain
nform
ercia
metals (e.g. alloys with copper) and affect or degrade certain
m
hose materials and plastics. Therefore, use only genuine re‐
at
om
io
placement parts ⇒ Electronic parts catalogue .
n
c
in t
or
his
e
♦ Only use components that are resistant to R1234yf refrigerant
at
do
riv
and its associated refrigerant oils. Do not use components
p
cum
or
(such as seals and hoses, which are made of plastic) that
f
en
g
cannot be clearly allocated ⇒ Electronic parts catalogue .
n
t.
yi Co
Cop py
♦ The pipes and hoses are held together by threaded connec‐
t. rig
gh ht
yri by
tions and / or special joints ⇒ Heating, air conditioning; Rep. cop Vo
by lksw
gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual). cted agen
Prote AG.
♦ Renew the sealing elements (e.g. seals) between the compo‐
nents ⇒ Electronic parts catalogue .
♦ For threaded connections, observe the specified torque set‐
tings. For pressure-fit connections, use dedicated release
tools ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual).
52 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.17 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 of approx. 38 bar (overpressure)
and closes again when the pressure has dropped (to approx. 35
bar).
Not all the refrigerant is lost from the system.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
♦ Depending on the version, a transparent plastic washer -B-
erm
ab
may be attached to the high pressure safety valve -A- which
ility
ot p
breaks off as soon as the valve is actuated.
wit
, is n
h re
♦ Depending on the version of high pressure safety valve -A-, a
hole
spec
cover -C- may also be pushed onto the high pressure safety
es, in part or in w
valve -A-. Should the pressure in the refrigerant circuit actually
t to the co
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-
rrectness of i
beneath the cover -C- instead.
l purpos
♦ If a high-pressure safety valve -A- needs to be renewed, the
specified torque for the new valve (depending on the manu‐
facturer and the version of the air conditioner compressor)
nform
ercia
must be observed when installing. Air conditioner compres‐
m
sors manufactured by “Denso”, “Sanden” and “Valeo” are
at
om
io
equipped with an O-ring seal (currently valid torque settings
n
c
in t
r
are: 10 Nm for “Denso” and “Zexel/Valeo” air conditioner com‐
o
his
e
pressors, and 15 Nm for “Sanden” air conditioner compres‐
at
do
riv
sors). Air conditioner compressors manufactured by “Delphi”
p
cum
or
are fitted with an oil seal (currently valid torque setting: 15 Nm).
f
en
ng
t.
yi Co
op
♦ Renewing seals (oil seals or O-rings) ⇒ Electronic parts cata‐ C py
t. rig
logue .
gh ht
pyri by
Vo
co lksw
by
♦ If a seal (oil seal or O-ring) fitted to the high-pressure safety cted agen
Prote AG.
valve is not available as a replacement part, the removed old
part can be reused (as an exception to the general rule of using
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
a commercially available new part ⇒ Electronic parts cata‐
logue .
♦ After filling the refrigerant circuit, check the installed high-
pressure safety valve for leaks using e.g. an electronic leak
detector.
1. Refrigerant circuit 53
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.18 Non-return valves
Non-return valves separate the refrigerant circuit into different
areas ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit en AG. Volkswagen AG
(vehicle-specific workshop manual). olks
wag does
no
yV t gu
db ara
ir se nte
ho eo
Note aut ra
ss c
ce
le
un
♦ The non-return valve -3- shown in installed e.g. in the Audi Q7
pt
an
d
e-tron ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
itte
y li
erm
circuit (vehicle-specific workshop manual).
ab
ility
ot p
♦ Non-return valves in the refrigerant circuit have a certain hold‐
wit
is n
ing pressure in the direction of flow (approx. 0.1 bar or
h re
ole,
100 mbar). To ensure that the refrigerant circuit can be evac‐
spec
urposes, in part or in wh
uated completely (residual pressure below 5 mbar), all of the
t to the co
electrically actuated valves must therefore be open.
♦ Depending on the version, the direction of flow may be indi‐
cated by a sticker.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
54 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.19 Quick-release coupling connections in
refrigerant circuit
Service connections with Schrader valve (needle valve or push
pin)
♦ Only valves and connections resistant to R1234yf refrigerant
and the related refrigerant oils may be used.
♦ Service connections -C- and -F- in an R1234yf refrigerant cir‐
cuit are configured in such a way thatwservice
agen
AG.couplings
Volkswagen cannot
AG do
es n
be connected to service connectionsyV
olks designed for an R134a ot g
ua
refrigerant circuit. ised b ran
r tee
ho
♦ Different connections (external
sa
ut diameter) for high pressure or
ac
and low pressure sides -C- and -F-.
ce
le
un
pt
♦ Before removing the valves or valve inserts -B- and -E-, empty
an
d
itte
y li
the refrigerant circuit.
rm
ab
pe
ility
♦ Always screw on sealing caps -A- and -D- with seal -G-.
ot
wit
, is n
h re
Layout in vehicle ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
hole
frigerant circuit (vehicle-specific workshop manual).
spec
es, in part or in w
t to the co
– Extract refrigerant before unscrewing the valves.
♦ Service connection, low pressure side -F-
rrectness of i
♦ Service connection, high pressure side -C-
l purpos
♦ Valve insert (designation: Schrader or needle valve)
♦ Sealing cap for service connection on low pressure side with
nform
ercia
seal -A-
m
a
♦ Sealing cap for service connection on high pressure side with
com
tio
seal -D-
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
co lksw
by
cted agen
Prote AG.
1. Refrigerant circuit 55
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Carefully, and no more than necessary, screw in the hand‐
wheel of the service coupling (after connecting) into the quick
release coupling adapter until the valve in the service connec‐
tion is open (observe pressure gauge; do not over-tighten
valve).
♦ Service connections in an R1234yf refrigerant circuit are con‐
figured in such a way that service couplings cannot be con‐
nected to service connections designed for an R134a
refrigerant circuit.
♦ The service connections are brazed into e.g. a refrigerant line
and therefore cannot be replaced individually.
♦ When removing and installing valve core with refrigerant cir‐
cuit discharged, use a socket - T10364- or similar.
♦ Exercise caution when tightening the valve insert due to the
low tightening torque.
♦ There are different versions of these valves; therefore tight‐
ening torques vary. For a valve insert -C- with a VG5 thread olkswagen AG
(5.2 x 0.7 mm, tyre valve) the tightening torque is 0.4 Nm swagen AG. V does
± 0.1 Nm; for a valve insert with an M6 x 0.75 mm thread by V the
olk not
gu
tightening torque is 0.9 Nm ± 0.1 Nm, and for a valveris
ed insert ara
nte
with an M8 x 1.0 mm thread the tightening torque uth is
o eo
ra
2.0 Nm ± 0.2 Nm. ss
a c
ce
e
nl
♦ These valve caps come in different versions, which means that
pt
du
an
the specified torques will differ. For a valve cap with an M8 x
itte
y li
erm
1 mm or M10 x 1 mm thread, the specified torque is
ab
ility
0.4 Nm ± 0.1 Nm respectively.
ot p
wit
, is n
♦ These valves, valve inserts and corresponding sealing caps
h re
hole
come in different versions. Make sure that the correct type of
spec
valve insert is used and allocation of the sealing caps is correct
es, in part or in w
t to the co
⇒ Electronic parts catalogue .
Dimensions of service connections
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.
56 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Valve insert -A- (different versions).
♦ Service connection -B- (different versions on high pressure
and low pressure side depending on refrigerant)
Dimensions of serv‐ Service connec‐ Service connection
ice connections -B- tion for R134a re‐ for R1234yf refriger‐
frigerant ant
High- Low- High- Low-
pressure pres‐ pressure pressure
side sure side side
side
External diameter 16.0 mm 13.0 m 17.0 mm 14.0 mm
-D1- m
External diameter 14.0 mm 11.0 m 13.0 mm 12.0 mm
-D2- m
Shoulder -L1- 4.6 mm 6.15 m 9.0 mm 4.75 mm
m
Shoulder -L2- 8.16 mm 9.16 m 12.5 mm 7.2 mm
m
Installation position of 6.1 - 7.1 6.1 - 7.1 8.3 - 9.3 8.3 - 9.3
valve (unactuated) mm mm mm mm
-C-
Service connections with primary sealing valve (ball valve)
♦ This type of service connection is currently not used in VW/
Audi refrigerant circuits.
♦ Only valves and connections resistant to R1234yf refrigerant
and the related refrigerant oils may be used.
♦ Service connections in an R1234yf refrigerant circuit are con‐
figured in such a way that service couplings cannot be con‐
nected to service connections designed for an R134a
refrigerant circuit.
♦ Different connections (external diameter) for high-pressure n AG. Volkswagen AG do
and low-pressure sides. olkswage es n
o V t gu
by ara
♦ Discharge refrigerant circuit before removing valve orris valve
ed nte
inserts. au
tho eo
ra
ss c
♦ Always screw on sealing caps with seal.
ce
e
nl
pt
du
an
Layout in vehicle ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
itte
y li
frigerant circuit (vehicle-specific workshop manual).
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
57
cted agen
Prote AG.
1. Refrigerant circuit
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
n AG. Volkswagen AG do
Connection with high pressure valve lkswage es n
o ot g
yV ua
1- Boss with internal thread (brazed on) ir se
d b ran
tee
tho
or
2- Seal (version and designation: black
au or coloured ⇒ Elec‐ ac
ss
tronic parts catalogue )
ce
e
nl
pt
du
3- Valve with external thread and groove for seal (designation:
an
itte
y li
ball valve)
erm
ab
ility
ot p
4- Seal for sealing cap
wit
, is n
h re
5- Sealing cap
hole
spec
es, in part or in w
t to the co
Note
♦ Carefully, and no more than necessary, screw in the hand‐
rrectness of i
wheel of the service coupling (after connecting) into the quick
release coupling adapter until the valve in the service connec‐
l purpos
tion is open (observe pressure gauge; do not over-tighten
valve).
nf
ercia
o
♦ When removing and installing the valve -3- with purged refrig‐
rm
m
atio
erant circuit, use e.g. an adapter from socket set - T10364- .
om
n in
c
♦ These valves come in different versions (with internal or ex‐
or
thi
e
ternal thread) and the specified torques can therefore differ.
t
sd
iva
o
For the valves -3- currently in use (external thread M12 x 1.5
r
rp
cu
o
m
mm) the tightening torque is 9 Nm ± 1 Nm.
f
en
ng
t.
yi Co
op
♦ These valves and corresponding sealing caps come in differ‐ C py
t. rig
ent versions. Make sure that the correct type of valve is used gh ht
yri by
and allocation of the sealing caps is correct ⇒ Electronic parts cop Vo
by lksw
catalogue .
cted agen
Prote AG.
Connection with low pressure valve
1- Boss with external thread and groove for O-ring (brazed in)
2- Seal (version and designation: black or coloured ⇒ Elec‐
tronic parts catalogue )
3- Valve with internal thread
4- Seal for sealing cap
5- Sealing cap
Note
♦ Carefully, and no more than necessary, screw in the hand‐
wheel of the service coupling into the quick release coupling
adapter until the valve in the service connection is open (ob‐
serve pressure gauge; do not over-tighten valve).
♦ When removing and installing the valve -3- with purged refrig‐
erant circuit, use e.g. an adapter from socket set - T10364- .
♦ These valves come in different versions (with internal or ex‐
ternal thread) and the specified torques can therefore differ.
For the valves -3- currently in use (internal thread
M10 x 1.25 mm) the tightening torque is 9 Nm ± 1 Nm.
♦ These valves and corresponding sealing caps come in differ‐
ent versions. Make sure that the correct type of valve is used
and allocation of the sealing caps is correct ⇒ Electronic parts
catalogue .
58 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.20 Connections with valve for switches in
refrigerant circuit
Note
Refer to vehicle-specific refrigerant circuit for switching pres‐
sures, removing and installing switches and location/design of
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual).
• The switches on the high pressure and low pressure sides
have different threads.
• Only valves and seals resistant to R1234yf refrigerant and the
related refrigerant oils may be used ⇒ Electronic parts cata‐
logue .
A - Connection (brazed)
en AG. V
olkswagen AG
wag does
B - Seal olks not
byV gu
ara
ed nte
ris
C- Valvetho (with seal) eo
au ra
c
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
♦ To remove and install the valve -C- with the refrigerant circuit
ility
ot p
empty, use e.g. an adapter from socket set - T10364- (speci‐
wit
, is n
fied torque ⇒ page 55 ).
h re
hole
spec
♦ There are different versions of these valves; therefore tight‐
es, in part or in w
ening torques vary. For a valve insert -C- with a VG5 thread
t to the co
(5.2 x 0.7 mm, tyre valve) the tightening torque is 0.4 Nm
± 0.1 Nm; for a valve insert with an M6 x 0.75 mm thread the
tightening torque is 0.9 Nm ± 0.1 Nm, and for a valve insert
rrectness of i
with an M8 x 1.0 mm thread the tightening torque is
2.0 Nm ± 0.2 Nm.
l purpos
nf
ercia
1.2.21 Pressure senders and switches in refrig‐
orm
m
erant circuit
atio
om
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
♦ Pressure senders and switches come in different versions,
t.
yi Co
op
with different functions and different designations ⇒ Heating,
C py
t. rig
gh
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐
ht
pyri by
cific workshop manual).
co Vo
by lksw
cted agen
Prote AG.
♦ Switching pressures, removing and installing switches and
switch layout and type ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
1. Refrigerant circuit 59
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ The high pressure sender shown is installed e.g. in the Golf 7
and Audi A3 ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific workshop manual).
♦ One version of pressure sender generates a square-wave sig‐ AG. Volkswagen AG d
agen
nal when voltage is applied. This signal changes with the Volksw
oes
not
gu
pressure in the system. The other version of pressure sender ed by ara
nte
exchanges information with the corresponding control unitthvia oris
eo
data bus (e.g. via the “LIN bus”) when voltage is applied ⇒s Cur‐
au ra
c
rent flow diagrams, Electrical fault finding and Fitting locations
s
ce
le
and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
un
pt
an
d
mode - air conditioning system. Therefore, pay attention to the
itte
y li
correct version of pressure sender.
erm
ab
ility
ot p
♦ The pressure senders come in different versions. Depending
wit
is n
on the version, they can currently only be distinguished exter‐
h re
ole,
nally by the part number, which is why attention should be paid
spec
during renewal to their correct allocation (part number ⇒ Elec‐ urposes, in part or in wh
t to the co
tronic parts catalogue ). Reason: These senders emit different
signals, and the relevant control units can only evaluate the
signal to which they have been matched ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode - air conditioning system
rrectne
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit (vehicle-specific workshop manual).
ss o
♦ One version of pressure sender only transmits the measured
cial p
f in
value for the pressure in the refrigerant circuit to the connected
form
mer
control unit. The other version transmits the measured value
atio
for the pressure in the refrigerant circuit and the measured
om
n
temperature to the connected control unit, which is why atten‐
c
i
or
n thi
tion should be paid to the correct version ⇒ Electronic parts
te
sd
a
catalogue .
iv
o
pr
cum
r
fo
♦ With this signal, the downstream control units calculate the
en
ng
t.
yi
pressure in the refrigerant circuit and actuate the radiator fans
Co
op py
and engine, the air conditioning system magnetic clutch - N25-
. C rig
ht ht
rig
accordingly or manipulate actuation of the air conditioner com‐ py by
co Vo
pressor regulating valve - N280- ⇒ Vehicle diagnostic tester in
by lksw
cted agen
Prote
“Guided Fault Finding” mode - air conditioning system and ⇒
AG.
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual).
1.2.22 Refrigerant pressure and temperature
sender
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.
– Wear protective gloves.
– Wear protective goggles.
– 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.
60 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Senders for connection to a refrigerant circuit with valve
AG. Volkswagen AG d
agen oes
Note o lksw not
byV gu
ara
ed
ris nte
♦ Refer to vehicle-specific
ut
ho refrigerant circuit for switching pres‐ eo
ra
sures, removing
ss a and installing switches and location/design ofc
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
ce
e
nl
pt
circuit (vehicle-specific workshop manual).
du
an
itte
y li
♦ These senders come in different versions, with different func‐
erm
ab
ility
tions and different designations. The refrigerant pressure and
ot p
temperature sender - G395- shown as follows is installed e.g.
wit
, is n
h re
in the Golf GTE, Audi A4, Audi Q5 and Audi Q5 Hybrid ⇒
hole
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
spec
System overview - refrigerant circuit .
es, in part or in w
t to the co
♦ Before loosening the threaded connection of the sender,
check which version of sender it is ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
rrectness of i
circuit .
l purpos
♦ For senders designed for connection to a refrigerant circuit
without valve. The refrigerant must be extracted before the
nform
ercia
threaded connection is loosened. If the sender is not removed
within 10 minutes after the system has been evacuated, pres‐
m
at
sure may develop in the refrigerant circuit due to re-evapora‐
om
ion
tion. Extract refrigerant again.
c
in t
or
his
te
♦ Different designations depending on the function and vehicle
a
do
riv
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
p
cum
or
System overview - refrigerant circuit .
f
en
ng
t.
yi Co
Cop py
ht. rig
♦ The sender for refrigerant pressure and refrigerant tempera‐ py
rig by
ht
ture is installed e.g. in place of the high pressure sender or co Vo
by lksw
pressure sender for refrigerant circuit ⇒ Heating, air condi‐
cted agen
Prote AG.
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific work‐
shop manual)
♦ The sender for refrigerant pressure and refrigerant tempera‐
ture, the pressure sender for refrigerant circuit and high pres‐
sure sender come in different versions. Depending on the
version, they can currently only be distinguished externally by
the part number, which is why attention should be paid during
renewal to their correct allocation (part number ⇒ Electronic
parts catalogue ). Reason: These senders emit different sig‐
nals, and the relevant control units can only evaluate the signal
to which they have been matched ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
♦ The sender for refrigerant pressure and refrigerant tempera‐
ture (and the pressure sender for refrigerant circuit) exchange
information with the respective control unit via the data bus
(e.g. “LIN bus”) when voltage is applied. The respective control
units use this information to calculate the pressure and tem‐
perature in the refrigerant circuit. Any faults detected in this
way are passed on to the control unit ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode.
♦ The sender for refrigerant pressure and refrigerant tempera‐
ture transmits the measured valve for the pressure in the
refrigerant circuit and the measured temperature to the con‐
nected control unit. The pressure sender for refrigerant circuit
only transmits the measured value for the pressure in the re‐
frigerant circuit to the connected control unit. Even though on
most vehicles only the pressure signal is evaluated, no other
pressure sender may be installed in a vehicle for which provi‐
sion is made for a refrigerant pressure and refrigerant tem‐
perature sender ⇒ Electronic parts catalogue .
1. Refrigerant circuit 61
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ The temperature measured by this refrigerant pressure and
temperature sender deviates from the actual temperature of
the refrigerant in the refrigerant circuit owing to the design of
the sender and the fitting location. It is therefore not evaluated
at present by all control units and is used to regulate the air
conditioning system ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific workshop manual).
♦ With this information, the respective control units calculate the
pressure in the refrigerant circuit and actuate the downstream
control units (radiator fan control unit, engine control unit etc.)
via data bus. These control units subsequently actuate e.g. the
air conditioning system magnetic clutch - N25- , the radiator
fan and the engine ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode - air conditioning system and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
Senders for connection to a refrigerant circuit without valve
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
ed
♦ These sendersthocome in different versions, with different func‐
ris nte
eo
tions and different
au designations. The sender for refrigerant ra
s refrigerant temperature shown as follows is in‐ c
pressure and
s
ce
e
stalled e.g. in the Audi Q7 e-tron ⇒ Heating, air conditioning;
nl
pt
du
an
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
itte
y li
circuit .
erm
ab
ility
ot p
♦ Different designations depending on the function and vehicle
wit
, is n
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
h re
System overview - refrigerant circuit .
hole
spec
es, in part or in w
t to the co
Possible designations for these senders
♦ Refrigerant pressure and temperature sender - G395- (e.g. in
rrectness of i
e-Golf, Audi Q7 e-tron)
l purpos
♦ Refrigerant pressure and temperature sender 2 - G826- (e.g.
in Audi Q7 e-tron)
nform
ercia
♦ Refrigerant pressure and temperature sender 3 - G827- (e.g.
m
in Audi Q7 e-tron)
at
om
ion
c
These senders -A- come in different versions that, depending on
in t
or
the version, can currently only be distinguished externally by the
his
ate
do
riv
part number or, if the part number is the same, by the designation
p
cum
label -B-, which is why when renewing them it is important to en‐
for
en
g
sure the correct allocation. Part number and designation ⇒
n
t.
yi Co
Electronic parts catalogue and ⇒ Heating, air conditioning; Rep. Cop py
ht. rig
gr. 87 ; Refrigerant circuit; System overview - Refrigerant circuit . opy
rig by
Vo
ht
c lksw
When a voltage is applied, these senders exchange information
by
cted agen
Prote
with the respective control unit via the data bus (e.g. via “LIN
AG.
bus”). The respective control units use this information to calcu‐
late the pressure and temperature in the refrigerant circuit. Any
faults detected in this way are passed on to the control unit ⇒ Ve‐
hicle diagnostic tester in “Guided Fault Finding” mode.
With this information, the respective control unit calculates the
pressure in the refrigerant circuit and actuates the downstream
control units or components (radiator fan control unit, pumps,
valves etc.) via data bus according to the specifications ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview
- refrigerant circuit (vehicle-specific workshop manual).
62 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.2.23 Air conditioner compressor regulating
valve - N280-
Note
Refer to vehicle-specific refrigerant circuit for switching pres‐
sures, removing and installing switches and location/design of
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit .
♦ The regulating valve is fitted to the air conditioner compressor.
It is actuated, for example, by the air conditioning system con‐
trol unit - J301- , the operating and display unit for front air
conditioning system - E87- or the Climatronic control unit -
J255- (potentially also via data bus and an additional control
unit depending on the vehicle) ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode - air conditioning system and ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual).
♦ The regulating valve influences the pressure on the low pres‐
sure side and thus the temperature at the evaporator.
Note
The air conditioner compressor regulating valve - N280- is an in‐
tegral part of the air conditioner compressor and cannot be re‐
newed individually on all air conditioner compressors ⇒
Electronic parts catalogue .
1.2.24 Refrigerant temperature sender
lksw
agen
AG. Volkswagen AG d
oes
no o t gu
yV
edb ara
ris nte
Note tho eo
au ra
c
ss
ce
le
♦ A refrigerant temperature sender (a temperature sender that
un
pt
an
d
does not evaluate the pressures) is currently not used by
itte
y li
Volkswagen/Audi.
rm
ab
pe
ility
ot
♦ Switching pressures, removing and installing switches and
wit
, is n
switch layout and design ⇒ Vehicle diagnostic tester in “Gui‐
h re
hole
ded Fault Finding” mode - air conditioning system and ⇒
spec
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
es, in part or in w
t to the co
hicle-specific workshop manual).
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.
1. Refrigerant circuit 63
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ The refrigerant temperature sender (with temperature-de‐
pendent resistor) is installed e.g. in the high pressure line in
the vicinity of the air conditioner compressor.
♦ There is a direct correlation between temperature and pres‐
sure in the refrigerant circuit: if there is too little refrigerant in
the refrigerant circuit, the temperature in the refrigerant circuit
rises during operation of the air conditioning system on the
high pressure side greater than permitted for this pressure.
Note
The respective control unit, e.g. the operating and display unit for
front air conditioning system - E87- or the Climatronic control unit
- J255- evaluates the pressure and the temperature in the refrig‐
erant circuit and switches off the air conditioner compressor if the
temperature increases above the value stored for this pressure
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air
conditioning system and ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
AG. Volkswagen AG d
agen oes
ksw
1.3 Possible complaints
ol not
y V gu
d b ara
rise nte
o
⇒ “1.3.1 Prerequisites
aut for investigating a complaint”, page 64
h eo
ra
ss c
⇒ “1.3.2 Possible complaints”, page 64
ce
le
un
pt
an
d
⇒ “1.3.3 Odours from heater and air conditioner unit”, page 66
itte
y li
erm
ab
1.3.1 Prerequisites for investigating a com‐
ility
ot p
wit
plaint
is n
h re
ole,
spec
• No fault was evident during fault finding in the electrical sys‐
urposes, in part or in wh
tem, vacuum system and air ducts/channels ⇒ Vehicle diag‐
t to the co
nostic tester in “Guided Fault Finding” mode - air conditioning
system (and battery control), ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations and ⇒ Heating, air
rrectne
conditioning; Rep. gr. 00 ; Repair instructions; Checking cool‐
ing output .
ss
• Self-diagnosis in “Guided Fault Finding” mode - air condition‐
o
cial p
f i
ing system (e.g. using ⇒ Vehicle diagnostic tester in “Guided
nform
Fault Finding” mode - air conditioning system) provides no
mer
evidence of a complaint.
atio
om
n
c
• No shut-off condition for the air conditioner compressor is dis‐
or
n thi
e
played in the measured values of the control unit of the air
t
sd
va
conditioning system ⇒ Vehicle diagnostic tester in “Guided
i
o
pr
cum
r
Fault Finding” mode - air conditioning system.
fo
en
ng
t.
yi Co
1.3.2 Possible complaints Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
♦ For all complaints marked with *
⇒ “2.14 Checking pressures”, page 165 .
♦ If on vehicles with 2 evaporators a problem is encountered in
just one evaporator, check the pressures in the refrigerant cir‐
cuit as well ⇒ “2.14 Checking pressures”, page 165 .
♦ The cooling has failed completely.*
♦ Insufficient cooling output at all vehicle speeds and engine
speeds.*
♦ No or insufficient cooling after driving a few miles. *
64 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ No cooling or insufficient cooling from one or two evaporators
(on vehicles with 2nd heater and air conditioner/evaporators).
*
♦ Actuation of the air conditioner compressor (via the air condi‐
tioning system magnetic clutch - N25- or the air conditioner
. Volkswagen AG
compressor regulating valve - N280- ) is switched ageoff
n AGby the does
ksw
respective control unit (e.g. the operatingbyand V display unit for
ol not
gu
ara
front air conditioning system - E87- , rtheis air conditioning sys‐
ed
nte
tem control unit - J301- or the Climatronic
ut
ho control unit - J255- ) eo
ra
due to pressure in the refrigerants circuit being too high or too
s a c
low * ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
ce
le
un
pt
mode - air conditioning system.
an
d
itte
y li
erm
♦ The electrical air conditioner compressor - V470- is not actu‐
ab
ility
ated by the control unit for air conditioning compressor - J842-
ot p
wit
due to pressure being too high or too low * ⇒ Vehicle diagnostic
is n
h re
tester in “Guided Fault Finding” mode - air conditioning system
ole,
spec
and battery regulation.
urposes, in part or in wh
t to the co
♦ If fresh air supply is lacking or drops significantly after a few
miles (evaporator iced up) *⇒ Vehicle diagnostic tester in “Gui‐
ded Fault Finding” mode - air conditioning system.
rrectne
In addition, the following problems may occur:
s
The air conditioner compressor is noisy.
s o
cial p
f
– Re-tighten the securing bolts for the air conditioner compres‐
inform
sor and the air conditioner compressor bracket using a torque
mer
wrench ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
atio
m
circuit; System overview - refrigerant circuit .
o
n
c
i
or
n thi
e
– Check the routing of the refrigerant lines. These must not rest
t
sd
va
against other components and must not be under any strain
i
o
pr
cum
(realign them if necessary) ⇒ Heating, air conditioning; Rep.
r
fo
en
ng
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐
t.
yi Co
op
cuit . C py
ht. rig
rig ht
Noises (refrigerant hammering) occur immediately after the air
py by
co Vo
by lksw
conditioning is switched on and/or in a curve or when the brakes Prote
cted AG.
agen
are applied:
– Drain the refrigerant circuit, evacuate it and recharge (too
much refrigerant or refrigerant oil in the circuit) ⇒ page 124
and ⇒ “2.14 Checking pressures”, page 165 .
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 con‐
ditioner compressor was renewed) ⇒ page 79 .
Water sprays out of the vents (in dash panel or footwell) although
air conditioning system is otherwise functioning properly:
– Check condensation drain to ensure that it is routed correctly.
It should not be kinked or crushed ⇒ Heating, air conditioning;
Rep. gr. 87 ; Front heater and air conditioner .
– The condensed water drain valve must not be hindered in its
operation by wax or underbody sealant and must open and
close properly ⇒ Heating, air conditioning; Rep. gr. 87 ; Front
heater and air conditioner .
– Check plenum chamber cover. It must not be damaged and
must be installed correctly (no water should run into the evap‐
orator) ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system; Overview of fitting
locations - components outside passenger compartment .
1. Refrigerant circuit 65
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Check water drainage points of plenum chamber. These
should not be blocked (e.g. by leaves) ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Overview of fitting locations - air condi‐
tioning system; Overview of fitting locations - components
outside passenger compartment .
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
Installation location sand other information about these compo‐
s a c
nents ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting
ce
le
un
pt
locations - air conditioning system .
an
d
itte
y li
erm
ab
ility
1.3.3 Odours from heater and air conditioner
ot p
wit
is n
unit
h re
ole,
spec
urposes, in part or in wh
⇒ page 66
t to the co
⇒ page 67
⇒ page 67
rrectne
Does the odour emanate from the evaporator or heat exchanger?
s
♦ Fishy smell
s o
cial p
f i
– Due to leak in engine's cooling system or in heat exchanger of
nform
heater and air conditioner unit.
mer
atio
om
n
c
i
or
Note n thi
te
sd
iva
o
pr
If the fishy smell is weaker when the temperature is set too “cold”
um
r
fo
en
ng
or stronger when the temperature is set to “warm”, check the heat
t.
yi Co
exchanger for leaks. Cop py
ht. rig
rig ht
py by
o Vo
♦ Smell of a burnt clutch by c lksw
cted agen
Prote AG.
♦ Vapours from foot mats, retrospectively installed seat covers
etc.
♦ Putrid, mouldy smell
– Caused by accumulation of debris, pine needles etc. in plenum
chamber
Note
Clean the plenum chamber.
– Stagnant water that cannot flow out of plenum chamber.
Note
Check the water drainage points in the plenum chamber.
♦ Smell from heater and air conditioner unit
Note
Smells that originate from the heater and air conditioner unit can
be detected in fresh air mode and in recirculation mode.
66 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Due to too much condensate in the heater and air conditioner
unit
Note
Check the condensation drain.
– Due to an old or very dirty dust and pollen filter
Note
Check the dust and pollen filter.
– Due to deposits on the fins of the evaporator
Note
Clean the evaporator with the ultrasonic air conditioner cleaning
unit ⇒ page 67 or suction feed spray-gun and corresponding
spray lance ⇒ page 67 .
Ultrasonic air conditioner cleaning unit . Volkswagen AG
gen AG does
swa
– The ultrasonic air conditioner cleaning unit must be placed yV
olk in not
gu
the front-passenger footwell and sprays the agent Aero-Clean.
ised b ara
nte
Aero-Clean neutralises microbes and bacteriauin th the heater
or eo
ra
and air conditioner unit. ss a c
ce
le
The device is provided with instructions for use.
un
pt
an
d
itte
y li
Current equipment ⇒ Electronic parts catalogue .
erm
ab
ility
ot p
Spraying the evaporator with the suction feed spray-gun and
wit
is n
spray lance
h re
ole,
Directly spray the evaporator with cleaning solution using a spray
spec
urposes, in part or in wh
lance (approx. 10 bar). The cleaning solution neutralises mi‐
t to the co
crobes and bacteria directly on the evaporator.
To enable access to the evaporator, preparatory measures and
different spray lances are required.
rrectne
Vehicle-specific operating instructions are provided with the
evaporator cleaning solution ⇒ Electronic parts catalogue . 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
Prote AG.
1. Refrigerant circuit 67
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.4 Investigating leaks
⇒ “1.4.1 General information about investigating leaks in the re‐
frigerant circuit”, page 68
⇒ “1.4.2 Searching for leaks in refrigerant circuits using an elec‐
tronic leak detector”, page 69
⇒ “1.4.3 Searching for leaks with UV leak detection system”, page
71
⇒ “1.4.4 Detecting leaks in a vacuum test using air conditioner
service station , or in a pressure test”, page 77
⇒ “1.4.5 Detecting leaks in a pressure test (with nitrogen or com‐
pressed air)”, page 77
1.4.1 General information about investigating
leaks in the refrigerant circuit
Note AG. Volkswagen AG d
agen oes
olksw not
♦ Small leaks canedbe by detected with e.g. an electronic gleak
V ua de‐
ran
tector or a UV thorileak
s detector lamp. tee
u or
a a
♦ This workshop
ss manual describes 2 ways of tracing leaks in c
refrigerant circuits. These procedures have been tested and
ce
e
nl
pt
du
lead to a reliable result under the different usage conditions if
an
itte
y li
they are performed correctly and in accordance with the spe‐
erm
ab
cific complaint.
ility
ot p
wit
, is n
♦ Various methods are offered in the open market with which
h re
leaks in refrigerant circuits can be traced. These methods are
hole
spec
not able to provide clear results in all cases and, unless the
es, in part or in w
exact procedure is adhered to, they can also result in various
t to the co
components of the refrigerant circuit being identified as having
leaks even though they do not. Furthermore, certain process‐
es can cause preliminary or permanent damage to the com‐
rrectness of i
ponents of the refrigerant circuit
l purpos
♦ Components that are found to be leaking must not be repaired.
They must be renewed instead.
nform
ercia
♦ A leaking refrigerant circuit must not be charged with refriger‐
m
at
om
ant. Therefore, evacuate an empty refrigerant circuit and
ion
c
check for leaks before charging the system with refrigerant
in t
or
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
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.
68 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ VW/Volkswagen/Audi does not endorse the use of chemical
substances (leak inhibitor additives) for purposes of sealing
leaks in refrigerant circuits.
♦ Chemical substances used to seal leaks form deposits in the
refrigerant circuit. These can impair the function of the air con‐
ditioning system and cause the air conditioning system (and
your air conditioner service station ) to fail.
♦ These chemical substances (leak stop additives) react mostly
with the ambient air or the humidity to stop leaks in the refrig‐
erant circuit. They cause deposits to build up in the refrigerant
circuit (and your air conditioner service station ), cause valves
to malfunction and defects in other components with which
they come into contact. These deposits cannot be completely
removed from the components (not even by cleaning/flush‐
ing). The refrigerant circuit can only be repaired by replacing
all components that have come into contact with this sub‐
stance.
. Volkswagen AG
gen AG
1.4.2 Searching foryleaks ksw in refrigerant circuits
a oes d
not
Vol gu
using an electronic leak detector
d b ara
ise nte
or e
h
ut or
Special tools and workshop
ss
a
equipment required ac
ce
e
nl
♦ Electronic leak detector or proprietary device
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
♦ Leaks in R1234yf refrigerant circuits can only be found using
hole
spec
electronic leak detection devices designed for R1234yf refrig‐
es, in part or in w
erant.
t to the co
♦ The various refrigerants have a different molecular structure.
The sensors of electronic leak detection devices are adapted
rrectness of i
to these molecules. If an electronic leak detection device is
used that is not designed for R1234yf refrigerant, it will not
l purpos
respond to R1234yf refrigerant at all or only in larger concen‐
trations in the vicinity of the leak. For this reason, electronic
nf
ercia
leak detection devices designed only for R134a refrigerant
o
cannot be used for leak detection in the R1234yf refrigerant
rm
m
atio
circuit.
om
n in
or c
♦ Depending on the type of heater and air conditioner unit, a leak
thi
e
from the evaporator can be investigated by holding the test
t
sd
iva
probe of the leak detector against the glove compartment
r
rp
cu
o
cooler connection in the heater and air conditioner unit, or by
f
en
ng
t.
holding the test probe against the open condensation drain
yi Co
op
connection of the heater and air conditioner unit with the con‐
C py
t. rig
gh
densation drain hose pulled off.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Performing leak detection on a completely empty refrigerant cir‐
cuit caused by a leak:
Note
With a completely empty refrigerant circuit, proceed as follows to
ensure that no more refrigerant than necessary enters the envi‐
ronment during testing:
– Evacuate refrigerant circuit using air conditioner service sta‐
tion ⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
1. Refrigerant circuit 69
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If a larger leak is detected during the evacuation process, de‐
termine the cause and rectify as described
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
♦ If during the evacuation process no leak is detected or a very
small leak is detected that cannot be located using the vacuum
test, proceed as follows.
– If the refrigerant circuit is completely empty, charge theGsystem olksw
with approx. 10% of refrigerant and perform leak en A . V in agen AG doe
agdetection
lksw s no
the same way as per a fully charged refrigerant by
Vo circuit t gu
ara
⇒ page 70 . rised
nte
ho eo
ut
Performing leak detection on a charged
ss
a refrigerant circuit: ra
c
ce
e
– Switch off ignition.
nl
pt
du
an
itte
y li
– Start the leak detector according to the operating instructions.
erm
ab
ility
ot p
– Always hold probe tip under location of suspected leak.
wit
, is n
h re
If, inherent of the design, the rate of clicks rises or a wailing noise
hole
is heard, a leak has been detected ⇒ operating instructions for
spec
es, in part or in w
leak detector .
t to the co
Note
rrectness of i
♦ Refrigerant gas is quickly dispersed by movement of air.
l purpos
Draughts must therefore be avoided during leak detection.
♦ Refrigerant gas is heavier than air and therefore sinks at the
nf
ercia
o
point at which it escapes.
rm
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.
70 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
n AG. Volkswagen AG do
wage
1.4.3 Searching for leaks with UV leak detec‐ lks es n
o ot g
byV ua
tion system
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ Certain leaks are difficult or impossible to find using an elec‐
ility
ot p
tronic leak detection device. To investigate these leaks, leak
wit
, is n
detection can be performed using the leak detection system
h re
⇒ Electronic parts catalogue .
hole
spec
es, in part or in w
♦ Refrigerant and refrigerant oil leaks out of the refrigerant circuit
t to the co
when the circuit has a leak. This oil generally remains in the
vicinity of the leak location. To make the oil visible under UV
light, a small amount of fluorescent fluid must be added to the
rrectness of i
refrigerant circuit. This fluid (PAG oil with an additive which
lights up under UV light) is injected into the refrigerant circuit
l purpos
and distributed with the refrigerant oil when the air conditioning
system is switched on.
nform
ercia
♦ The air conditioning system must be operated for at least
60 minutes to ensure that the injected leak detecting additive
m
at
om
i
is distributed throughout the entire refrigerant circuit (air con‐
on
c
in t
ditioner compressor must run). The leak may become visible
or
his
e
under UV light after a short period, but this depends on the
at
do
riv
size of the leak.
p
cum
for
en
g
♦ The refrigerant oil with additive, which lights up under UV light,
n
t.
yi Co
can be added directly in an open circuit or charged after emp‐ Cop py
. rig
tying the circuit with air conditioner service station via the
t
gh ht
yri by
service connection. cop Vo
by lksw
cted agen
Prote
♦ If the leak detection additive is added to the refrigerant circuit
AG.
via the service connection, a small amount of leak detection
additive will be deposited in the service connection. Carefully
remove any deposits so that this area is not mistaken for a leak
during subsequent leak detection.
♦ If a component from a circuit in which leak detection additive
is filled is renewed, thoroughly clean the connection points to
other components after assembling the refrigerant circuit. Dur‐
ing subsequent leak detection, deposits of leak detection ad‐
ditive could otherwise be mistaken for leaks at the connecting
point.
♦ When purging the refrigerant circuit, refrigerant oil and there‐
fore also leak detection additive also enter the air conditioner
service station . The refrigerant oil is separated from the re‐
frigerant in the oil separator of the air conditioner service
station and removed from the air conditioner service station
via the drainage outlet. The drained refrigerant oil may not be
reused. It must be replaced with fresh refrigerant oil.
♦ If leak detection fluid was injected during a previous repair of
the refrigerant circuit, observe the following: do not inject new
leak detection fluid unless the refrigerant machine oil has been
replaced. If only some of the refrigerant machine oil was re‐
placed then only the respective amount of leak detection fluid
should be injected. If, for example, 100 ml of refrigerant oil is
replaced in a vehicle with 250 ml of refrigerant oil, inject only
1 ml (cm3) of leak detection additive.
♦ Certain materials and their compounds (e.g. oxidisation prod‐
ucts on components made from aluminium, corrosion protec‐
tion wax, etc.) also light up under UV light.
1. Refrigerant circuit 71
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Depending on the type of air conditioner service station , it can
also be used to add the leak detection additive directly into the
system. See the operating instructions of your air conditioner
service station ⇒ Operating instructions air conditioner service
station .
Leak detection on an empty, leaking refrigerant circuit
– With a completely empty refrigerant circuit, proceed as follows
to ensure that no more refrigerant than necessary enters the
environment during testing:
– Evacuate refrigerant circuit with air conditioner service station
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
Note
If a larger leak is detected during the evacuation process, deter‐
mine the cause and rectify as described
⇒ “1.4.4 Detecting leaks in a vacuum test using air conditioner
service station , or in a pressure test”, page 77 and
⇒ “2.5 Evacuating refrigerant circuit”, .page 135 .
Volkswag
AG en AG
agen does
olksw not
If during the evacuation ed bprocess no leak is detected or a very
y V gu
ara
small leak is detectedhoris that cannot be located during evacuation, nte
eo
proceed as follows.aut ra
c
ss
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Only use UV leak detection additive approved for R1234yf re‐
ot
wit
frigerant.
, is n
h re
hole
♦ The leak detection additive contains refrigerant oil for the most
spec
part. Since special refrigerant oils are required for R1234yf
es, in part or in w
t to the co
refrigerant, only UV leak detection additives may be used that
use this oil as a carrier. UV leak detection additives developed
for R134a refrigerant are therefore unsuitable.
rrectness of i
♦ For refrigerant circuits with R1234yf and R134a refrigerant,
l purpos
different refrigerant oils (PAG oils) are used, which is why it is
important to ensure correct allocation of the leak detection ad‐
ditive (PAG oil with an additive that lights up under UV light).
nform
ercia
♦ Charge the refrigerant circuit with UV leak detection additive
m
using the air conditioner service station ⇒ page 75 .
com
tion in
r
♦ Charge the refrigerant circuit with UV leak detection additive
te o
thi
using the leak detection system ⇒ page 75 .
s
iva
do
r
rp
cum
fo
en
g
– Charge the refrigerant circuit with the specified amount of UV
n
t.
yi Co
leak detection additive and the requisite amount of refrigerant t. Cop py
⇒ page 72 , ⇒ “2.6 Charging refrigerant circuit”, page 141
rig
gh ht
yri by
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data . op Vo
by c lksw
cted agen
Prote
– Run the air conditioning system for at least 60 minutes with
AG.
the air conditioner compressor switched on.
– Investigate leaks with UV leak detection system
⇒ page 75 .
Charge the refrigerant circuit with UV leak detection additive using
the air conditioner service station .
– Charge the refrigerant circuit with UV leak detection additive
and the requisite amount of refrigerant using air conditioner
service station ⇒ “2.6 Charging refrigerant circuit”, page 141
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data .
72 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant
wage
n AG. VoR1234yf - General
lkswagen AG
doe information - Edition 01.2018
ks s no
Vol t gu
d by ara
e nte
ris
tho eo
Note au ra
c
ss
ce
e
nl
♦ The amount of UV leak detection additive to be charged in the
pt
du
an
itte
refrigerant circuit with a refrigerant oil volume up to 150 cm3
y li
erm
ab
is 3.0 ± 0.5 ml. If the volume of refrigerant oil in the refrigerant
ility
circuit is greater, more UV leak detection additive must be ot p
wit
, is n
added accordingly, e.g. 5.0 ± 0.5 ml in a refrigerant circuit with
h re
a refrigerant oil volume of 250 cm3. If the UV leak detection
hole
spec
additive is filled with an air conditioner service station , the
es, in part or in w
volume to be set in your air conditioner service station may
t to the co
differ. Therefore, observe the relevant operating instructions
⇒ Operating instructions Air conditioner service station .
rrectness of i
♦ For the specific volume of refrigerant oil in the refrigerant cir‐
cuit, refer to the vehicle-specific workshop manual ⇒ Heating,
l purpos
air conditioning; Rep. gr. 00 ; Technical data .
♦ If leak UV leak detection additive was injected during a previ‐
nform
ercia
ous repair of the refrigerant circuit, observe the following: do
m
not inject new UV leak detection additive unless the refrigerant
at
om
io
machine oil has been replaced. If only some of the refrigerant
n
c
in t
r
machine oil was replaced then only the respective amount of
o
his
e
UV leak detection additive should be injected. If, for example,
at
do
riv
50 ml of refrigerant oil is replaced in a vehicle with 150 ml of
p
cum
or
refrigerant oil, inject only 1.0 ml (cm3) of UV leak detection
f
en
ng
t.
yi
additive.
Co
Cop py
t. rig
gh ht
yri by
The leak detection system comprises the following parts: cop Vo
by lksw
cted agen
Prote
♦ Cleaning agent -3-
AG.
♦ UV leak detection lamp -4-
♦ UV absorbing eye protection -5-
♦ Sticker -6-
♦ Gloves -8-
Note
Items -1-, -2- and -7- in the diagram can be disregarded.
Special tools and workshop equipment required
♦ Leak detecting system
♦ Air conditioner service station with means of adding UV leak
detection additive in the refrigerant circuit ⇒ Electronic parts
catalogue .
♦ Approved leak detection additive ⇒ Electronic parts cata‐
logue .
– Evacuate the refrigerant circuit as per the instructions, and
charge the system with UV leak detection additive and refrig‐
erant ⇒ “2.5 Evacuating refrigerant circuit”, page 135 and
⇒ “2.6 Charging refrigerant circuit”, page 141 .
– Wait until the pressures on the high pressure and low pressure
side have settled.
1. Refrigerant circuit 73
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Detach the air conditioner service station from the refrigerant
circuit and switch off
⇒ “2.8 Switching off air conditioner service station and sepa‐
rating from refrigerant circuit”, page 146 .
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
74 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
. Volkswagen AG
Air conditioning
s wa systems
gen AG with refrigerant
does R1234yf - General information - Edition 01.2018
k not
Vol gu
d by ara
– Attach a orislabel close to the service connections thatntshows
e
ee that
the refrigerant
auth circuit has been injected with a UV leakor detec‐
ac
tionss additive.
ce
le
un
pt
– Remove any remains of UV leak detection additive from the
an
d
itte
service connection e.g. with absorbent paper, and clean the
y li
erm
ab
area with cleaning agent - VAS 6201/3- .
ility
ot p
wit
– Seal the service connection with a cap.
is n
h re
ole,
– Bring the air conditioning system into operation.
spec
urposes, in part or in wh
– Run the air conditioning system for at least 60 minutes with
t to the co
the air conditioner compressor switched on.
– Search for leaks in the refrigerant circuit using a UV lamp
rrectne
⇒ page 75 .
Searching for leaks in refrigerant circuit using a UV lamp
ss o
cial p
f i
CAUTION
nform
mer
Risk of eyes being dazzled by UV light.
atio
om
– Wear protective goggles.
n
c
i
or
n thi
e
– Never glare into the UV lamp.
t
sd
iva
o
r
– Never point a UV lamp at another person.
p
cum
r
fo
en
ng
t.
yi Co
op
– On vehicles with high-voltage system, switch off “stationary air
C py
t. rig
conditioning” function (deactivate)⇒ Owner's Manual and ⇒
gh ht
yri by
Operating instructions of infotainment/MMI .
cop Vo
by lksw
cted agen
Prote AG.
– Switch off ignition.
1. Refrigerant circuit 75
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
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
under UV light after a short period, but this depends on the
size of the leak.
♦ Depending on the size and location of the leak, it can take
several days until sufficient refrigerant oil with UV leak detec‐
tion additive has leaked out and the leak can be easily identi‐
fied as such.
♦ 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 work, a check of the con‐
densed water drain point can indicate a leaking evaporator.
This does however require the additive to have been in the
refrigerant circuit for a lengthy period (several days).
♦ The protective eye wear is not only required to protect the
eyes. It also amplifies the illumination of the UV leak detection
additive under the UV lamp.
♦ Depending on how easy it is to reach various components in
the refrigerant circuit, it may be necessary to remove certain
parts from the vehicle (e.g. bumper or air filter).
AG. Volkswagen AG d
♦ Only a small amount of refrigerant oil reaches certainlksareas
wage of
n oes
not
the refrigerant circuit during operation of the aird bconditioning
yV
o gu
ara
system (e.g. a cap fitted at the top of a receiver
oris installed on
e nte
the condenser). If there is a leak in theseauareas,
th it may take eo
ra
quite some time before a sufficient quantity
ss of refrigerant with c
refrigerant oil and additive escapes at this point and can be lit
ce
le
un
pt
up under UV light showing where the leak is. At these points,
an
d
itte
y li
therefore, it may be more pertinent to search for a leak using
erm
ab
an electronic leak detection device
ility
ot p
⇒ “1.4.2 Searching for leaks in refrigerant circuits using an
wit
is n
electronic leak detector”, page 69 . h re
ole,
spec
urposes, in part or in wh
t to the co
– Position the vehicle in a darker area of the workshop (in day‐
light or under strong lighting the effect of the UV lamp is greatly
reduced).
rrectne
– Check accessibility to various components of the refrigerant
circuit and remove parts in the vicinity of the refrigerant circuit
s
that obstruct the view of the refrigerant circuit components
s o
(e.g. noise insulation and bumper).
cial p
f inform
– Protect eyes with safety goggles.
mer
atio
m
– Connect UV lamp to a 12 V battery (vehicle battery). Ensure
o
n
c
that the polarity of the connections is correct.
or
n thi
te
sd
va
– Switch on the UV lamp and light up the components in the
i
o
pr
cum
refrigerant circuit. Positions at which refrigerant - along with
r
fo
en
ng
refrigerant oil and leak detection additive - can leak out fluo‐
t.
yi Co
resce (light-up) under UV light. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
76 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.4.4 Detecting leaks in a vacuum test using
air conditioner service station , or in a
pressure wagtest
olkswagen AG
en AG. V does
olks
V
no
t gu
by ara
All vehicles rised nte
o th eo
au ra
CAUTION
ss c
ce
e
nl
pt
Risk of freezing injury caused by escaping pressurised refrig‐
du
an
itte
erant.
y li
erm
ab
There is a risk of injury to the skin and parts of the body due to
ility
ot p
freezing.
wit
, is n
h re
– Wear protective gloves.
hole
spec
– Wear protective goggles.
es, in part or in w
t to the co
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
rrectness of i
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
l purpos
erant circuit from continued evaporation.
nf
ercia
o
– Switch off ignition.
rm
m
atio
m
♦ Detecting leaks in a vacuum test using air conditioner service
o
n in
c
station , or in a pressure test
or
thi
e
⇒ “2.5 Evacuating refrigerant circuit”, page 135
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
♦ Smaller leaks in the refrigerant circuit (less than 100 g refrig‐
pyri by
Vo
o
by c
erant loss per year) cannot usually be found by means of the
lksw
cted agen
Prote
vacuum test or pressure test. The amount of air entering the
AG.
system or the nitrogen-air escaping it is too low to detect the
faulty area through noise.
♦ It is also not always possible to detect leaks in the refrigerant
circuit with more than 100 g refrigerant loss per year by means
of the vacuum test or pressure test, depending on the envi‐
ronmental conditions (noise around the area, location of leak,
etc.). The air entering the system and nitrogen escaping it
could be too low to generate a noise that would be noticeable
in the faulty area.
♦ Larger leaks in the refrigerant circuit (e.g. more than 100 g
refrigerant loss per day caused by a stone hitting the con‐
denser) can be detected depending on the environmental
conditions, e.g. noise coming from the faulty area, which is
noticeable during the vacuum test or pressure test
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
– Perform vacuum or pressure test ⇒ page 138 .
1.4.5 Detecting leaks in a pressure test (with
nitrogen or compressed air)
♦ Perform a vacuum test using the air conditioner service station
to see if any leaks can be found
⇒ “2.5 Evacuating refrigerant circuit”, page 135 . If a leak can
be detected but not the exact location of the leak, an additional
pressure test can be performed using nitrogen or compressed
air ⇒ page 138
1. Refrigerant circuit 77
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Smaller leaks in the refrigerant circuit (less than 100 g refrig‐
erant loss per year) cannot usually be found by means of the
vacuum test or pressure test. The amount of air entering the
system or the nitrogen-air escaping it is too low to detect the
faulty area through noise.
♦ It is also not always possible to detect leaks in the refrigerant
circuit with more than 100 g refrigerant loss per year by means
of the vacuum test or pressure test, depending on the envi‐
ronmental conditions (noise around the area, location of leak,
etc.). The air entering the system and nitrogen escaping it
could be too low to generate a noise that would be noticeable
in the faulty area.
♦ Larger leaks in the refrigerant circuit (e.g. more than 100 g
refrigerant loss per day caused by a stone hitting the con‐
denser) can be detected depending on the environmental
conditions, e.g. noise coming from the faulty area, which is
noticeable during the vacuum test or pressure test
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
♦ A larger leak in the refrigerant circuit can be detected, for ex‐
ample, by pressurising the circuit to a maximum of 15 bar using
cleaned and dried compressed air or nitrogen ⇒ page 119 . If
the leak is large enough, the leakage point can be detected by
sound as the gas escapes.
n AG. Volkswagen AG do
lkswage es n
Tools required: d byV
o ot g
ua
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
78 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Quick-release coupling adapter -A- (you can also unscrew the
adapter from your air conditioner service station and use it for
this test).
♦ Charge hose -A- (e.g. with a M12 x 1.5-6G thread, SAE J639
standard), depending on the thread of the quick-release cou‐
pling adapter (cut off), with a suitable adapter -B- (for connec‐
tion to the compressed air system used in your workshop or
to a pressure reducer for nitrogen)
♦ Combination fine filter element for compressed air system with
an oil, dirt and water separator (to ensure that the refrigerant
circuit is pressurised with compressed air that is clean, dry and
free of oil) for the leakage test with compressed air
♦ Manifold gauge with pressure reducer for nitrogen (maximum
reduced pressure: 15 bar) -1-, a full nitrogen gas cylinder -3-
and a charge hose -2- (e.g. with M12 x 1.5-6G thread in
accordance with SAE J639, to which a quick-release coupling
adapter for service connection is fitted) for leakage test with
nitrogen
– Perform pressure test ⇒ page 138 .
1.5 Renewing components
⇒ “1.5.1 General information about renewing components”, page
79
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐
frigerant circuit (apart from air conditioner compressor and re‐
ceiver)”, page 81
⇒ “1.5.3 Renewing leaking or damaged components of charged
refrigerant circuit (apart from air conditioner compressor and re‐
ceiver)”, page 84 Volkswa AG. gen AG
agen do
⇒ “1.5.4 Renewing air conditioner olkscompressor with no need
w es n
to
ot g
yV
clean refrigerant circuit”, page
sed b 85 . ua
ran
ri tee
ho
⇒ “1.5.5 Renewing airauconditioner
t compressor due to leaks or in‐ or
ac
ternal damage”, page
ss 87
ce
e
nl
pt
du
⇒ “1.5.6 Renewing desiccant cartridge / receiver after cleaning
an
itte
y li
refrigerant circuit”, page 88
erm
ab
ility
ot p
⇒ “1.5.7 Renewing receiver with no need to clean refrigerant cir‐
wit
cuit”, page 90 .
, is n
h re
hole
⇒ “1.5.8 Renewing desiccant cartridge / desiccant bag with no
spec
need to clean refrigerant circuit”, page 91
es, in part or in w
t to the co
1.5.1 General information about renewing
components
rrectness of i
The receiver or desiccant cartridge need not be renewed under
l purpos
the following circumstances:
♦ The opened refrigerant circuit is sealed immediately with clean
nf
ercia
plugs, e.g. from the engine bung set - VAS 6122- .
rm
m
atio
m
♦ After an accident in which there was no damage to the receiv‐
o
n in
c
er.
or
thi
te
sd
a
♦ Repairs are performed quickly (not for longer than the normal
iv
o
r
rp
cu
repair time).
o
m
f
en
ng
t.
yi
♦ The vehicle is no more than 5 years old.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Refrigerant circuit 79
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
The receiver or dryer cartridge should be renewed under the fol‐
lowing circumstances:
♦ The refrigerant circuit has been opened for in indeterminate
period (seepage leak).
♦ The receiver is damaged (e.g. in an accident).
♦ Repairs are performed over a longer time than the normal re‐
pair time. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
♦ The refrigerant circuit was opened and the vehicle eisd bmore
y than ara
5 years old. ho
ris nte
eo
t
au ra
♦ The refrigerant circuit has been blown through
ss with nitrogen. c
ce
le
un
pt
♦ The refrigerant circuit has been flushed with R1234yf.
an
d
itte
y li
♦ The air conditioner compressor seizes.
rm
ab
pe
ility
ot
• All components of the refrigerant circuit that were submitted to
wit
, is n
quality monitoring must be sealed (use the original sealing
h re
hole
caps from the replacement part).
spec
es, in part or in w
• Renew damaged or leaky components of the refrigerant circuit
t to the co
⇒ page 79 .
• All components of the refrigerant circuit that were submitted to
rrectness of i
quality monitoring must be sealed (use the original sealing
caps from the replacement part).
l purpos
• The replacement air conditioner compressor, receiver, evap‐
orator and condenser were previously charged with nitrogen.
nform
ercia
This filling is being gradually discontinued, or the pressure of
m
the nitrogen filling is so low that escaping gas is no longer
a
com
ti
perceptible when the part is initially opened.
on in
r
te o
thi
• Where vehicles are fitted with an air conditioner compressor
s
iva
do
without a magnetic clutch, the engine should be started only
r
rp
c
when the refrigerant circuit has been fully assembled (since
um
fo
en
g
the air conditioner compressor will always run when the engine
n
t.
yi Co
is running) . Cop py
t. rig
gh ht
yri
• The air conditioner compressor with air conditioner compres‐ p by
co Vo
lksw
sor regulating valve - N280- (without air conditioning system
by
cted agen
Prote
magnetic clutch - N25- ) is switched to internal lubrication in
AG.
the event of an empty refrigerant circuit, in which case only a
small amount of oil is pumped from the air conditioner com‐
pressor into the circuit.
80 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The following replacement parts (air conditioner compressor,
receiver, evaporator and condenser) could be filled with nitro‐
gen gas, though this filling is not always guaranteed. There‐
fore, little or no pressure equalisation may be perceived when
the sealing plugs of the replacement part are unscrewed.
♦ Depending on the storage location and storage period, it is
possible on components filled with nitrogen ex-works that
barely any pressure equalisation - if at all - is perceptible and,
as such, nothing can be said about the leak-tightness of the
component. This means, for example, that the nitrogen gas
filling could escape through the shaft seal of a replacement air
conditioner compressor in the course of time, even though the
air conditioner compressor is leak-tight.
♦ Since spare parts are sometimes stored for long periods in
various places, there is a good chance that gas may escape
from some parts when first opened but not from others (even
of the same part number). Therefore, be careful when un‐
screwing the sealing plugs from the replacement part connec‐
tions and allow the nitrogen gas to escape slowly.
♦ One or 2 expansion valves and a receiver or desiccant con‐
tainer are installed in the refrigerant circuit ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - refrigerant circuit .
♦ Renew the desiccant cartridge or components with desiccant
bag (receiver) aftergecleaning
n AG. Volksthe
wagerefrigerant
n AG d circuit (flush with
R1234yf refrigerant
olkswa oes
not
⇒ “1.6 Cleaning
ed
by
V
refrigerant circuit”, page 92 g).uaWhen
ran doing
so, keep
horis the circuit closed for as long as possible teeto keep the
ingress
sa
ut
of moisture as low as possible. ora
c
s
♦ Seal open connections and pipes (to prevent absorption of
ce
le
un
pt
moisture).
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Contaminated refrigerant oils are to be disposed of as used oil of
es, in part or in w
t to the co
unknown origin (observe local regulations) ⇒ VW / Audi Service‐
Net .
rrectness of i
1.5.2 Renewing leaking or damaged compo‐
l purpos
nents of empty refrigerant circuit (apart
from air conditioner compressor and re‐
nform
ercia
ceiver)
m
a
com
tio
The refrigerant circuit was completely empty (e.g. larger leaks or
n in
ruptured hose line)
r
te o
thi
s
iva
do
♦ Observe the general information about renewing components
r
rp
cum
⇒ “1.5.1 General information about renewing components”,
fo
en
g
page 79
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Refrigerant circuit 81
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If there is just a small leak and the refrigerant only escaped in
small quantities (e.g. small leakage point), the amount of re‐
frigerant oil that escapes and the degree of moisture ingress
are not enough to impair the function of the air conditioning
system once the repair has been carried out.
♦ The measures marked with * should only be performed if leaks
are more pronounced (e.g. following an accident).
Electrical air conditioner compressor
– Remove defective component * ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
circuit . Volkswa AG. gen AG
agen do
– Remove electrical air conditioning Vol compressor and clean
ksw es n
ot g
(flush with R1234yf refrigerant) d by * ua
ran
ise
⇒ “1.6 Cleaning refrigerant
thor circuit”, page 92 and ⇒ Heating, tee
or
air conditioning; Rep.ssgr.
au 87 ; Air conditioner compressor; Re‐ ac
moving and installing electrical air conditioning compressor
ce
le
un
(vehicle-specific workshop manual).
pt
an
d
itte
y li
– Clean the refrigerant circuit (flush with R1234yf refrigerant)*
rm
ab
pe
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
ility
ot
wit
, is n
– Completely charge the air conditioner compressor or refriger‐
h re
ant circuit with the requisite amount of oil
hole
spec
⇒ “1.5.4 Renewing air conditioner compressor with no need to
es, in part or in w
clean refrigerant circuit”, page 85 and ⇒ Heating, air condi‐
t to the co
tioning; Rep. gr. 00 ; Technical data (approved refrigerant oils
and fill capacities for refrigerant oil in vehicle-specific work‐
shop manual). rrectness of i
Mechanical air conditioner compressor
l purpos
– Remove defective component * ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
nform
ercia
circuit .
m
a
com
– Remove air conditioner compressor.* ⇒ Heating, air condi‐
ion in
tioning; Rep. gr. 87 ; Air conditioner compressor .
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
82 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Unscrew oil drain plug -B- / -D- from air conditioner compres‐
sor -A-.*
Note
♦ The design of the oil drain plug -B- / -D- and seal -C- / -E- may
vary (depending on the manufacturer of the air conditioner
compressor) ⇒ Heating, air conditioning; Rep. gr. 87 ; Air
conditioner compressor (vehicle-specific workshop manual).
♦ When installing the oil drain plug -B-/-D-, observe the corre‐
sponding torque specification (depending on the manufacturer
of the air conditioner compressor and the design of the oil drain
plug). Please note that the oil drain plug of air conditioner AG. Volkswagen AG d
agen oes
ksw
compressors manufactured by Denso and Delphi by V is equipped
ol not
gu
with an oil seal ⇒ Heating, Air conditioning; ris Rep. gr. 87 ; Air
ed ara
nte
conditioning compressor, Assembly overviewut
ho - drive unit of air eo
ra
conditioner compressor (currently valid
ss a
specified torque: c
30 Nm for “Denso” and 15 Nm for “Delphi” air conditioner com‐
ce
e
nl
pt
pressor). The oil drain plug of air conditioner compressors
du
an
itte
manufactured by “Sanden” and “Zexel- / Valeo” may be equip‐
y li
erm
ab
ped with an O-ring or an oil seal (depending on the vehicle
ility
ot p
equipment; currently valid specified torque: 10 Nm, respec‐
wit
, is n
tively).
h re
hole
spec
♦ On the Denso air conditioner compressor, for example, the oil
es, in part or in w
drain plug -D- has an oil seal -E-; renew ⇒ Heating, air con‐
t to the co
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific workshop manual) and ⇒ Electronic parts catalogue .
rrectness of i
♦ On the Sanden air conditioner compressor, for example, the
oil drain plug -B- has a seal -C-; renew ⇒ Heating, air condi‐
l purpos
tioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific workshop manual) and ⇒ Electronic parts catalogue .
nform
ercia
♦ If the seal fitted on the oil drain plug is not available as a re‐
placement part, it may be reused. However, check before
m
at
om
reinstalling to ensure that it is not damaged. Replace with a
ion
c
commercially available seal if necessary.
in t
or
his
ate
♦ After filling the refrigerant circuit, check the installed oil drain
do
riv
plug for leaks using e.g. an electronic leak detector.
p
cum
for
en
ng
t.
♦ To speed up draining of the refrigerant oil, rotate the shaft of
yi Co
op
the air conditioner compressor e.g. using the belt pulley or the
C py
ht. rig
magnetic clutch pulley.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pour out old refrigerant oil from the air conditioner compressor
*
⇒ “1.5.4 Renewing air conditioner compressor with no need to
clean refrigerant circuit”, page 85 (disposal ⇒ VW / Audi
ServiceNet ).
1. Refrigerant circuit 83
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
All vehicles
Note
♦ Then pour new refrigerant oil in the air conditioner compressor
in a volume that equates to the refrigerant oil in the replace‐
ment compressor * ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data; refrigerant oil .
♦ Different refrigerant oil and volumes for different air condition‐
er compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data; refrigerant oil .
♦ 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 40 cm3 of refrigerant oil; the re‐
mainder can be poured e.g. into the new reservoir or receiver
or a refrigerant line ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data; refrigerant oil .
♦ If dirt enters the air conditioner compressor whilst the refrig‐
erant circuit is open (e.g. after an accident), the air conditioner
compressor is to be renewed ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor
wage
n AG. .Volkswagen AG do
e
olks s no
t
♦ Clean the refrigerant
ed
circuit
by
V
(flush with R1234yf refrigerant)
gu *
ara
⇒ “1.6 Cleaning hrefrigerant
or
is circuit”, page 92 . nte
eo
t
au ra
c
ss
– Renew desiccant cartridge and receiver ⇒ Heating, air con‐
ce
le
un
pt
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
an
d
itte
refrigerant circuit .
y li
erm
ab
ility
– Assemble the refrigerant circuit, evacuate and refill
ot p
⇒ page 124 .
wit
is n
h re
ole,
spec
1.5.3 Renewing leaking or damaged compo‐
urposes, in part or in wh
t to the co
nents of charged refrigerant circuit
(apart from air conditioner compressor
rrectne
and receiver)
There is still refrigerant in the refrigerant circuit (e.g. the leak is
ss
small)
o
cial p
f inform
♦ Observe the general information about renewing components
mer
⇒ “1.5.1 General information about renewing components”,
atio
m
page 79
o
n
c
i
or
n thi
– Drain refrigerant circuit ⇒ page 124 .
te
sd
iva
o
r
– Remove the defective part, blow through with compressed air
p
cum
r
fo
and collect any escaping refrigerant oil.
en
ng
t.
yi Co
op
– The refrigerant oil that is blown out (plus 20 cm3 for the evap‐
C py
t. rig
gh ht
orator, plus 10 cm3 for the condenser, refrigerant lines and pyri by
Vo
co
refrigerant hoses) should be poured into the new component
by lksw
cted agen
Prote
as fresh refrigerant oil.
AG.
Note
Dispose of old refrigerant oil (observing local regulations) ⇒ VW /
Audi ServiceNet .
– Assemble the refrigerant circuit, evacuate and charge
⇒ page 124 .
84 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.5.4 Renewing air conditioner compressor
with no need to clean refrigerant circuit
Note
Clean the refrigerant circuit. In other words, flush with R1234yf
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ Observe the general information about renewing components
⇒ “1.5.1 General information about renewing components”,
page 79
For example with external damage from an accident
– Drain refrigerant circuit
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor .
Electrical air conditioner compressor
– Flush the defective electrical air conditioning compressor to
remove the refrigerant oil (make a note of the volume of re‐
frigerant oil flushed out)
⇒ “2.11 Cleaning electrical air conditioning compressor”, page
150 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
Note rised ara
nte
ho eo
aut ra
♦ If the volume of refrigerant
ss oil flushed out of the defective air c
conditioner compressor is more than 75% of that in the re‐
ce
e
nl
pt
du
placement air conditioner compressor, do not flush the re‐
an
itte
y li
placement air conditioner compressor (a residual amount
erm
ab
always remains in the air conditioner compressor, which
ility
ot p
means that the amount of refrigerant oil in the refrigerant circuit
wit
, is n
is negligible).
h re
hole
spec
♦ If less than 75% of the specified amount of refrigerant oil is
es, in part or in w
flushed out of the defective air conditioner compressor, the
t to the co
remaining amount is still in the components of the refrigerant
circuit. To prevent the system from being overfilled with refrig‐
erant oil, the refrigerant circuit or the electrical air conditioning
rrectness of i
compressor is to be flushed.
l purpos
– Flush the refrigerant circuit or new electrical air conditioning
compressor to remove the refrigerant oil
nform
ercia
⇒ “1.6 Cleaning refrigerant circuit”, page 92 and
⇒ “2.11 Cleaning electrical air conditioning compressor”, page
m
at
om
150 .
on
c
in t
or
– Dispose of refrigerant oil flushed out of defective and new air
his
ate
conditioner compressor / refrigerant circuit ⇒ VW / Audi Serv‐
do
priv
iceNet (observe local regulations).
um
for
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
The design of the electrical air conditioning compressor is such Prote AG.
that flushing is a requisite to remove the refrigerant oil (the refrig‐
erant oil cannot be poured out as is the case with mechanical air
conditioning compressors with oil drain plug)
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐
frigerant circuit (apart from air conditioner compressor and re‐
ceiver)”, page 81 .
1. Refrigerant circuit 85
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Arteon 2018 ➤ , Atlas 2017 ➤ rise , CC 2012 ➤ , Caddy 2016 ➤ , Crafteran201
d b ar
te
...
Air conditioning systems awith
ut
ho
refrigerant R1234yf - General information -e oEditionra 01.2018
ss c
ce
le
– Only fill the replacement air conditioner compressor with fresh
un
pt
refrigerant oil equivalent to volume of oil that was flushed out
an
d
itte
y li
(from the defective air conditioner compressor).
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
urposes, in part or in wh
♦ If for instance 70 cm3 refrigerant oil was poured out of the de‐
t to the co
fective air conditioner compressor, and 140 cm3 oil was pour‐
ed out of the replacement air conditioner compressor (a small
quantity of refrigerant oil remains in the air conditioner com‐
rrectne
pressor and potentially in the air conditioner service station ).
The air conditioner compressor to be installed must be filled
s
in this instance with 70 cm3 of refrigerant oil (the refrigerant oil
s o
cial p
f
flushed out of the replacement air conditioner compressor
in
must not be used as it may have been contaminated in the air
form
mer
conditioner service station ).
atio
om
n
♦ Different refrigerant oils and volumes for different air condi‐
c
i
or
n
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;
thi
te
sd
a
Technical data .
iv
o
pr
cum
r
fo
♦ If quite a large amount of refrigerant oil was flushed out of the
en
ng
t.
defective air conditioner compressor (more than approx.
yi Co
op py
40 cm 3), the remaining refrigerant oil can also be poured in
t. C rig
gh ht
the evaporator, a refrigerant line or the reservoir/receiver/inner pyri by
Vo
co
heat exchanger ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
by lksw
cted agen
Prote
frigerant circuit; System overview - refrigerant circuit , ⇒
AG.
Heating, air conditioning; Rep. gr. 00 ; Technical data .
Mechanical air conditioner compressor
– Remove oil drain plug from air conditioner compressor ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
Note
If the seal fitted on the oil drain plug is not available as a replace‐
ment part, it may be reused. However, check before reinstalling
to ensure that it is not damaged. Replace with a commercially
available seal if necessary.
– To speed up draining of the refrigerant oil, rotate the shaft of
the air conditioner compressor using e.g. the magnetic clutch
pulley.
– Pour out old refrigerant oil from the air conditioner compressor
and dispose ⇒ VW / Audi-ServiceNet (observe local regula‐
tions).
– Remove oil drain screw from replacement air conditioner com‐
pressor, pour out refrigerant oil and replace it with only the
quantity of fresh refrigerant oil equal to the amount of refrig‐
erant oil poured out of the defective air conditioner compressor
⇒ “1.5.2 Renewing leaking or damaged components of empty
refrigerant circuit (apart from air conditioner compressor and
receiver)”, page 81 .
86 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If for instance 50 cm3 refrigerant oil was poured out of the de‐
fective air conditioner compressor, and 100 cm3 oil was pour‐
ed out of the replacement air conditioner compressor (a small
quantity of refrigerant oil remains in the air conditioner com‐
pressor), pour 50 cm3 refrigerant oil into the replacement air
conditioner compressor (the refrigerant oil previously poured
from the air conditioner compressor spare part may be used).
♦ Different refrigerant oils and volumes for different air condi‐
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data .
♦ If quite a large amount of refrigerant oil was poured out of the
defective air conditioner compressor (more than approx. 50
cm 3), the remaining refrigerant oil can also be poured in the
evaporator or reservoir/receiver/inner heat exchanger ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
AG. Volkswagen AG d
overview - refrigerant circuit . lksw
agen oes
n o ot g
yV ua
db ran
All ir se tee
ho
aut or
ac
– Renew restrictor (only if installed in this refrigerant
ss circuit).
ce
le
un
pt
– Assemble the refrigerant circuit, evacuate and charge
an
d
itte
⇒ page 124 .
y li
rm
ab
pe
ility
1.5.5 Renewing air conditioner compressor
ot
wit
, is n
due to leaks or internal damage
h re
hole
spec
♦ Observe the general information about renewing components
es, in part or in w
t to the co
⇒ “1.5.1 General information about renewing components”,
page 79
Vehicles with high-voltage system (hybrid vehicles)
rrectness of i
– Observe the risk category of the high-voltage system ⇒ Rep.
l purpos
gr. 00 ; Risk category of the high-voltage system .
– Observe safety precautions when working on the high-voltage
nform
ercia
system
m
⇒ “1.5 Safety measures for working on vehicles with high-volt‐
a
com
tio
age system”, page 3 .
n in
r
te o
thi
– Observe safety precautions when working in the vicinity of s
iva
do
high-voltage components
r
rp
cum
⇒ “1.6 Safety precautions when working in the vicinity of high-
fo
en
g
voltage components”, page 4 .
n
t.
yi Co
Cop py
All vehicles
t. rig
gh ht
pyri by
Vo
o
Renew air conditioner compressor e.g. owing to noise from the
c by lksw
cted agen
air conditioner compressor or lack of performance.
Prote AG.
– Drain refrigerant circuit ⇒ page 124 .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor .
– Clean refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
1. Refrigerant circuit 87
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ In the event of internal damage (to the air conditioner com‐
pressor), check the refrigerant hoses and condenser. If con‐
taminated by swarf, for example, clean the refrigerant hoses
and condenser (flush with R1234yf refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ); renew refrig‐
erant hoses if necessary.
♦ On certain vehicles (e.g. vehicles with 2 evaporators), the vol‐
ume of refrigerant oil in the refrigerant circuit may be greater
than the volume in the replacement air conditioner compres‐
sor. Replenish the refrigerant circuit on these vehicles with the
amount of refrigerant oil necessary ⇒ Heating, air condition‐
ing; Rep. gr. 00 ; Technical data (vehicle-specific workshop
manual).
♦ In the event of a fault in the electronics of an electrical air con‐
ditioning compressor (e.g. control unit for air conditioning com‐
pressor - J842- defective), the refrigerant circuit need not be
flushed. In this case, the air conditioner compressor is to be
renewed without there being a requirement to clean the re‐
frigerant circuit
⇒ “1.5.4 Renewing air conditioner compressor with no need to
clean refrigerant circuit”, page 85
– Renew desiccant bag/desiccant cartridge (reservoir/receiver)
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Check expansion valve for contamination or corrosion, renew
if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐ agen
AG. Volkswagen AG d
oes
erant circuit; System overview - refrigerant circuit . olksw not
y V gu
b ara
ed nte
– Assemble the refrigerant circuit, evacuate and charge thoris e or
⇒ page 124 . sa
u ac
s
ce
le
1.5.6 Renewing desiccant cartridge / receiver
un
pt
an
d
itte
after cleaning refrigerant circuit
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
Installed in the receiver is usually a desiccant cartridge or desic‐
t to the co
cant bag (depending on the layout of the refrigerant circuit) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - refrigerant circuit rrectness of i
l purpos
♦ Observe the general information about renewing components
⇒ “1.5.1 General information about renewing components”,
page 79
nform
mercia
a
com
Note
ion in
r
te o
thi
Clean the refrigerant circuit. In other words, flush with R1234yf
s
iva
do
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
r
rp
cum
fo
en
ng
t.
yi Co
For example due to moisture ingress (the refrigerant circuit was Cop py
open for too long) or contamination
t. rig
gh ht
pyri by
Vo
co
– Drain refrigerant circuit ⇒ page 124 .
by lksw
cted agen
Prote AG.
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor .
88 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant
AG. VolR1234yf
kswagen A - General information - Edition 01.2018
n G do
wage es n
V olks ot g
– Rectify cause of fault ⇒ Heating, ed bair
y conditioning; Rep. gr. 87 ; ua
ran
Refrigerant circuit; System hoverview
oris - refrigerant circuit . tee
ut or
a ac
– Clean refrigerant circuitss(flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
ce
le
un
pt
an
d
itte
Electrical air conditioner compressor
y li
rm
ab
pe
ility
– Flush air conditioner compressor of old refrigerant oil
ot
wit
⇒ “2.11 Cleaning electrical air conditioning compressor”, page
, is n
h re
150 .
hole
spec
Mechanical air conditioner compressor
es, in part or in w
t to the co
– Remove oil drain plug from air conditioner compressor ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor .
rrectness of i
l purpos
Note
nform
ercia
Different versions of oil drain plug and corresponding seal, renew
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐
m
a
com
ti
frigerant circuit (apart from air conditioner compressor and re‐
on in
ceiver)”, page 81 , ⇒ Heating, air conditioning; Rep. gr. 87 ;
r
te o
thi
Refrigerant circuit; System overview - refrigerant circuit (vehicle-
s
iva
do
specific workshop manual) and ⇒ Electronic parts catalogue .
r
rp
cum
fo
en
ng
t.
yi
– To speed up draining of the refrigerant oil, rotate the shaft of
Co
Cop py
the air conditioner compressor e.g. using the belt pulley or the ht. rig
rig ht
magnetic clutch pulley ⇒ Heating, air conditioning; Rep. gr. py by
co Vo
lksw
87 ; Air conditioner compressor .
by
cted agen
Prote AG.
– Pour out old refrigerant oil from air conditioner compressor
⇒ “1.5.4 Renewing air conditioner compressor with no need to
clean refrigerant circuit”, page 85 .
Note
Dispose of old refrigerant oil (observing local regulations) ⇒ VW /
Audi ServiceNet .
All air conditioner compressors
– Check expansion valve for contamination or corrosion, renew
if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; System overview - refrigerant circuit .
– Then fill the air conditioner compressor with new refrigerant oil
by the same amount of refrigerant oil filled in the replacement
air conditioner compressor (or by the specified amount of re‐
frigerant oil if the vehicle is fitted with 2 evaporators) ⇒
Heating, air conditioning; Rep. gr. 00 ; Technical data; Re‐
frigerant oil .
1. Refrigerant circuit 89
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Different refrigerant oils and volumes for different air condi‐
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data (vehicle-specific workshop manual).
♦ 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 40 cm3 of refrigerant oil; the re‐
mainder can be poured e.g. into a refrigerant line or the new
reservoir/receiver/inner heat exchanger
⇒ “1.5.1 General information about renewing components”,
page 79 , ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical
data .
♦ If dirt enters the air conditioner compressor while the refriger‐
ant circuit is open (e.g. after an accident), the refrigerant circuit
must be cleaned and the air conditioner compressor renewed
⇒ “1.6 Cleaning refrigerant circuit”, page 92 and ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor .
♦ On vehicles with 2 evaporators, the volume of refrigerant oil in
the refrigerant circuit may be greater than the volume in the
replacement air conditioner compressor. Replenish the refrig‐
erant circuit with the amount of refrigerant noil
AG.necessary
Volkswagen A⇒
G do
Heating, air conditioning; Rep. gr. V00 wage
olk;s Technical data (vehicle- s not g
e
specific workshop manual). ed b y ua
ra
ris nte
utho eo
ra
– Renew desiccant cartridge (receiver) ⇒ Heat‐ bag/desiccant
ss
a c
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
ce
le
un
pt
overview - refrigerant circuit .
an
d
itte
y li
– Assemble the refrigerant circuit, evacuate and charge
erm
ab
ility
⇒ page 124 .
ot p
wit
is n
1.5.7 Renewing receiver with no need to clean
h re
ole,
spec
refrigerant circuit
urposes, in part or in wh
t to the co
Note
rrectne
Installed in the receiver is usually a desiccant cartridge or desic‐
cant bag (depending on the layout of the refrigerant circuit) ⇒
ss
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
o
cial p
f i
overview - refrigerant circuit
nform
mer
atio
m
♦ Observe the general information about renewing components
o
n
c
⇒ “1.5.1 General information about renewing components”,
i
or
n thi
page 79
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
Clean the refrigerant circuit. In other words, flush with R1234yf
ht
pyri by
Vo
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
co lksw
by
cted agen
Prote AG.
♦ For example, refrigerant has leaked out but no dirt has entered
the circuit.
♦ If the gas analysis shows that contaminated refrigerant was in
the circuit but there appears to be no problem with the function
of the air conditioning system
⇒ “2.3 Performing gas analysis of refrigerant”, page 129
– Drain refrigerant circuit ⇒ page 124 .
90 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Remove receiver ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - refrigerant circuit .
– Remove dirt from receiver.
– Weigh removed receiver.
n AG. Volkswagen AG do
wage es n
– Fill enough refrigerant yV
olkoil into the new receiver so
s that
ot g it has
ua
the same weight edas the item that was removed.
b ran
oris tee
h
– Install news areceiver
ut
⇒ Heating, air conditioning; Rep. gr. 87or ;ac
Refrigerant
s circuit; System overview - refrigerant circuit .
ce
le
un
pt
– Assemble the refrigerant circuit, evacuate and charge
an
d
itte
y li
⇒ page 124 .
rm
ab
pe
ility
1.5.8 Renewing desiccant cartridge / desic‐
ot
wit
, is n
cant bag with no need to clean refriger‐
h re
hole
spec
ant circuit
es, in part or in w
t to the co
Note
rrectness of i
Desiccant cartridges or desiccant bags are usually installed de‐
l purpos
pending on the layout of the refrigerant circuit ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
nform
ercia
refrigerant circuit
m
a
com
t
♦ Observe the general information about renewing components
ion in
⇒ “1.5.1 General information about renewing components”,
r
te o
thi
page 79
s
iva
do
r
rp
cum
fo
en
ng
Note
t.
yi Co
Cop py
ht. rig
ht
Clean the refrigerant circuit. In other words, flush with R1234yf
rig by
opy Vo
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
by c lksw
cted agen
Prote AG.
♦ For example, refrigerant has leaked out but no dirt has entered
the circuit.
♦ If the gas analysis shows that contaminated refrigerant was in
the circuit but there appears to be no problem with the function
of the air conditioning system
⇒ “2.3 Performing gas analysis of refrigerant”, page 129
– Drain refrigerant circuit ⇒ page 124 .
– Renew desiccant cartridge/desiccant bag ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
refrigerant circuit (vehicle-specific workshop manual).
Note
If the desiccant cartridge/desiccant bag is permanently installed
in a component (e.g. in the receiver on the condenser) and cannot
be renewed individually, renew the receiver or condenser ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - refrigerant circuit .
– Assemble the refrigerant circuit, evacuate and charge
⇒ page 124 .
1. Refrigerant circuit 91
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.6 Cleaning refrigerant circuit
⇒ “1.6.1 General information about cleaning refrigerant circuit”,
page 92
⇒ “1.6.2 Preparations for cleaning refrigerant circuit (flushing with
R1234yf refrigerant)”, page 94
⇒ “1.6.3 Refrigerant circuit cleaning procedure”, page 97
⇒ “1.6.4 Principle circuit diagrams for cleaning (flushing circuits)
- refrigerant circuit with expansion valve and receiver”,
page 98
⇒ “1.6.5 Principle circuit diagrams for cleaning (flushing circuits)
- refrigerant circuit with restrictor and receiver (without high-volt‐
age system)”, page 103
⇒ “1.6.6 Principle circuit diagrams for cleaning (flushing circuits)
- vehicles with high-voltage system (without auxiliary air condi‐
tioning functions)”, page 106
⇒ “1.6.7 Principle circuit diagrams for cleaning (flushing circuits)
- vehicles with high-voltage system (with auxiliary air conditioning
functions, e.g. heat pump mode)”, page 106
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
⇒ “1.6.9 General information about blowing through with com‐
pressed air or nitrogen”, page 115
⇒ “1.6.10 Blowing through refrigerant circuit with compressed air
or nitrogen”, page 119
1.6.1 General information about cleaning re‐
frigerant circuit
swa
gen AG
. Volkswagen AG
does
olk not
yV gu
edb ara
ris nte
Note tho eo
au ra
c
ss
ce
e
♦ Work on the refrigerant circuit that involves the air conditioner
nl
pt
du
service station can usually be carried out without the need to
an
itte
y li
de-energise the high-voltage system.
erm
ab
ility
ot p
♦ Since certain components have to be removed to clean (flush)
wit
, is n
the refrigerant circuit, the high-voltage system must be de-
h re
energised before work commences ⇒ Electrical system -
hole
spec
hybrid; Rep. gr. 93 ; Electric drive; General warning notices
es, in part or in w
for work on high-voltage system .
t to the co
♦ If there is reason to believe that chemical substances (leak
stop additives) have been poured in the refrigerant circuit (that
rrectness of i
is be flushed) to seal leaks, do not connect your air conditioner
service station to this refrigerant circuit and do not flush this
l purpos
refrigerant circuit.
♦ Chemical substances (leak stop additives) used to seal leaks
nf
ercia
form deposits in the refrigerant circuit. These can impair the
rm
function of the air conditioning system and cause the air con‐
m
atio
m
ditioning system (and your air conditioner service station) to
o
n in
c
fail.
or
thi
te
sd
a
♦ Bring the customer's attention to the presence of substances
iv
o
r
rp
cu
in the air conditioning system that are not approved by Volks‐
o
m
f
en
ng
wagen/Audi, which prevent the air conditioning system from
t.
yi Co
being flushed and repaired. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
92 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
All vehicles
Note
♦ VW/Volkswagen/Audi does not endorse the use of chemical
substances (leak inhibitor additives) for purposes of sealing
leaks in refrigerant circuits.
♦ These chemical substances (leak stop additives) react mostly
with the ambient air or the humidity to stop leaks in the refrig‐
erant circuit. They cause deposits AG. Vto
olksbuild
wagenup
AGin the refrigerant
agen
circuit (and your air conditioner
olksw service station ),
does
cause
not valves
to malfunction and ed b defects in other components with which
yV gu
ara
they come into ho contact. These deposits cannot be completely
ris nte
e
removed froms aut the components again (not even by flushing).or a
c
The refrigerant
s circuit can only be repaired by replacing all
ce
le
components that have come into contact with this substance.
un
pt
an
d
itte
y li
♦ There are often no external signs to suggest that chemical
rm
ab
substances (leak stop additives) have been used to seal leaks
pe
ility
in a refrigerant circuit. Often, the stickers provided to mark
ot
wit
, is n
such systems are missing. Therefore, exercise caution on ve‐
h re
hicles for which you have no service or repair record.
hole
spec
es, in part or in w
♦ If there is no suitable air conditioner service station available
t to the co
for the R1234yf refrigerant, the air conditioner service station
designed for R134a refrigerant may also be used and the re‐
frigerant circuit may also be flushed with R134a refrigerant.
rrectness of i
Using R134a refrigerant to clean the refrigerant circuit is cur‐
rently permissible ⇒ Air conditioning system with R134a re‐
l purpos
frigerant; Rep. gr. 87 ; General information about the air
conditioning system and refrigerant circuit . nform
ercia
♦ If during the gas analysis it is found that R1234yf refrigerant
m
has been contaminated with a different gas, it must be extrac‐
a
com
tio
ted from the refrigerant circuit and disposed of as a gas of
n in
r
unknown composition in accordance with the relevant legisla‐
te o
thi
tion ⇒ VW / Audi-ServiceNet and
s
iva
do
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder
r
rp
cum
fo
for analysis, processing or disposal”, page 156 .
en
ng
t.
yi Co
op
♦ Contaminated refrigerant can cause decomposition products C py
t. rig
to form and accumulate in the refrigerant circuit. These cannot
gh ht
pyri by
be extracted with the refrigerant. The contaminated refrigerant
o Vo
by c lksw
cted
oil, in this case, must be removed from the refrigerant circuit
agen
Prote AG.
by flushing with refrigerant.
• To work as cleanly as possible, without being wasteful of the
refrigerant, without complex assembly work and in an envi‐
ronmentally friendly manner when removing moisture, con‐
taminants (e.g. friction dust and particles from the defective air
conditioner compressor) and old refrigerant oil, the refrigerant
circuit must be flushed (using R1234yf refrigerant).
The refrigerant circuit must be cleaned (flushed) with refrigerant
R1234yf:
– If dirt or other contamination is in the circuit.
– The search for faults in the electrical system, the vacuum sys‐
tem and the air ducts did not turn up any fault.(Moisture is in
the refrigerant circuit and builds up pressure.)
– If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
– Pressure and temperature measurements in the circuit indi‐
cate that there is moisture in the refrigerant circuit.
– There is doubt about the amount of refrigerant oil in the refrig‐
erant circuit.
1. Refrigerant circuit 93
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Under certain circumstances if contaminated R1234yf refrig‐
erant was charged in the refrigerant circuit
⇒ “1.5 Renewing components”, page 79 and
⇒ “2.3 Performing gas analysis of refrigerant”, page 129
Note
If contaminated refrigerant is found and components of the re‐
frigerant circuit exhibit signs of internal damage (e.g. corrosion on
the inside of the refrigerant lines or breakdown of the inner layer
of refrigerant hoses), flushing the refrigerant circuit may not be
sufficient. In this case, all of the components of the refrigerant
circuit must be renewed (owing to a gas being charged that se‐
verely damaged the components).
– The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or lack of power)
⇒ “1.5 Renewing components”, page 79 .
– If it is required by the workshop manual for the specific vehicle
following the renewal of certain components.
Tools required
♦ Air conditioner service station with flushing device (this air
conditioner service station incorporates the auxiliary function
“flushing refrigerant circuit” and the corresponding flushing
device for refrigerant circuits
swa
⇒G.Electronic
gen A parts
Volkswagen AG
doescatalogue .
k not
Vol g
♦ Adapter case foredVolkswagen/Audi
by passenger vehicles
ua
ran
is
⇒ page 106 tand
ho ⇒ Electronic parts catalogue .
r tee
o
au ra
c
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ If you do not have an air conditioner service station with flush‐
ility
ot p
ing device ⇒ Electronic parts catalogue in your workshop, it
wit
, is n
may be possible depending on the version of your air condi‐
h re
tioner service station to use the refrigerant circuit flushing
hole
spec
device ⇒ Electronic parts catalogue to flush the refrigerant
es, in part or in w
circuit. However, the flushing routine must be performed man‐
t to the co
ually ⇒ page 154 .
♦ In adapter case passenger vehicle set there is also a filling
rrectness of i
hose with 5/8 -18 UNF connections and large inner diameter,
short type (commercially available).
l purpos
1.6.2 Preparations for cleaning refrigerant cir‐
nform
ercia
cuit (flushing with R1234yf refrigerant)
m
at
om
ion
– Drain refrigerant circuit
c
in t
or
⇒ “2.4 Emptying refrigerant circuit”, page 132 .
his
ate
do
riv
– Remove air conditioner compressor ⇒ Heating, air condition‐
p
cum
or
ing; Rep. gr. 87 ; Refrigerant circuit; System overview -
f
en
ng
t.
refrigerant circuit (vehicle-specific workshop manual).
yi Co
Cop py
t. rig
On vehicles with restrictor and reservoir
gh ht
pyri by
Vo
o
by c lksw
– Remove restrictor (vehicle-specific) and join the lines together Prote
cted AG.
agen
again ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit (vehicle-specific
workshop manual).
– Remove the reservoir (vehicle-specific) and join the lines to‐
gether again (using an adapter and the charging hose from the
adapter case for VW/Audi passenger vehicles )
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
94 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
cuit; System overview - refrigerant circuit (vehicle-specific
workshop manual).
AG. Volkswagen AG d
agen oes
ksw
Note by Vol not
gu
ara
d
rise nte
o eo
The reservoir could be flushed. However, due
aut to its large interior
h
ra
volume it draws too much refrigerant and when this is extracted,
ss c
ce
le
the reservoir ices up too heavily. This causes the refrigerant to
un
pt
evaporate only very slowly, lengthening the extraction process
an
d
itte
y li
too much as a result.
erm
ab
ility
ot p
wit
On vehicles with expansion valve and receiver
is n
h re
ole,
– If possible and necessary with this refrigerant circuit (see no‐
spec
urposes, in part or in wh
tice), remove the receiver or remove the desiccant cartridge
t to the co
from the receiver (vehicle-specific) and join the lines together
again (using an adapter and the charge hose from the adapter
case for Volkswagen/Audi passenger vehicles )
rrectne
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit; System overview - refrigerant circuit (vehicle-specific
ss
workshop manual).
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n
♦ Depending on the design, the receiver can be flushed (if nec‐
thi
te
sd
a
essary, remove dryer cartridge installed in receiver)
iv
o
r
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
p
cum
r
fo
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
en
ng
t.
yi
cuit; System overview - refrigerant circuit (vehicle-specific
Co
op py
workshop manual).
t. C rig
gh ht
pyri by
Vo
o
♦ If the receiver is attached to the condenser, it must not be re‐
c by lksw
cted agen
moved for flushing (its design makes it suitable for flushing, Prote AG.
and it is only renewed after flushing)
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit; System overview - refrigerant circuit (vehicle-specific
workshop manual).
♦ With condensers in which the receiver / desiccant cartridge are
integrated and cannot be renewed individually or are not avail‐
able as individual parts, the condenser is to be renewed after
flushing. On these vehicles, the condenser in this case is to
be renewed with the receiver ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐
cuit (vehicle-specific workshop manual) and ⇒ Electronic
parts catalogue .
♦ Depending on the version, receivers - in which the desiccant
cartridge is to be renewed individually - may feature an addi‐
tional filter element, which will need to be renewed with the
desiccant cartridge if necessary.
– On vehicles with a dryer cartridge in the receiver on the con‐
denser (vehicle-specific), remove the dryer cartridge and seal
the opening on the receiver again ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
circuit (vehicle-specific workshop manual).
– Remove expansion valve (vehicle-specific) and fit an adapter
from the adapter case for Volkswagen/Audi passenger vehi‐
cles in its place
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit; System overview - refrigerant circuit (vehicle-specific
workshop manual).
1. Refrigerant circuit 95
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
If there is not a suitable adapter for the expansion valve in the
adapter case VW/Audi passenger vehicle set - VAS 6338/1- or
adapter case commercial vehicle set - VAS 6338/50- , the re‐
moved expansion valve can also be drilled out (the old expansion
valve must be subsequently renewed).
Note
♦ Disregard item -3-.
♦ When drilling out, ensure that the flow holes -2- and -4- in the
expansion valve -1- are located offset to each other.
♦ Failure to observe this measure can result in the sealingagsur‐
en AG. V
olkswagen AG
do
face on the expansion valve -1- becoming damaged yV
olkwhen
sw es n
ot g
drilling, thereby rendering the expansion valveisuseless
ed
b for set‐ ua
ran
ting up the flushing circuit. tho
r tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
96 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Before drilling, remove the regulator element and drill out the
expansion valve using e.g. a suitably sized drill bit (diameter
of drill bit e.g. 6.0 mm).
♦ Before drilling out, some parts may have to be removed from
the expansion valve depending on the version.
♦ There are different types of expansion valve with different de‐
signs. For type -A-, parts -B-, -C- and -D- must be removed,
for example. Separate component -D- and then part -E- (the
regulating element). Then drill out the expansion valve in area
-F- using a suitably sized drill bit.
♦ On version -G-, parts -H-, -I- and -K-, for example, must be G. Volkswagen AG d
removed and then area -L- drilled out using a suitably sizedwage
nA oes
olks not
drill bit. db
y V gu
ara
e nte
ris
tho eo
– Clean the drilled out expansion valve of swarfs a(metal particles).
u ra
c
s
ce
le
– Reinstall parts -B-, -C- and -D- on type -A- or part -H- on type
un
pt
-G-.
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
On vehicles with 2 evaporators, separate the circuit to the second
urposes, in part or in wh
evaporator from the circuit of the first evaporator and flush it in a
t to the co
separate work step
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106 and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Sys‐
rrectne
tem overview - refrigerant circuit (vehicle-specific workshop man‐
ual).
ss o
cial p
f
♦ Clean (flush) the refrigerant circuit
in
⇒ “2.12 Cleaning refrigerant circuit”, page 152
form
mer
atio
m
1.6.3 Refrigerant circuit cleaning procedure
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
Note
r
fo
en
ng
t.
yi Co
op
The procedure runs automatically as per the program in the air
C py
t. rig
gh
conditioner service station ⇒ Operating instructions air condi‐
ht
pyri by
tioner service station .
co Vo
by lksw
cted agen
Prote AG.
♦ After switching on, the flushing circuit (refrigerant circuit with
connecting hoses and flushing device for refrigerant circuits)
is evacuated first and, in the process, the refrigerant circuit is
checked for leaks (it may be necessary to proceed to the next
step manually depending on the version of air conditioning
service station ).
♦ Once the refrigerant circuit has been checked for leaks by
means of evacuating, a certain amount of refrigerant is filled
in the system to check the flushing/refrigerant circuit for correct
assembly (pressure test).
♦ After the pressure test, the refrigerant is extracted, the refrig‐
erant circuit is evacuated again, if necessary, and the cleaning
(flushing) process begins.
♦ A predefined volume of refrigerant is charged in the refrigerant
circuit via the high pressure side of the air conditioner service
station (in the opposite direction of normal flow during air con‐
ditioning system operation and therefore on the low pressure
side of the vehicle's refrigerant circuit). Alternatively, refriger‐
1. Refrigerant circuit 97
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
ant is charged continually (depending on the internal volume
of the flushing circuit e.g. 3 kg) until the refrigerant circuit and
the inspection windows of the flushing device for refrigerant
circuits are completely full with liquid refrigerant (the system
detects, e.g. over a certain period of time, when refrigerant
ceases to flow depending on the version of air conditioner
service station ).
♦ Once the predetermined amount of refrigerant has been filled
. Volkswagen AG
in the system, the heater, for example, of the kflushing n AGdevice
l swage does
not
for refrigerant circuits is switched on depending byV
o on the type of gu
ara
air conditioner service station and flushing ris
ed
device for refriger‐ nte
ant circuits (only if the refrigerant isauextracted in gaseous form
tho eo
ra
out of the flushing device for refrigerant
ss circuits). c
ce
e
nl
♦ When the refrigerant has been extracted, the heater of the
pt
du
an
itte
flushing device for refrigerant circuits is switched off (if fitted),
y li
erm
ab
the refrigerant circuit may have to be evacuated briefly again
ility
ot p
depending on the type, and following evacuation the refriger‐
wit
ant oil evacuated by the air conditioner service station out of
, is n
h re
the refrigerant circuit is separated of water.
hole
spec
♦ The procedure for charging with refrigerant, extracting (and
es, in part or in w
t to the co
evacuating) is carried out three times (that means a total of
four times).
♦ After extracting for the fourth time, the flushing circuit is evac‐
rrectness of i
uated depending on the type of air conditioner service station .
l purpos
1.6.4 Principle circuit diagrams for cleaning
(flushing circuits) - refrigerant circuit with
nf
ercia
or
expansion valve and receiver
m
m
atio
om
n in
c
♦ With 1 or 2 evaporators
or
thi
te
sd
a
♦ With and without high-voltage system
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
98 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The arrows in the following illustrations show the direction of
refrigerant flow during flushing (during flushing, the refrigerant
flows against the direction of flow with normal air conditioning
operation, which is why the high pressure side of the air con‐
ditioner service station is connected on the low pressure con‐
nection of the refrigerant circuit to the air conditioner
compressor).
♦ This principle circuit diagram shows a refrigerant circuit with
expansion valve, receiver and a second evaporator (extra
equipment on certain vehicles).
♦ On vehicles with expansion valve and receiver, the expansion
valve is removed and an adapter installed in its place. The
receiver is also removed depending on the vehicle and the line
connections to the receiver are joined together with 2 adapters
and a filling hose.
♦ On vehicles with just one evaporator, the components from
position “16” are not installed or not required.
♦ Depending on the design of the air conditioner service station
there may be non-return valves installed between the refrig‐
erant circuit and the air conditioner service station (to assure
the correct direction of refrigerant flow during flushing).
♦ The adapters from the adapter case for VW/Audi passenger
vehicles have a 5/8 -18 UNF thread. To ensure that the charge
hoses of the R1234yf- air conditioner service station can be
connected, additional adapters from the case are to be
swa
genused
AG. Volkswagen AG d
oes
adapter case for VW/Audi passenger vehiclesby⇒V Electronic
olk not
gu
parts catalogue . ris
ed ara
nt ee
tho or
♦ Installed in the refrigerant circuit on vehicles
sa
u with a high-volt‐ ac
age system are electrically actuated svalves that have to be
ce
e
removed for cleaning (flushing) and replaced with manual
nl
pt
du
an
shut-off valves or adapters ⇒ Heating, air conditioning; Rep.
itte
y li
gr. 87 ; Refrigerant circuit .
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.
1. Refrigerant circuit 99
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1 - Air conditioner service sta‐
tion
❑ With electronics and
flushing program, air
conditioner service sta‐
tion with flushing device
⇒ Electronic parts cata‐
logue (Tools; Workshop
equipment/tools; Air
conditioning system/
heating)
❑ If an air conditioner
service station without
flushing program is
used, the sequence has
to be carried out man‐
ually (evacuate, flush
4 times with at least 3 kg
of refrigerant each time
and extract refrigerant
again, evacuate).
2 - Refrigerant hose of airacon‐ gen AG
. Volkswagen AG
does
ditioner service station Volksw not
gu
y
db ara
❑ From high ris pressure side
e nte
of airaconditioner
ut
ho
service eo
ra
station
ss (normally col‐ c
oured red) for connect‐
ce
e
nl
pt
du
ing low pressure side of
an
itte
y li
air conditioner compres‐
erm
ab
sor to refrigerant circuit
ility
ot p
(larger diameter)
wit
, is n
h re
3 - Adapter for connection to
hole
spec
low pressure side in refrigerant
es, in part or in w
circuit
t to the co
❑ Different versions de‐
pending on vehicle
⇒ “1.6.8 Adapters for
rrectness of i
setting up flushing cir‐
l purpos
cuits”, page 106
❑ The item to be used between the refrigerant hose -2- and adapter -3- is adapter - VAS 6338/48- .
nform
ercia
❑ From adapter case VW/Audi passenger vehicle set
m
❑ Depending on the version of adapter, an additional adapter is required here to connect the charge hose
at
om
of the air conditioner service station
on
c
in t
or
his
te
Note
a
do
priv
cum
for
♦ The charge hose of the air con‐
en
ng
t.
yi
ditioner service station has an
Co
op py
M12 x 1.5-6G external thread in
t. C rig
gh ht
yri
accordance with SAE J639. Lo‐
p by
o Vo
by c
cated on the adapter for connec‐
lksw
cted agen
Prote
tion of the low pressure side is a
AG.
5/8 -18 UNF external thread. To
ensure that both components
can be connected together, an
additional adapter is required ⇒
Electronic parts catalogue
(Tools; Workshop equipment/
tools; Air conditioning system/
heating).
100 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ To attain the fastest flow speed
possible, the service coupling is
removed from the charge hose
for purposes of flushing (bottle-
necks are present in the service
coupling that would significantly
reduce the flow speed).
4 - Connection of low pressure side in refrigerant circuit
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
5 - Adapter for removed expansion valve
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ From adapter case for VW/Audi passenger vehicles ⇒ Electronic parts catalogue (Tools; Workshop
equipment/tools; Air conditioning/heating)
6 - Evaporator
7 - Connection to receiver
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ Not fitted in vehicles with a dryer cartridge in the receiver on the condenser or with a receiver installed
in the condenser ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - refrig‐
erant circuit (vehicle-specific workshop manual).
AG. Volkswagen A
8 - Adapter for bridging removed receiver ksw
agen G do
es n
Vol ot g
❑ Not required on all vehicles ed by ua
ran
ris tee
❑ Different versions depending on vehicle ⇒ “1.6.8
utho
Adapters for setting up flushing circuits”, page
or 106
a ac
ss
❑ From adapter case VW/Audi passenger vehicle set
ce
le
un
pt
9 - Charge hose for refrigerant
an
d
itte
y li
❑ For example charge hose from adapter case VW/Audi for passenger vehicles
rm
ab
pe
ility
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
ot
wit
, is n
10 - Condenser
h re
hole
spec
❑ If a receiver with dryer cartridge is fitted at the condenser, the dryer cartridge must be removed (seal
es, in part or in w
receiver at or in condenser again following removal) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
t to the co
circuit; System overview - refrigerant circuit (vehicle-specific workshop manual).
❑ If the receiver is attached directly to the condenser, flush the system before removing and renewing the
receiver ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant circuit
rrectness of i
(vehicle-specific workshop manual).
l purpos
Note
nform
ercia
On certain vehicles, the receiver is
m
integrated in the condenser and the
a
com
tio
desiccant cartridge cannot be re‐
n in
newed individually or is not availa‐
r
te o
thi
ble individually as a replacement
s
iva
do
part. On these vehicles, the con‐
r
rp
cum
fo
denser in this case is to be renewed
en
ng
t.
with the receiver ⇒ Heating, air con‐
yi Co
op
ditioning; Rep. gr. 87 ; Refrigerant
C py
t. rig
gh
circuit; System overview - refriger‐
ht
pyri by
Vo
o
ant circuit and ⇒ Electronic parts by c lksw
cted agen
catalogue . Prote AG.
11 - Connection for high pressure side on refrigerant circuit
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
12 - Adapter for connection of high pressure side in refrigerant circuit
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ From adapter case VW/Audi passenger vehicle set
1. Refrigerant circuit 101
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
13 - Charging hose of flushing device for refrigerant circuits
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
ameter) to inlet of flushing device for refrigerant circuits.
14 - Flushing device for refrigerant circuits
❑ Different versions and different design of flushing devices for refrigerant circuits ⇒ Electronic parts cata‐
logue (Tools; Workshop equipment/tools; Air conditioning/heating)
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
❑ Depending on the design of the air conditioner service station and the flushing device for refrigerant
circuits, there may be a non-return valve installed at the outlet of the flushing device for refrigerant circuits
(to assure the correct direction of refrigerant flow during flushing).
❑ Depending on the flushing device there may be a 5/8 -18 UNF external thread, a connection for R134a
or a R1234yf high pressure service coupling at the outlet to the air conditioner service station
Note
♦ To ensure that the flushing de‐
vice can be connected to the air
conditioner service station ,
flushing devices with a 5/8 -18
UNF external thread or a con‐
nection for an R134a low pres‐
sure service coupling require an
additional adapter to facilitate
connection of the R1234yf low
pressure service coupling or the
AG. Volkswagen AG d
charge hose to the air condition‐ ksw
agen oes
not
er service station (with an M12 x by
Vol
gu
ara
1.5-6G external thread in ac‐ rised
nte
cordance with SAE J639) at the aut
ho eo
ra
outlet of the flushing device. ss c
ce
le
un
♦ The charge hose of the air con‐
pt
an
d
itte
ditioner service station has an
y li
rm
ab
M12 x 1.5-6G external thread in
pe
ility
accordance with SAE J639. De‐
ot
wit
pending on the type of service
, is n
h re
connection, there may be a low
hole
spec
pressure service coupling in ac‐
es, in part or in w
cordance with SAE J639 for the
t to the co
R1234yf refrigerant, an M12 x
1.5-6G internal thread in accord‐
ance with SAE J639, a service
rrectness of i
connection for an R134a low
pressure service coupling or a
l purpos
5/8 - 18 UNF external thread on
the flushing device for refrigerant
nform
ercia
circuits. To ensure that both
components can be connected
m
to each other, an additional
com
tio
adapter may be necessary ⇒
n in
r
te o
Electronic parts catalogue .
thi
s
iva
do
♦ Since refrigerant is only drawn in
r
rp
cum
fo
by the air conditioner service sta‐
en
ng
t.
tion at a low flow speed, the low
yi Co
op
pressure service coupling can be
C py
t. rig
gh
used here.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
15 - Refrigerant hose of air conditioner service station
AG.
❑ From the low pressure side of the air conditioner service station (normally coloured blue) to the outlet of
the flushing device for refrigerant circuits.
16 - Adapter to seal outlet to second evaporator
❑ Only required on certain vehicles with “second evaporator” (optional equipment)
❑ From adapter case VW/Audi passenger vehicle set
102 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
17 - Adapter to seal outlet to second evaporator
❑ Only required on certain vehicles with “second evaporator” (optional equipment)
❑ From adapter case VW/Audi passenger vehicle set
18 - Connection of low pressure side in refrigerant circuit to second evaporator
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment)
19 - Connection of high pressure side on refrigerant circuit to second evaporator
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment)
20 - Adapter for removed expansion valve on second evaporator
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ Only required on certain vehicles with “second evaporator” (optional equipment)
❑ From adapter case VW/Audi passenger vehicle set
21 - Second evaporator
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment)
1.6.5 Principle circuit diagrams for cleaning
(flushing circuits) - refrigerant circuit with
restrictor and receiver (without high-volt‐
age system)
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
d by ara
♦ On vehicles with restrictor and reservoir,
orise
the restrictor and the nte
eo
reservoir must be removed. Thes alines that were detached to
h
ut ra
remove the restrictor are reinstalled. The line connections to
s c ce
e
the removed reservoir are joined together with 2 adapters and
nl
pt
du
the charge hose (from the adapter case for VW/Audi passen‐
an
itte
y li
ger vehicles ).
erm
ab
ility
ot p
♦ This layout with restrictor and refrigerant circuit reservoir is
wit
, is n
currently not used at Volkswagen/Audi.
h re
hole
spec
♦ The arrows in the following illustrations show the direction of
es, in part or in w
refrigerant flow during flushing (during flushing, the refrigerant
t to the co
flows against the direction of flow with normal air conditioning
operation, which is why the high pressure side of the air con‐
ditioner service station is connected on the low pressure con‐
rrectness of i
nection of the refrigerant circuit to the air conditioner
compressor).
l purpos
♦ Depending on the design of the air conditioner service station
there may be non-return valves installed between the refrig‐
nform
ercia
erant circuit and the air conditioner service station (to assure
m
the correct direction of refrigerant flow during flushing).
at
om
ion
c
♦ The adapters from the adapter case for VW/Audi passenger
in t
or
his
vehicles have a 5/8 -18 UNF thread. To ensure that the charge
ate
do
riv
hoses of the R1234yf- air conditioner service station can be
p
cum
connected, additional adapters from the case are to be used
for
en
g
adapter case for VW/Audi passenger vehicles .
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Refrigerant circuit 103
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1 - Air conditioner service sta‐
tion
❑ With electronics and
flushing program, e.g.
air conditioner service
station with flushing de‐
vice ⇒ Electronic parts
catalogue (Tools; Work‐
shop equipment/tools;
Air conditioning/heat‐
ing)
❑ If an air conditioner
service station without
flushing program iswagen AG. Volkswagen AG doe
used, the sequence yV
olks has s no
t gu
to be carried ise
d out man‐
b ara
nte
ually (evacuate,
ut
hor
flush eo
4 times
ss a with at least 3 kg ra
c
of refrigerant each time
ce
e
nl
and extract refrigerant
pt
du
an
itte
again, evacuate).
y li
erm
ab
2 - Refrigerant hose of air con‐
ility
ot p
ditioner service station
wit
, is n
h re
❑ From high pressure side
hole
spec
of air conditioner service
es, in part or in w
station (normally col‐
t to the co
oured red) for connect‐
ing low pressure side of
air conditioner compres‐
rrectness of i
sor to refrigerant circuit
(larger diameter)
l purpos
3 - Adapter for connection to
low pressure side in refrigerant
nf
ercia
circuit
rm
m
atio
❑ Different versions de‐
om
n in
pending on vehicle
or c
thi
⇒ “1.6.8 Adapters for
te
sd
a
setting up flushing cir‐
iv
o
r
rp
cu
cuits”, page 106
o
m
f
en
ng
❑ The item to be used between the refrigerant hose -2- and adapter -3- is adapter - VAS 6338/48- .
t.
yi Co
Cop py
❑ From adapter case VW/Audi passenger vehicle set
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note cted agen
Prote AG.
♦ The charge hose of the air con‐
ditioner service station has an
M12 x 1.5-6G external thread in
accordance with SAE J639. Lo‐
cated on the adapter for connec‐
tion of the low pressure side is a
5/8 -18 UNF external thread. To
ensure that both components
can be connected to each other,
an additional adapter is required
⇒ Electronic parts catalogue .
♦ To attain the fastest flow speed
possible, the service coupling is
removed from the charge hose
for purposes of flushing (bottle-
necks are present in the service
coupling that would significantly
reduce the flow speed).
104 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
4 - Connection of low pressure side in refrigerant circuit
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ On refrigerant line from air conditioner compressor to reservoir
5 - Connection to reservoir
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ On refrigerant line from air conditioner compressor to reservoir
6 - Adapter for bridging removed reservoir
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
❑ From adapter case VW/Audi passenger vehicle set
7 - Charge hose for refrigerant AG. Volkswagen AG d
agen oes
ksw
❑ For example charge hose by V from adapter case VW/Audi for
o l not
gupassenger vehicles
ara
⇒ “1.6.8 Adapters for
ris setting up flushing circuits”, page 106 nte
ed
tho eo
8 - Adapter for bridging
ss
auremoved reservoir ra
c
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
ce
e
nl
pt
du
an
❑ From adapter case VW/Audi passenger vehicle set
itte
y li
erm
ab
9 - Connection to reservoir
ility
ot p
wit
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
, is n
h re
hole
10 - Evaporator
spec
es, in part or in w
11 - Location of restrictor
t to the co
❑ The restrictor is removed.
❑ Remove restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - re‐
rrectness of i
frigerant circuit (vehicle-specific workshop manual).
l purpos
12 - Threaded connection in refrigerant line
❑ Screw back together following removal of the restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
nf
ercia
frigerant circuit; System overview - refrigerant circuit (vehicle-specific workshop manual). orm
m
13 - Condenser
atio
om
n in
c
14 - Connection for high pressure side on refrigerant circuit
or
thi
te
sd
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
iva
o
r
rp
cu
15 - Adapter for connection of high pressure side in refrigerant circuit
o
m
f
en
ng
t.
yi
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
Co
Cop py
t. rig
❑ From adapter case VW/Audi passenger vehicle set
gh ht
pyri by
Vo
co lksw
by
16 - Charging hose of flushing device for refrigerant circuits Prote
cted AG.
agen
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
ameter) to inlet of flushing device for refrigerant circuits.
17 - Flushing device for refrigerant circuits
❑ Different versions and different design of flushing devices for refrigerant circuits ⇒ Electronic parts cata‐
logue (Tools; Workshop equipment/tools; Air conditioning/heating)
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
❑ Depending on the design of the air conditioner service station and the flushing device for refrigerant
circuits, there may be a non-return valve installed at the outlet of the flushing device for refrigerant circuits
(to assure the correct direction of refrigerant flow during flushing).
❑ Depending on the layout of the flushing device for refrigerant circuits, there may be a connection for a
service coupling for refrigerant circuits at the outlet and possibly the inlet of the flushing device (instead
of a 5/8-18 UNF external thread). If a service connection with a valve is installed at the outlet of the
flushing device, this valve must be opened completely when the service coupling is connected (an in‐
completely opened valve represents a bottle-neck). If a connection for a service coupling is present at
the inlet of the flushing device, the inlet must be converted in such a way that the refrigerant hose coming
from the vehicle can be connected directly (a service coupling and a valve in the inlet of the flushing
device represent a bottle-neck that can hinder the flow of refrigerant out of the vehicle into the flushing
device and thereby affect the flushing process).
1. Refrigerant circuit 105
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
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.
1.6.6 Principle circuit diagrams for cleaning
(flushing circuits) - vehicles with high-
voltage system (without auxiliary air
conditioning functions)
Note
♦ The refrigerant circuit is cleaned in 2 flushing cycles (first the
section with the evaporator in the front heating and air condi‐
tioning unit and then the section with the heat exchanger for
high-voltage battery or evaporator in the battery cooling mod‐
ule) ⇒ page 106
♦ On vehicles with 2 evaporators or an evaporator and heat ex‐
changer, separate the circuit to the second evaporator or the
heat exchanger from the circuit of the first evaporator via hand
shut-off valves, and flush it in a separate work step
⇒ page 106 and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐ en AG. Volkswagen AG
cle-specific workshop manual). olks
wag does
not
V gu
by ara
♦ The layout of the various flushing circuits for these vehicles
ris
ed is nte
similar to that on a vehicle with 2 evaporators. au
tho eo
ra
ss c
ce
e
1.6.7 Principle circuit diagrams for cleaning
nl
pt
du
an
itte
(flushing circuits) - vehicles with high-
y li
erm
ab
ility
voltage system (with auxiliary air condi‐
ot p
wit
, is n
tioning functions, e.g. heat pump mode)
h re
hole
spec
es, in part or in w
t to the co
Note
♦ The refrigerant circuit is cleaned in several flushing cycles
⇒ page 106 and ⇒ Heating, air conditioning; Rep. gr. 87 ; rrectness of i
Refrigerant circuit (cleaning refrigerant circuit of air condition‐
l purpos
ing system).
♦ For flushing, the circuit is split into several sections and then
nform
ercia
flushed in one cleaning cycle respectively. The division is per‐
m
formed by means of the integrated electric valves that are
at
om
io
switched electrically and the manual shut-off valves that are
n
c
in t
r
switched manually ⇒ Heating, air conditioning; Rep. gr. 87 ;
o
his
te
Refrigerant circuit (cleaning refrigerant circuit of air condition‐
a
do
riv
ing system).
p
cum
for
en
g
♦ The layout of the various flushing circuits for these vehicles is
n
t.
yi Co
op
described in the relevant vehicle-specific workshop manual ⇒ C py
ht. rig
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit rig ht
py by
(cleaning refrigerant circuit of air conditioning system
co Vo
by lksw
cted
⇒ “1.6.4 Principle circuit diagrams for cleaning (flushing cir‐
agen
Prote AG.
cuits) - refrigerant circuit with expansion valve and receiver”,
page 98 ).
1.6.8 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.
106 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– On condensers with a permanent dryer, this can be flushed
along with the other components. A new condenser must then
be installed.
Note
If a flushed refrigerant circuit is not reassembled immediately after
flushing, the adapters must be left on the connections. These as
well as components that are still open must be sealed with clean
bungs from engine bung set - VAS 6122- .
On successful completion of flushing procedure, remove all
adapters and renew following components during assembly
♦ Air conditioner compressor
♦ Restrictor and expansion valve
Volkswa AG. gen AG
agen does
♦ Desiccant bagy Vand
olks desiccant cartridge
w not
gu
b ara
ed
♦ Evacuatingris and charging valve, high-pressure sidenand tee low-
tho
pressure
au side or
ac
ss
♦ Oil seals
ce
e
nl
pt
du
an
itte
Passenger cars
y li
erm
ab
Assembling flushing circuit ility
ot p
wit
, is n
Arteon 2018 ▶ ⇒ page 108
h re
hole
spec
Atlas 2017 ▶ ⇒ page 108
es, in part or in w
t to the co
CC 2012 ▶ ⇒ page 109
e-Golf 2014 ▶ ⇒ page 109
e-Golf 2014 ▶ with heat pump ⇒ page 109
rrectness of i
Golf 2013 ▶, Golf Estate 2014 ▶ ⇒ page 110
l purpos
Golf 2015 ▶, Golf Estate 2015 ▶ ⇒ page 110
Golf GTE ⇒ page 110
nform
ercia
Golf Cabriolet 2012 ▶ ⇒ page 110
m
at
om
io
Golf SV 2015 ▶ ⇒ page 110
n
c
in t
or
Jetta 2015 ▶ ⇒ page 113
his
ate
do
riv
Jetta 2018 ▶ ⇒ page 113
p
cum
for
en
g
Passat 2015 ▶, Passat Estate 2015 ▶ ⇒ page 110
n
t.
yi Co
op py
Passat 2018 ▶, Passat Estate 2018 ▶ ⇒ page 110
t. C rig
gh ht
yri by
Passat GTE ⇒ page 110
cop Vo
by lksw
cted agen
Passat (NMS-US) 2016 ▶ Prote
⇒ page 111
AG.
Polo 2014 ▶ ⇒ page 111
Polo 2018 ▶ ⇒ page 111
Scirocco 2015 ▶ ⇒ page 110
Sharan 2016 ▶ ⇒ page 112
T-Roc 2018 ▶ ⇒ page 112
The Beetle 2017 ▶, The Beetle Cabriolet 2017 ▶ ⇒ page 113
Tiguan 2016 ▶, Tiguan MEX 2017 ▶ ⇒ page 112
Touareg 2015 ▶ ⇒ page 113
Touran 2016 ▶ ⇒ page 110
up! 2017 ▶ ⇒ page 113
e-up! 2017 ▶ ⇒ page 113
1. Refrigerant circuit 107
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Commercial vehicles ⇒ page 108 AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
Note hor eo
aut ra
ss c
For a detailed description of assembling the flushing circuit, refer
ce
e
nl
pt
to the workshop manual ⇒ Air conditioning system with refrigerant
du
an
itte
R134a; Rep. gr. 00 ; Cleaning refrigerant circuit, commercial ve‐
y li
erm
ab
hicles .
ility
ot p
wit
, is n
h re
Assembling flushing circuit
hole
spec
Caddy 2016 ▶ ⇒ page 114
es, in part or in w
t to the co
Crafter 2017 or MAN TGE ▶ ⇒ page 114
Transporter 2016 ▶ ⇒ page 114
rrectness of i
l purpos
Passenger cars
nf
ercia
Arteon 2018 ▶
orm
m
atio
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
om
compressor
n in
or c
thi
e
Low-pressure side ♦ Adapter - VAS 6338/38-
t
sd
iva
♦ Adapter - VAS 6338/12-
o
r
rp
cu
or
o
m
f
en
ng
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
t.
yi Co
♦ Adapter - VAS 6338/3- Cop py
t. rig
gh ht
yri
Adapter - VAS 6338/48- for air conditioner service sta‐ p by
o Vo
by c lksw
tion Prote
cted AG.
agen
Atlas 2017 ▶
Flushing adapter refrigerant lines to Flushing adapter expansion valve Sealing adapter and flushing adapt‐
air conditioner compressor er for vehicles with second evapo‐
rator
Low-pressure side ♦ Adapter - VAS 6338/38- Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- ant circuit
or ♦ Sealing adapter - VAS 6338/63-
High-pressure side ♦ Drilled out expansion valve
♦ Adapter - VAS 6338/3- ⇒ page 96 High-pressure side of front refriger‐
ant circuit
Adapter - VAS 6338/48- for air con‐ Rear refrigerant circuit ♦ Sealing adapter - VAS 6338/5-
ditioner service station ♦ Drilled out expansion valve
⇒ page 96 Low-pressure side to second evap‐
orator
♦ Adapter - VAS 6338/3-
High-pressure side to second evap‐
orator
♦ Adapter - VAS 6338/60-
108 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
CC 2012 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/18-
♦ Adapter - VAS 6338/12-
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3-
Adapter - VAS 6338/48- for air conditioner service sta‐ gen AG
. Volkswagen AG
does
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tion yV
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tho or
au ac
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e-Golf 2014 ▶
ce
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an
Flushing adapter refrigerant lines to air conditioner itte
Flushing adapter expansion valve
y li
erm
compressor
ab
ility
ot p
Low-pressure side ♦ Adapter - VAS 6338/38-
wit
, is n
♦ Adapter - VAS 6338/12-
h re
or
hole
spec
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
es, in part or in w
♦ Adapter - VAS 6338/3-
t to the co
Electrical air conditioner compressor
♦ Adapter - VAS 6338/40- and adapter - VAS
rrectness of i
6338/41-
l purpos
Adapter - VAS 6338/48- for air conditioner service sta‐
tion
nf
ercia
orm
m
atio
m
e-Golf 2014 ▶ with heat pump
o
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or c
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Flushing adapter refriger‐ Flushing adapter expan‐ Other adapters Miscellaneous
t
sd
iva
ant lines to air conditioner sion valve
o
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compressor
o
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t.
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Low-pressure side ♦ Adapter - VAS Bridge removed refriger‐
Cop
Select
– function
py
♦ Adapter - VAS 6338/38- ant lines on condenser “Charge refrigerant cir‐
ht. rig
rig ht
by
6338/12- ♦ Adapter - VAS cuit” using ⇒ Vehicle di‐
copy Vo
or
by lksw
cted 6338/6- , qty. 2 agnostic tester.
agen
Prote
High-pressure side ♦ Drilled out expansion
AG.
♦ Adapter - VAS 6338/3- valve ⇒ page 96 ♦ Hose - VAS 6338/31- Leave ⇒– Vehicle diag‐
Electrical air conditioner nostic tester connected
compressor to keep the valves
♦ Adapter - VAS open.
6338/40- and adapter -
VAS 6338/41-
Adapter - VAS 6338/48-
for air conditioner service
station
1. Refrigerant circuit 109
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Golf 2013 ▶, Golf 2015 ▶, Golf Estate 2014 ▶, Golf Estate 2015
▶, Golf SV 2015 ▶, Touran 2016 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/18- or adapter - VAS 6338/38-
♦ Adapter - VAS 6338/12-
or
High-pressure side agen AG. Volkswagen ♦
AGDrilled
does out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3- Vol
ksw not
g y ua
db ran
Adapter - VAS 6338/48- foroair
ris conditioner service sta‐
e
tee
aution
th or
ac
ss
ce
e
nl
pt
du
an
itte
y li
Golf GTE, Passat GTE
erm
ab
ility
ot p
Flushing adapter refrigerant lines to Flushing adapter expansion valve Other adapters
wit
, is n
air conditioner compressor
h re
hole
spec
Low-pressure side ♦ Adapter - VAS 6338/38- Renew shut-off valves -N541- and -
es, in part or in w
♦ Adapter - VAS 6338/12- N542-
t to the co
or ♦ Shut-off tap - VAS 6338/42- qty.
High-pressure side ♦ Drilled out expansion valve 2
♦ Adapter - VAS 6338/3- ⇒ page 96
rrectness of i
Remove restrictor in refrigerant line
Adapter - VAS 6338/48- to air con‐ to heat exchanger for high-voltage
l purpos
ditioner service station Electric air battery and drill it out
conditioner compressor
♦ Adapter - VAS 6338/40- and
nform
ercia
adapter - VAS 6338/41-
m
at
om
ion
c
in t
or
his
ate
Golf Cabriolet 2012 ▶, Scirocco 2015 ▶
do
priv
cum
for
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
en
ng
t.
yi
compressor
Co
Cop py
t. rig
gh
Low-pressure side ♦ Adapter - VAS 6338/18-
ht
pyri by
Vo
♦ Adapter - VAS 6338/12-
co lksw
by
or
cted agen
Prote AG.
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3-
Adapter - VAS 6338/48- for air conditioner service sta‐
tion
Passat 2015 ▶, Passat Estate 2015 ▶, Passat 2018 ▶, Passat
Estate 2018 ▶
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.
110 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side G. Volkswa
ag♦
en AAdapter - gVAS
en AG6338/18- or adapter - VAS 6338/38-
does
ksw
♦ Adapter - VAS 6338/12- yV
ol not
gu
ed b or ara
nte
is
High-pressure side hor ♦ Drilled out expansion valve ⇒
e o page 96
♦ Adapter - VAS 6338/3- aut ra
ss c
ce
e
Adapter - VAS 6338/48- for air conditioner service sta‐
nl
pt
du
tion
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Passat (NMS-US) 2016 ▶
h re
hole
spec
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
es, in part or in w
compressor
t to the co
Low-pressure side ♦ Adapter - VAS 6338/18- or adapter - VAS 6338/38-
♦ Adapter - VAS 6338/12-
rrectness of i
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
l purpos
♦ Adapter - VAS 6338/3-
Adapter - VAS 6338/48- for air conditioner service sta‐
nf
ercia
tion
orm
m
atio
om
n in
or c
thi
Polo 2014 ►
te
sd
iva
o
r
rp
cu
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
o
m
f
en
ng
compressor
t.
yi Co
op py
Low-pressure side ♦ Adapter - VAS 6338/39-
. C rig
ht ht
rig
♦ Adapter - VAS 6338/12- py by
Vo
or
co lksw
by
cted agen
High-pressure side Prote
♦ Drilled out expansion valve ⇒ page 96
AG.
♦ Adapter - VAS 6338/3- or adapter - VAS 6338/2-
Adapter - VAS 6338/48- for air conditioner service sta‐
tion
Polo 2018 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/38-
♦ Adapter - VAS 6338/12-
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3-
Adapter - VAS 6338/48- for air conditioner service sta‐
tion
1. Refrigerant circuit 111
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Sharan 2016 ▶
Flushing adapter refrigerant lines to Flushing adapter expansion valve Sealing adapter and flushing adapt‐
air conditioner compressor er for vehicles with second evapo‐
rator
Low-pressure side Front refrigerant circuit Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- ♦ Adapter - VAS 6338/18- ant circuit
♦ Sealing adapter - VAS 6338/11-
High-pressure side or
♦ Adapter - VAS 6338/3- ♦ Drilled out expansion valve High-pressure side of front refriger‐
⇒ page 96 ant circuit
Adapter - VAS 6338/48- for air con‐ ♦ Sealing adapter - VAS 6338/5-
ditioner service station Rear refrigerant circuit
♦ Adapter - VAS 6338/33- Low-pressure side to second evap‐
orator
or ♦ Adapter - VAS 6338/3-
♦ Drilled out expansion valve
⇒ page 96 High-pressure side to second evap‐
orator
♦ Adapter - VAS 6338/4-
T-Roc 2018 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/38-
♦ Adapter - VAS 6338/12-
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3-
. Volkswagen AG
Adapter - VAS 6338/48- for air conditioner service
ksw
agsta‐
en AG does
tion by
Vol not
gu
ara
ed nte
oris eo
th
au ra
c
ss
Tiguan 2016 ▶, Tiguan MEX 2017 ▶
ce
e
nl
pt
du
an
itte
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
y li
erm
ab
compressor
ility
ot p
Low-pressure side ♦ Adapter - VAS 6338/38-
wit
, is n
h re
♦ Adapter - VAS 6338/12-
hole
or
spec
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
es, in part or in w
♦ Adapter - VAS 6338/3-
t to the co
Adapter - VAS 6338/48- for air conditioner service sta‐
tion
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
sd
iva
o
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o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
112 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Touareg 2015 ▶ AG. Volkswagen AG d
agen oes
olksw not
V
Flushing adapter refrigerant lines to Flushing adapter expansion
ed by valve Sealing adapter and gu
aflushing
ran adapt‐
air conditioner compressor thoris er for vehicles with secondtee evapo‐
au rator or
ac
ss
Low-pressure side ♦ Adapter - VAS 6338/17- or Low-pressure side of front refriger‐
ce
le
un
pt
♦ Adapter - VAS 6338/12- adapter - VAS 6338/33- ant circuit
an
d
itte
y li
♦ Sealing adapter - VAS 6338/11-
erm
ab
High-pressure side or
ility
ot p
♦ Adapter - VAS 6338/2- or adapt‐ ♦ Drilled out expansion valve High-pressure side of front refriger‐
wit
is n
er - VAS 6338/3- ⇒ page 96 ant circuit
h re
♦ Sealing adapter - VAS 6338/5-
ole,
Adapter - VAS 6338/48- to air con‐
spec
urposes, in part or in wh
ditioner service station Electric air Low-pressure side to second evap‐
t to the co
conditioner compressor orator
♦ Adapter - VAS 6338/40- and ♦ Adapter - VAS 6338/3-
adapter - VAS 6338/41-
High-pressure side to second evap‐
rrectne
orator
♦ Adapter - VAS 6338/4-
ss o
cial p
f inform
mer
atio
up! 2017 ▶, e-up! 2017 ▶
om
n
c
i
or
n
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
thi
te
sd
a
compressor
iv
o
pr
cum
r
fo
Low-pressure side ♦ Adapter - VAS 6338/34- or adapter - VAS 6338/36-
en
ng
t.
♦ Adapter - VAS 6338/12-
yi Co
op
or C py
t. rig
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
gh ht
yri by
♦ Adapter - VAS 6338/3-
op Vo
by c lksw
cted agen
Prote AG.
Adapter - VAS 6338/48- to air conditioner service sta‐
tion Electric air conditioner compressor
♦ Adapter - VAS 6338/40- and adapter - VAS
6338/41-
Jetta 2015 ▶, The Beetle 2017 ▶, The Beetle Cabriolet 2017 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/18- or adapter - VAS 6338/38-
♦ Adapter - VAS 6338/12-
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3-
Adapter - VAS 6338/48- for air conditioner service sta‐
tion
Commercial vehicles
Note
For a detailed description of assembling the flushing circuit, refer
to the workshop manual ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Cleaning refrigerant circuit, commercial ve‐
hicles .
1. Refrigerant circuit 113
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Caddy 2016 ▶
Flushing adapter refrigerant lines to air conditioner Flushing adapter expansion valve
compressor
Low-pressure side ♦ Adapter - VAS 6338/18-
♦ Adapter - VAS 6338/12-
or
High-pressure side ♦ Drilled out expansion valve ⇒ page 96
♦ Adapter - VAS 6338/3-
Adapter - VAS 6338/48- for air conditioner service
gen AG
. Volkswasta‐
gen AG
does
swa
tion y V olk not
gu b ara
ed nte
oris e
th or
au ac
ss
Crafter 2017 or MAN TGE ▶
ce
e
nl
pt
du
an
Flushing adapter refrigerant lines to Flushing adapter expansion valve Sealing adapter and flushing adapt‐
itte
y li
erm
air conditioner compressor er for vehicles with second evapo‐
ab
ility
rator
ot p
wit
, is n
Low-pressure side ♦ Adapter - VAS 6338/38- Low-pressure side of front refriger‐
h re
hole
♦ Adapter - VAS 6338/12- ant circuit
spec
or ♦ Sealing adapter - VAS 6338/5-
es, in part or in w
High-pressure side ♦ Drilled out expansion valve
t to the co
♦ Adapter - VAS 6338/3- ⇒ page 96 High-pressure side of front refriger‐
ant circuit
Adapter - VAS 6338/48- for air con‐ Rear refrigerant circuit ♦ Sealing adapter - VAS 6338/63-
rrectness of i
ditioner service station ♦ Drilled out expansion valve
⇒ page 96 Low-pressure side to second evap‐
l purpos
orator
♦ Adapter - VAS 6338/3-
nform
ercia
High-pressure side to second evap‐
m
orator
at
om
io
♦ Adapter - VAS 6338/60-
n
c
in t
or
his
ate
do
priv
cum
for
en
g
Transporter 2016 ▶
n
t.
yi Co
Cop py
.
Flushing adapter refrigerant lines to Flushing adapter expansion valve Sealing adapter and flushing adapt‐
ht rig
rig ht
by
air conditioner compressor er for vehicles with second evapo‐
copy Vo
by lksw
rator
cted agen
Prote AG.
Low-pressure side ♦ Adapter - VAS 6338/56- Low-pressure side of front refriger‐
♦ Adapter - VAS 6338/12- ant circuit
or ♦ Sealing adapter - VAS 6338/62-
High-pressure side ♦ Drilled out expansion valve
♦ Adapter - VAS 6338/3- ⇒ page 96 ♦ Connecting adapter angle piece
- VAS 6338/64-
Adapter - VAS 6338/48- for air con‐ Rear refrigerant circuit
ditioner service station ♦ Drilled out expansion valve High-pressure side of front refriger‐
⇒ page 96 ant circuit
♦ Sealing adapter - VAS 6338/63-
Low-pressure side to second evap‐
orator
♦ Adapter - VAS 6338/61-
High-pressure side to second evap‐
orator
♦ Adapter - VAS 6338/60-
On vehicles– with 1 evaporator
system, flush once
On vehicles– with 2 evaporator
systems, flush twice
114 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.6.9 General information about blowing
through with
agen
compressed
AG. Volkswagen AG air or nitrogen
d
w oes
olks no
In order to remove by moisture and other contaminants
V t gu as well as
ara
ed
old refrigerant orisoil from the refrigerant circuit as cleanly nas
tee possi‐
ble, withoutaut wasting the refrigerant and in an uncomplicated
h or and
a
environmentally
ss compatible way, the refrigerant circuit mustcbe
ce
e
cleaned with refrigerant R1234yf (flushed with R1234yf refriger‐
nl
pt
du
ant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
an
itte
y li
erm
ab
Blowing through the refrigerant circuit with compressed air and
ility
ot p
nitrogen is a method to be applied e.g. only if individual compo‐
wit
, is n
nents are to be cleaned.
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.
1. Refrigerant circuit 115
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General
wage information - Edition
n AG. Volkswagen AG do
e 01.2018 ks s no
Vol t gu
d by ara
e nte
ris
tho eo
Note au ra
c
ss
ce
le
un
♦ The refrigerant circuit should then only be blown through with
pt
an
d
compressed air and then with nitrogen if there are no means
itte
y li
erm
of flushing the refrigerant circuit, or the amount of work nec‐
ab
ility
essary to flush individual components would be too great
ot p
wit
(removed refrigerant lines can also be blown through, for ex‐
is n
h re
ample, to remove low level contaminants and moisture without
ole,
spec
taking much time).
urposes, in part or in wh
t to the co
♦ The method of blowing through the whole refrigerant circuit
with compressed air and nitrogen often requires a lot more
work than cleaning (flushing) with refrigerant R1234yf. When
rrectne
flushing with refrigerant R1234yf, cleaning of the components
is also far more efficient. It is therefore always best to flush the
system in the event of complaints (the method of blowing
ss
through should only be selected for certain complaints and for
o
cial p
f
individual components).
inform
mer
♦ Under certain circumstances it may be sufficient, for example,
atio
m
to blow through selected components (e.g. individual refriger‐
o
n
c
ant lines or refrigerant hoses) with compressed air (e.g. to
i
or
n thi
force out old refrigerant oil from individual removed compo‐
te
sd
va
nents) or nitrogen (to dry individual components).
i
o
pr
cum
r
fo
♦ Certain contaminants are difficult or impossible to remove
en
ng
t.
yi
from the refrigerant circuit with compressed air. These con‐
Co
Cop py
taminants can be removed, for example, by cleaning (flushing)
t. rig
gh ht
yri
with refrigerant R1234yf
p by
co Vo
by lksw
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Prote
cted AG.
agen
♦ When blowing through (with compressed air or nitrogen), the
maximum working pressure should not exceed 15 bar (equa‐
tes to the pressure in a filled refrigerant circuit with an ambient
temperature of approx. 60°C, if necessary use pressure limiter
for compressed air as well).
♦ If during the gas analysis it is found that R1234yf refrigerant
has been contaminated with a different gas, it must be extrac‐
ted from the refrigerant circuit and disposed of as a gas of
unknown composition in accordance with the relevant legisla‐
tion ⇒ VW / Audi-ServiceNet and ⇒ page 156 .
♦ Contaminated refrigerant can cause decomposition products
to form and accumulate in the refrigerant circuit. These cannot
be extracted with the refrigerant. The contaminated refrigerant
oil, in this case, must be removed from the refrigerant circuit
by flushing with refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ If there is no suitable air conditioner service station available
for the R1234yf refrigerant, the air conditioner service station
designed for R134a refrigerant may also be used and the re‐
frigerant circuit may also be flushed with R134a refrigerant.
Using R134a refrigerant to clean the refrigerant circuit is cur‐
rently permissible ⇒ Air conditioning system with R134a re‐
frigerant; Rep. gr. 87 ; Refrigerant circuit; Flushing (cleaning)
refrigerant circuit with R134a refrigerant .
CAUTION
Risk of injury from nitrogen escaping under high pressure.
– Use pressure limiter for nitrogen tank.
– Always clean components against the direction of refrigerant
flow (flush with R1234yf refrigerant) or blow through.
116 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Extract the mixture of refrigerant, refrigerant oil, compressed
air or nitrogen escaping out of the components with an extrac‐
tion system.
Note
Compressed air and nitrogen cannot be blown through the re‐
strictor, expansion valve, air conditioner compressor, receiver or
reservoir.
– In cases where condensers have a drying agent cartridge in
the integrated receiver, this drying agent cartridge must be re‐
moved. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
Note thoris nte
eo
au ra
c
ss
♦ With condensers in which the receiver / desiccant cartridge are
ce
e
nl
integrated and cannot be renewed individually, the condenser
pt
du
an
is to be renewed after cleaning (flushing).
itte
y li
erm
ab
♦ Depending on the version, receivers - in which the desiccant
ility
ot p
cartridge is to be renewed individually - may feature an addi‐
wit
, is n
tional filter element, which will need to be renewed with the
h re
hole
desiccant cartridge if necessary.
spec
es, in part or in w
t to the co
– First blow out old refrigerant oil and contaminants with com‐
pressed air, then blow out components with nitrogen (clean,
blow out or dehumidify old refrigerant oil).
rrectness of i
– Adapter for connecting pressure hose to refrigerant circuit
l purpos
Adapter case for VW/Audi passenger vehicles ⇒ Electronic
parts catalogue .
nf
ercia
To prevent oil and moisture from the compressed air system
orm
making its way into the refrigerant circuit, the following points must
m
atio
m
be observed.
o
n in
or c
thi
♦ The compressed air must be fed through a compressed air
te
sd
a
cleaning unit to clean and dry it. Therefore, use a filter and
iv
o
r
rp
cu
dryer for compressed air (included in the supply of tools for
o
m
f
en
ng
paint systems) ⇒ Electronic parts catalogue .
t.
yi Co
op py
♦ On refrigerant lines with threads or union nuts on the connec‐
t. C rig
gh ht
yri
tion, use adapter from refrigerant circuit adapter set - V.A.G p by
o Vo
by c
1785- ( adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- )
lksw
cted agen
Prote
to connect the 5/8" - 18 UNF charges hose (one part of this
AG.
adapter is also included in the adapter case for VW/Audi pas‐
senger vehicles ).
♦ On refrigerant lines without thread or union nut on the con‐
nection (for connection of adapters), use adapter from adapter
case VW/Audi passenger vehicle set or proprietary air blow
gun with rubber nozzle.
Note
Always extract any escaping air and/or nitrogen from the compo‐
nents using appropriate local exhaust ventilation LEV (e.g. work‐
shop extraction system).
The refrigerant circuit (or individual components) must be blown
through if there are no means of flushing or flushing does not ap‐
pear to be the appropriate solution.
– if there is dirt or contamination in individual components of the
refrigerant circuit.
1. Refrigerant circuit 117
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– The search for faults in the electrical system, the vacuum sys‐
tem and the air ducts did not turn up any fault.(Moisture is in
the refrigerant circuit and builds up pressure.)
– If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
– Pressure and temperature measurements in the circuit indi‐
cate that there is moisture in the refrigerant circuit.
– The vehicle-specific workshop manual deems it necessary af‐
ter replacement of certain components ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit, System overview -
refrigerant circuit .
Note
Certain contaminants and old refrigerant oil are difficult or impos‐
sible to remove from the refrigerant circuit with compressed air or
nitrogen. These contaminants can be removed, for example, by
flushing with refrigerant R1234yf
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ Blow through refrigerant circuit with compressed air or nitro‐
gen
⇒ “1.6.10 Blowing through refrigerant circuit with compressed
air or nitrogen”, page 119 swage
n AG. Volkswagen AG do
es n
olk ot g
byV ua
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u or
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es, in part or in w
t to the co
rrectness of i
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ercia
orm
m
atio
om
n in
or c
thi
te
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o
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t.
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Cop py
t. rig
gh ht
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co lksw
by
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Prote AG.
118 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.6.10 Blowing through refrigerant circuit with
compressed air or nitrogen
Note
♦ Vehicles with refrigerant lines that do not have a thread on
which to connect adapter - 1785- require e.g. a compressed
air gun with rubber nozzle or an adapter from adapter case for
VW/Audi passenger vehicles to blow out individual compo‐
nents. When using a compressed air gun with rubber nozzle,
be particularly careful 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 blow out components against the direction of refriger‐
ant flow (or flush with R1234yf refrigerant).
♦ Examine the expansion valve; renew if dirty or corroded.
♦ If there are dark sticky deposits in the components, and these
cannot be removed with compressed air, flush these compo‐
nents with refrigerant R1234yf or renew.
♦ Thin, light grey deposits on the insides of pipes do not impair
the function of the components.
♦ After blowing out, renew the receiver (desiccant cartridge) or
reservoir and restrictor. In cases where condensers have a
drying agent cartridge in the integrated receiver, this drying
agent cartridge must be renewed.
♦ On vehicles having condensers with an integrated receiver/
desiccant cartridge which cannot be renewed separately or
which are not available as a replacement part, the condenser wagen AG. Volkswagen AG doe
must be renewed after flushing the refrigerant circuit ⇒ Elec‐ Vol
ks s no
t gu
by
tronic parts catalogue and ⇒ Heating, air conditioning; isRep.
ed
ara
nte
gr. 87 ; Refrigerant circuit; System overview - refrigerant
ut
hor
cir‐ eo
cuit (vehicle-specific workshop manual). ss a ra
c
ce
e
♦ Depending on the version, receivers - in which the desiccant
nl
pt
du
an
cartridge is to be renewed individually - may feature an addi‐
itte
y li
tional filter element, which will need to be renewed with the
erm
ab
desiccant cartridge if necessary.
ility
ot p
wit
, is n
After blowing out the refrigerant circuit: h re
hole
spec
es, in part or in w
– Renew these vehicle-specific components (restrictor and res‐ t to the co
ervoir, expansion valve and receiver / dryer cartridge) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit (vehicle-specific work‐
rrectness of i
shop manual) and ⇒ Electronic parts catalogue
l purpos
– Depending on complaint, renew air conditioner compressor ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit (vehicle-specific work‐
nf
ercia
shop manual) and ⇒ Electronic parts catalogue or drain
orm
remaining refrigerant oil from removed air conditioner com‐
m
atio
m
pressor ⇒ “1.5 Renewing components”, page 79 and refill with
o
n in
c
requisite amount of fresh refrigerant oil ⇒ Heating, air condi‐
or
thi
e
tioning; Rep. gr. 00 ; Technical data (vehicle-specific work‐
t
sd
iva
shop manual) and ⇒ Heating, air conditioning; Rep. gr. 00 ;
o
r
rp
cu
Technical data; Refrigerant oil .
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Refrigerant circuit 119
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Replacement compressors contain a certain specified quantity
of refrigerant oil. On vehicles with two evaporators, a certain
amount of refrigerant oil may also have to be filled in the circuit
if necessary ⇒ Heating, air conditioning; Rep. gr. 00 ; Tech‐
nical data and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - refrigerant circuit .
♦ If the air conditioner compressor does not need to be renewed,
replenish the refrigerant oil accordingly up to the prescribed fill
level (empty refrigerant oil and pour the prescribed volume
back into the air conditioner compressor or refrigerant circuit)
⇒ page 79 , ⇒ Heating, air conditioning; Rep. gr. 00 ; Tech‐
nical data; refrigerant oil .
– Completely reassemble the refrigerant circuit again ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - refrigerant circuit (vehicle-specific workshop man‐
ual).
– Evacuate and charge the refrigerant circuit in the prescribed
manner ⇒ “2.5 Evacuating refrigerant circuit”, page 135 and
⇒ “2.6 Charging refrigerant circuit”, page 141
– Bring the air conditioning system into operation in the prescri‐
bed manner ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; Bringing air conditioning system into operation
after charging refrigerant circuit and
⇒ “2.7 Bringing air conditioning system into service after
charging”, page 144 n AG. Volkswagen AG do
wage e ks s no
Vol t gu
d by ara
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es, in part or in w
t to the co
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by
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Prote AG.
120 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1.7 Checking pressures with pressure
gauge
⇒ “1.7.1 Display on pressure gauges”, page 121
⇒ “1.7.2 Pressure gauges
agen enable the following
AG. Volkswagen AG d
oes test and meas‐
urement work”, page
olksw121 not
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1.7.1 au
tho Display on pressure gauges e or
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1- Temperature scale for R1234yf refrigerant (CF3CF = CH2)
ce
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in °C
an
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2- Pressure scale in bar overpressure
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hole
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es, in part or in w
♦ Pressure is indicated in various units: 1 MPa (Mega-Pascal)
t to the co
is equal to 10 bar or 145 psi; 1 bar absolute pressure is equal
to 0 bar, which is about the same as ambient pressure (at‐
mospheric pressure).
rrectness of i
♦ This diagram shows a pressure gauge displaying pressure on
l purpos
the low pressure side. The display here is shown in bar over‐
pressure (noticeable by “-1” in the display).
nform
ercia
In addition to the pressure scale, the pressure gauges can have
m
a
com
t
one or more temperature scales. The scale values for R1234yf
ion in
are assigned according to the vapour pressure table. Because
r
te o
thi
different refrigerants have different vapour pressures at the same
s
iva
do
temperature, each temperature scale is labelled for the respective
r
rp
cum
refrigerant.
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♦ Pressure gauges enable the following testing and measuring
Cop py
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t. rig
gh ht
yri
⇒ “1.7.2 Pressure gauges enable the following test and meas‐
p by
co Vo
by lksw
urement work”, page 121 . Prote
cted AG.
agen
1.7.2 Pressure gauges enable the following
test and measurement work
Pressure and temperature measurement in refrigerant circuit
♦ The high pressure gauge allows the pressure (and tempera‐
ture) to be measured with the air conditioning system switched
on irrespective of whether this is at the outlet of the air condi‐
tioner compressor through the condenser up to the restriction
(restrictor or expansion valve).
♦ The low pressure gauge facilitates measurement of the pres‐
sure (and temperature) that spreads evenly from the restric‐
tion (restrictor or expansion valve) through the evaporator up
to the inlet of the air conditioner compressor with the air con‐
ditioning system switched on.
Note
The relationship between pressure and temperature shown on
the pressure gauges is valid only where the refrigerant in the cir‐
cuit 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.
Evidence of refrigerant in a closed container
R1234yf refrigerant is present in a closed container or refrigerant
circuit if the temperature indicated on the pressure gauge corre‐
1. Refrigerant circuit 121
olkswagen AG
en AG. V
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤o,lkCaddy
swa
g 2016 ➤ , Crafter
doe201
s no ...
V t gu
Air conditioning systems with refrigerant
ed R1234yf
by - General information - Edition
ara 01.2018
ris nte
utho eo
sponds to the temperature of the refrigerant
temperature of ss (the
a ra
c
a standing fluid stabilises at ambient temperature).
ce
e
nl
pt
du
an
A closed container or isolated refrigerant circuit is empty if the
itte
y li
temperature indicated on the pressure gauge is below the tem‐
erm
ab
perature of the refrigerant.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ The dependency between pressure and temperature descri‐
bed on the pressure gauges no longer applies when there is
no liquid and the pressure is created by gas alone.
rrectness of i
♦ Since the R1234yf and R134a refrigerant pressures are very
l purpos
close to each other over a broad temperature range, it is not
possible to distinguish between them by means of the pres‐
sure measurement. It is possible to distinguish between them
nform
ercia
e.g. by means of a gas analysis
m
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 24 .
at
om
ion
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in t
or
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ate
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for
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t.
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Cop py
t. rig
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by
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Prote AG.
122 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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urposes, in part or in wh
t to the co
rrectness o
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by
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Prote AG.
2. Working with air conditioner service station 123
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
AG. Volkswagen AG d
agen oes
ksw
2 Working with air conditioner service ol not
y V gu
d b ara
ise
station r nte
tho eo
au ra
ss c
⇒ “2.1 Working with air conditioner service station”, page 124
ce
le
un
pt
an
d
⇒ “2.2 Connecting air conditioner service station to refrigerant
itte
y li
circuit”, page 126
erm
ab
ility
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⇒ “2.3 Performing gas analysis of refrigerant”, page 129
wit
is n
h re
⇒ “2.4 Emptying refrigerant circuit”, page 132
ole,
spec
urposes, in part or in wh
⇒ “2.5 Evacuating refrigerant circuit”, page 135
t to the co
⇒ “2.6 Charging refrigerant circuit”, page 141
⇒ “2.7 Bringing air conditioning system into service after charg‐
rrectne
ing”, page 144
⇒ “2.8 Switching off air conditioner service station and separating
ss o
from refrigerant circuit”, page 146
cial p
f inform
⇒ “2.9 Charging refrigerant in reservoir”, page 148
mer
atio
m
⇒ “2.10 Emptying air conditioner service station”, page 149
o
n
c
i
or
n
⇒ “2.11 Cleaning electrical air conditioning compressor”,
thi
te
sd
a
page 150
iv
o
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cum
r
fo
⇒ “2.12 Cleaning refrigerant circuit”, page 152
en
ng
t.
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op
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder for C py
t. rig
analysis, processing or disposal”, page 156
gh ht
pyri by
Vo
co lksw
by
⇒ “2.14 Checking pressures”, page 165 Prote
cted AG.
agen
2.1 Working with air conditioner service sta‐
tion
Note
♦ Should there be any reason to believe that chemical substan‐
ces (leak stop additives) have been used to seal leaks in the
refrigerant circuit from which refrigerant is to be extracted, do
not connect the air conditioner service station to this refriger‐
ant circuit and do not extract the refrigerant.
♦ Chemical substances used to seal leaks form deposits in the
refrigerant circuit. These can impair the function of the air con‐
ditioning system and cause the air conditioning system (and
your air conditioner service station ) to fail.
♦ Bring the customer's attention to the presence of substances
in the air conditioning system that are not approved by Volks‐
wagen/Audi, which prevent the air conditioning system from
being flushed and repaired.
♦ Volkswagen/Audi does not authorise the use of chemical sub‐
stances (leak stop additives) for purposes of sealing leaks in
refrigerant circuits. There are currently no long-term tests, ef‐
fectiveness or material-compatibility tests. As such, there is no
way of ruling out damage or malfunctions in an air conditioning
system or air conditioner service station .
♦ The leak stop additives currently available on the market have
different physical and chemical properties. These could impair
the function of the air conditioning system and air conditioner
service station with lasting effect or even cause a total failure.
VW/Volkswagen/Audi does not endorse the use of chemical
substances (leak inhibitor additives) for purposes of sealing
leaks in refrigerant circuits.
124 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ These chemical substances (leak stop additives) react mostly
with the ambient air or the humidity to stop leaks in the refrig‐
erant circuit. They cause deposits to build up in the refrigerant
circuit (and your air conditioner service station ), cause valves
to malfunction and defects in other components with which
they come into contact. These deposits cannot be completely
removed from the components (not even by flushing).
♦ There are often no external signs to suggest that chemical
substances (leak stop additives) have been used to seal leaks
in a refrigerant circuit. Often, the stickers that are meant to be
used to mark such systems are missing. Therefore, exercise
caution on vehicles for which you have no service or repair
record.
♦ Containers or tanks with integrated filters are offered as ac‐
cessories on the open market that are designed to separate
these chemical substances (leak stop additives for sealing
leaks). Since Volkswagen/Audi is unaware of the composition
and the physical and chemical properties of these substances,
no statement can be made at this point as to the effectiveness
and the filtering capability of these filters.
If repair work needs to be carried out on the refrigerant circuit of
the air conditioning system on a vehicle whose refrigerant circuit
has been filled with chemical substances (leak stop additives) to
seal leaking components (or there is good reason to believe that
this has been the case), bring the client's (the vehicle owner's)
attention to the following situation:
♦ The refrigerant of the air conditioning system cannot be ex‐
tracted owing to the substances (leak stop additives) that it
contains, which can damage your air conditioner service sta‐
tion . To extract the refrigerant, it can be filled in a recycling
cylinder in the way described for contaminated refrigerant
⇒ “2.13 Filling contaminated refrigerant . Volin
kswaarecycling
gen AG cylinder
gen AG
for analysis, processing orolkdisposal”,
swa page 156 . Should
does
no this
not be possible, it may d bbe
y V necessary e.g. for a companyt to gu be
ara
entrusted with extraction
rise of the contaminated refrigerant using nte
ho eo
a suitable device. a This should then be processed (or disposed
ut ra
c
of) e.g. by a local
ss
disposal company well versed in the proce‐
ce
e
dures relating to the disposal of refrigerants.
nl
pt
du
an
itte
y li
♦ For proper repair of the air conditioning system, it is necessary
erm
ab
to renew all components of the refrigerant circuit that have
ility
ot p
come into contact with the leak stop additive. The leak stop
wit
, is n
additive could already have damaged some components of
h re
the refrigerant circuit (e.g. the air conditioner compressor reg‐
hole
spec
ulating valve - N280- ) or subsequently cause damage when
es, in part or in w
the system is brought back into operation and, after a short
t to the co
time, failure of said components. Furthermore, deposits of leak
stop additive in the components of the refrigerant circuit may
work loose at a later stage, leading to renewed failure of the
rrectness of i
air conditioning system (completely cleaning these compo‐
l purpos
nents using workshop equipment is currently not possible).
♦ Contaminated refrigerant can render the whole filling in your
nf
ercia
air conditioner service station unusable.
orm
m
♦ Before extracting with a suitable tester, check the composition
atio
m
of the refrigerant in the refrigerant circuit
o
n in
or c
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
thi
te
sd
iva
♦ Extract contaminated refrigerant into a recycling cylinder and
o
r
rp
cu
send this in to your gas supplier for analysis, processing or
o
m
f
en
ng
disposal
t.
yi Co
op
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for C py
t. rig
analysis, processing or disposal”, page 25 .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Working with air conditioner service station 125
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Contaminated refrigerant can change the way in which the air
conditioning system works and / or permanently damage com‐
ponents of the refrigerant circuit.
♦ Mixtures of different refrigerants (e.g. R1234yf refrigerant with
an unknown quantity of R134a refrigerant) may not be filled in
a vehicle that has been given type approval for R1234yf re‐
frigerant.
Important instructions for working with air conditioner
agen
AG. Volksservice
wagen AGsta‐
does
tion Volksw not
g y ua
db ran
To operate the air conditioner oservice
ris
e
station ( air conditioner tee
service station currently available
auth
⇒ Workshop equipment and or
ac
special tools catalogue ), the
ss following must be observed:
ce
e
nl
pt
♦ The fitted filter and dryer must be renewed at the latest when
du
an
itte
the operational time specified in the related operating instruc‐
y li
erm
ab
tions has been reached.
ility
ot p
wit
♦ If an air conditioner service station is also used to clean (flush)
, is n
h re
the refrigerant circuit, the dryer and filter installed in the system
hole
spec
must be replaced at shorter intervals ⇒ page 119 .
es, in part or in w
t to the co
♦ Only refrigerant oils that are approved for the vehicle-specific
refrigerant circuit may be filled in the reservoir (pour the re‐
frigerant oil directly into the refrigerant circuit if necessary) ⇒
rrectness of i
Electronic parts catalogue .
l purpos
♦ Depending on the version of air conditioner service station and
the measures to be performed, there is a minimum volume of
refrigerant, refrigerant oil and UV leak detection additive that
nform
ercia
must be in the respective supply reservoirs of the air condi‐
tioner service station ⇒ Operating instructions air conditioner
m
at
om
service station
ion
c
in t
or
In the event of any doubt regarding the composition of the refrig‐
his
ate
erant extracted from the refrigerant circuit, the extracted refriger‐
do
priv
ant must not be re-used even after it has been cleaned in the air
um
for
conditioner service station
en
ng
t.
yi
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
Co
Cop py
t. rig
gh
♦ If the wrong refrigerant has been accidentally poured in the air
ht
pyri by
Vo
o
conditioner service station , it must be emptied by c lksw
cted agen
⇒ “2.4 Emptying refrigerant circuit”, page 132 and Prote AG.
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 . The system may also need to be cleaned,
including renewal of the filters, dryers and refrigerant oil.
♦ Contaminated refrigerant, e.g. in Germany, can be returned to
the supplier in so-called recycling cylinders for analysis, pro‐
cessing or environmentally-compatible disposal (in other
countries, different or additional regulations may apply)
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
analysis, processing or disposal”, page 25 .
2.2 Connecting air conditioner service sta‐
tion to refrigerant circuit
Connecting
• Depending on the type of equipment chosen, there may be
variations in the required procedure; therefore always follow
the user's manual for the equipment being used.
126 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
The procedure described in the instruction manual for your air
conditioning service station is to be followed ⇒ Operating instruc‐
tions air conditioner service station .
The charging hoses must only be connected according to the fol‐
lowing work procedure to prevent air or moisture from entering
the refrigerant circuit:
– On vehicles with high-voltage system, switch off “stationary air
conditioning” function (deactivate)⇒ Owner's Manual and ⇒
Operating instructions of infotainment / MMI .
– Switch off ignition.
– Connect the air conditioner service station to the power sup‐
ply.
– Switch on the air conditioner service station and bring it into
operation as described in the instructions ⇒ Operating in‐
structions air conditioner service station .
– Unscrew the sealing caps from the service connections (see
vehicle-specific refrigerant circuit) ⇒ Heating, air conditioning; agen AG. Volkswagen AG do
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop yV
olks
w es n
ot g
manual). ised b ua
ran
r tee
ho
– Evacuate the charge hoses if necessary. aut or
ac
ss
– Check service connections of refrigerant circuit for contami‐
ce
e
nl
pt
du
nation or corrosion, clean if necessary.
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
Dirt or a rough surface on the service connections caused by cor‐
spec
rosion can cause damage to the seals and thereby premature
es, in part or in w
t to the co
failure of the quick-release couplings.
– Fit quick-release couplings to the service connections of the
rrectness of i
refrigerant circuit.
l purpos
NOTICE
nf
ercia
Risk of damage to the air conditioner compressor or air condi‐
tioner service station. orm
m
atio
m
Opening the valves with the air conditioning system switched
o
n in
c
on can cause a short circuit between the high pressure and low
or
thi
e
pressure side.
t
sd
iva
o
r
– Never open valves on the high pressure or low pressure side
rp
cu
o
with the air conditioning system switched on.
f
en
ng
t.
yi Co
Cop py
ht. rig
– Turn the handwheel of the quick-release coupling adapter on rig ht
py by
the low pressure side no further than necessary to completely
co Vo
by lksw
cted
open the service connection (observe pressure gauge; do not
agen
Prote AG.
over-tighten valve).
– Perform a gas analysis using the air conditioner service station
(only necessary if refrigerant needs to be extracted or pres‐
sures in the refrigerant circuit need to be checked)
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
2. Working with air conditioner service station 127
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
Connect the gas analysis device or air conditioner service station
to the refrigerant circuit as instructed to do so, and bring it into
operation ⇒ Operating instructions of gas analysis device ,
⇒ page 126 and / or ⇒ Operating instructions air conditioner
service station .
If during the gas analysis it is found that the refrigerant in the cir‐
cuit meets the specifications:
– Turn the handwheel of the quick-release coupling adapter on
the high pressure side no further than necessary to completely
open the service connection (observe pressure gauge; do not
over-tighten valve).
– Perform the measures as required on the refrigerant circuit
using the air conditioner service station .
Note
♦ If, during the gas analysis, it is found that the R1234y refrig‐
erant is contaminated, extract the refrigerant from the refrig‐
erant circuit and send it back e.g. to your gas supplier for
processing (or disposal)
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder
for analysis, processing or disposal”, page 156 ,
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
analysis, processing or disposal”, page 25 and
⇒ “6.1 Basics of air conditioning technology”, page 16 .
♦ Should there be no means of doing
wage
nthis,
AG. Voextract the
lkswagen AG contami‐
doe
nated refrigerant immediately Vol from the refrigerant circuit ofotthe
ks sn
gu
by
vehicle and collect in aisrecycling
ed cylinder. Unscrew (close) thearant
handwheel of the quick ut
hor
release coupling adapter on the low ee
or
pressure side, switch
ss
a off the air conditioner service station ac
(and isolate from the power supply if necessary). Then sepa‐
ce
e
nl
rate the quick release coupling adapter on the low pressure
pt
du
an
side from the vehicle. The quick release coupling adapter on
itte
y li
erm
ab
the low pressure side must then be separated - e.g. with a
ility
suction hose from the workshop extraction unit - from the
ot p
wit
charge hose for the air conditioner service station and the
, is n
h re
contaminated refrigerant allowed to flow out of the charge
hole
spec
hose into the extraction hose of the workshop extraction unit.
es, in part or in w
To restore operational readiness of the air conditioner service
t to the co
station , reinstall the quick release coupling adapter on the low
pressure side on the charge hose for the air conditioner serv‐
ice station and evacuate using the air conditioner service
rrectness of i
station as instructed to do so in the relevant operating instruc‐
tions ⇒ Operating instructions air conditioner service station .
l purpos
– Perform the measures as required using the air conditioner
nform
ercia
service station .
m
at
♦ ⇒ “2.3 Performing gas analysis of refrigerant”, page 129
om
ion
c
in t
r
♦ ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
o
his
ate
do
riv
♦ ⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
p
cum
for
en
g
♦ ⇒ “2.6 Charging refrigerant circuit”, page 141 .
n
t.
yi Co
op py
♦ ⇒ “2.8 Switching off air conditioner service station and sepa‐
t. C rig
gh ht
yri
rating from refrigerant circuit”, page 146 p by
co Vo
by lksw
cted agen
♦ ⇒ “2.9 Charging refrigerant in reservoir”, page 148 . Prote AG.
♦ ⇒ “2.10 Emptying air conditioner service station”, page 149 .
128 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ ⇒ “2.14 Checking pressures”, page 165
2.3 Performing gas analysis of refrigerant
Note
♦ For operation of the air conditioning system, it is important that
the refrigerant used has a certain degree of purity.
♦ Contamination with other refrigerants or gases can cause
damage and thereby failure of the air conditioning system.
♦ Contaminated refrigerant must be returned as gas of unknown
composition e.g. to your gas supplier for processing (or dis‐
posal) in accordance with legislative requirements ⇒ VW /
Audi-ServiceNet .
♦ To prevent liquid components (e.g. droplets of refrigerant oil)
in the extracted refrigerant gas from falsifying the result of the
gas analysis, separators (filters) are installed in the gas anal‐
ysis device that separate these droplets of liquid. Renew
separators in accordance with specifications of gas analysis
device or operating instructions of air conditioner service sta‐
tion ⇒ Operating instructions of gas analysis device or ⇒
Operating instructions of air conditioner service station .
All vehicles
– Connect the gas analysis device or air conditioner service sta‐
tion to the refrigerant circuit as instructed to do so, and bring
it into operation ⇒ Operating instructions of gas analysis de‐
vice ,
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 and / or ⇒ Operating instructions air condi‐
tioner service station .
G. Volkswage
– Perform the gas analysis
lksw
as
ageper
n A the operating instructions.
n AG d
oes
n o ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
e
♦ A faulty gas analysis is possible from air in the refrigerant ho‐
nl
pt
du
an
ses or non-observance of the procedure for gas analysis as
itte
y li
detailed in the operating instructions.
erm
ab
ility
ot p
♦ Carefully follow the operating instructions of the gas analysis
wit
, is n
device / air conditioner service station .
h re
hole
spec
♦ Evacuate refrigerant hoses of the air conditioner service sta‐
es, in part or in w
tion before connecting the service couplings to the refrigerant
t to the co
circuit / gas cylinder with R1234yf refrigerant hose (see oper‐
ating instructions of gas analysis device / air conditioner serv‐
ice station
rrectness of i
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
l purpos
The gas analysis may provide the following results:
nf
ercia
♦ The R1234yf refrigerant complies with the specifications, the
or
planned measures may be performed with the air conditioner
m
m
atio
m
service station .
o
n in
or c
♦ A fault occurred during the gas analysis. The fault is to be in‐
thi
te
sd
vestigated and rectified after which the gas analysis must be
iva
o
r
repeated.
rp
cu
o
m
f
en
ng
t.
♦ The analysed R1234yf refrigerant does not comply with the op
yi Co
specifications, the analysed refrigerant must be extracted as
C py
t. rig
gh
refrigerant of unknown composition and returned e.g. to your
ht
pyri by
Vo
gas supplier for processing (or disposal)
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 129
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
analysis, processing or disposal”, page 25
Note
♦ Should the analysis of the refrigerant - to be extracted e.g. from
the refrigerant circuit of a vehicle - indicate that it is contami‐
nated: you can also perform a gas analysis on the refrigerant
e.g. of another cylinder from your gas supplier if you wish to
verify the analysis result.
♦ Since R1234yf refrigerant is so pure, even small amounts of
ambient air in the charge hoses of the air conditioner service
station can falsify the results. For this reason, most air condi‐
tioner service stations have a feature via which the gas anal‐
ysis is repeated up to 2 times before a not OK result is
displayed ⇒ Operating manual for air conditioner service sta‐
tion .
♦ You can perform a simple function check on your gas analysis
device e.g. using ambient air (unscrew the service coupling
from the refrigerant hose with which the gas analysis is per‐
formed and analyse the gas with the refrigerant hose open).
The result of this test should then indicate that the analysed
gas is not OK.
♦ The method of gas analysis employed here was developed for
motor vehicle workshops. It provides no details about the pre‐
cise composition of the refrigerant. This gas analysis can
therefore only show how high the percentage of R1234yf re‐
frigerant is in the refrigerant analysed. If the percentage of
R1234yf is below 95%, the refrigerant does not comply with
the specifications and can cause damage to the components
of the refrigerant circuit. A gas analysis that also provides de‐
tails about the precise composition of the analysed refrigerant
is currently not available for workshops. Gas analyses with
which the precise composition of gases can be investigated
require complicated equipment and procedures and can usu‐
ally only be performed with dedicated testing facilities.
AG. Volkswagen AG d
agen oes
ksw
Should contaminated brefrigerant
yV
ol
be found during the ngas
ot g analy‐
sis, notify the customer ed before continuing work and bringuathe ran
ris tee
customer's attention
ut
ho to the following: or
a ac
ss
There is contaminated refrigerant or refrigerant of unknown com‐
ce
e
nl
position in the refrigerant circuit of his vehicle that does not
pt
du
an
comply with the vehicle manufacturer's specifications. This re‐
itte
y li
erm
frigerant:
ab
ility
ot p
♦ must be returned e.g. to the gas supplier as refrigerant of un‐
wit
, is n
known composition for analysis, processing (or disposal)
h re
hole
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
spec
analysis, processing or disposal”, page 25 .
es, in part or in w
t to the co
♦ can be the cause of a malfunction or may already have caused
damage that makes the inevitability of malfunctions in the near
future probable.
rrectness of i
♦ Depending on its composition, the use of contaminated refrig‐
l purpos
erant could lead to the operating permit of the vehicle being
withdrawn.
nform
ercia
♦ If, as a result of contaminated refrigerant, internal damage to
m
the refrigerant circuit has been caused (e.g. decomposition
at
om
io
products of the contaminated refrigerant have affected the
n
c
in t
r
components of the refrigerant circuit
o
his
e
⇒ “1.5 Renewing components”, page 79 ), the refrigerant cir‐
at
do
riv
cuit can only be restored to full functionality once all compo‐
p
cum
or
nents that came into contact with the contaminated refrigerant
f
en
ng
t.
have been renewed. The internal condition of the refrigerant
yi Co
op
circuit can be appraised e.g. by visually inspecting certain
C py
t. rig
gh ht
yri by
130
cop Vo
by lksw
Rep. gr.87 - Air conditioning system Prote
cted AG.
agen
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Volkswagen AG
components of the refrigerant circuit (e.g. the conditionagen of the
AG. does
ksw
internal surfaces of removed refrigerant lines and refrigerant
yV
ol not
gu
hoses, the internal surface of the refrigerant db ara
rise reservoir and the nte
condition of the removed dryer cartridge).
ut
ho eo
ra
a c
ss
♦ If internal damage has been caused to the refrigerant circuit
ce
le
un
through contaminated refrigerant (e.g. failure of the air condi‐
pt
an
d
tioner compressor has ensued owing to damaged control
itte
y li
rm
elements or overheating, refrigerant oil has a stronger colour
ab
pe
ility
than usual but the parts containing refrigerant have not been
ot
wit
affected ⇒ “1.5 Renewing components”, page 79 ), the refrig‐
, is n
h re
erant circuit can be charged again once it has been flushed hole
spec
(renew air conditioner compressor, dryer and expansion
es, in part or in w
valve). However, since there is no way of anticipating the long-
t to the co
term effect of the contaminated refrigerant on the refrigerant
oil and the components of the refrigerant circuit, no guarantee
can be given in this case that the components of the refrigerant
rrectness of i
circuit will function correctly in future.
l purpos
♦ If the contaminated refrigerant has not caused internal dam‐
age to the refrigerant circuit (e.g. the refrigerant oil does not
have a stronger colour than usual, the components of the re‐
nform
ercia
frigerant circuit have not been affected), the refrigerant circuit
m
can be charged again once the dryer has been renewed and
a
com
ti
the refrigerant circuit has been evacuated for an extended pe‐
on in
riod (at least 1 hour). However, since there is no way of
r
te o
thi
anticipating the long-term effect of the contaminated refriger‐
s
iva
do
ant on the refrigerant oil and the components of the refrigerant
r
rp
cum
circuit, no guarantee can be given in this case that the com‐
fo
en
ng
ponents of the refrigerant circuit will function correctly in future
t.
yi Co
op
⇒ “1.5 Renewing components”, page 79 .
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 131
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
AG. Volkswagen AG d
Note agen oes
olksw not
y V gu
d b ara
ise
♦ If there is a complaint that can be attributed to the contamina‐thor nte
eo
ted refrigerant (e.g. leaking seals or hoses, damage to the s a air
u ra
c
conditioner compressor, contaminated refrigerant oil), the re‐
s
ce
le
frigerant circuit must be flushed and then all components that
un
pt
an
d
were damaged by the contaminated refrigerant (seals, hoses,
itte
y li
reservoir or dryer cartridge, expansion valve and air condi‐
erm
ab
ility
tioner compressor) must be renewed. If it is found that the
ot p
contaminated refrigerant has affected other components as
wit
is n
h re
well (e.g. the internal surfaces of the refrigerant pipes and re‐
ole,
frigerant hoses, damaged seals), the complete refrigerant cir‐
spec
urposes, in part or in wh
cuit must be renewed. The refrigerant circuit must then be
t to the co
recharged with clean refrigerant. Then check the function of
the air conditioning system. For the customer and to safeguard
yourself, make a note that the refrigerant circuit was charged
rrectne
with contaminated refrigerant.
♦ If there is a complaint that can be attributed to the contamina‐
ss
ted refrigerant (e.g. loss or lack of cooling output) and no other
o
cial p
f
complaints can be found in the refrigerant circuit, or if the re‐
inform
frigerant has to be extracted because work in the area of the
mer
refrigerant circuit so requires, proceed as follows after evacu‐
atio
m
ating the system. Remove the dryer and check for contami‐
o
n
c
nation. Since there could also be refrigerant oil on or in the
i
or
n thi
e
dryer, check this as well. If the refrigerant oil is contaminated,
t
sd
va
dark or viscous or if deposits of dirt have built-up on the dryer,
i
o
pr
cum
r
flush the refrigerant circuit and renew the parts as described
fo
en
ng
above (damage may already have been caused, which could
t.
yi Co
op
soon lead to failure of the air conditioning system). If the re‐ C py
t. rig
frigerant oil is OK and the dryer is not contaminated any more
gh ht
pyri by
than is usual from normal operation, renew the dryer. Evacu‐
co Vo
by lksw
cted
ate the refrigerant circuit for an extended period (at least 1
agen
Prote AG.
hour) and then recharge with clean refrigerant. Check the
function of the air conditioning system. For the customer and
to safeguard yourself, make a note that the refrigerant circuit
was charged with contaminated refrigerant.
2.4 Emptying refrigerant circuit
• Depending on the type of equipment chosen, there may be
changes to the procedure (always follow user's manual for the
equipment being used) ⇒ Operating instructions air condi‐
tioner service station .
• The refrigerant circuit should be emptied if parts of the refrig‐
erant circuit are to be removed, if it is unclear whether there is
refrigerant in the circuit, if contaminated refrigerant was de‐
termined during the gas analysis, or if safety precautions so
demand.
• All of the operating instructions for work involving refrigerant
with the air conditioner service station can be found in the op‐
erating instructions of the air conditioner service station ⇒
Operating instructions air conditioner service station .
Draining
– On vehicles with high-voltage system, switch off “stationary air
conditioning” function (deactivate)⇒ Owner's Manual .
– Switch off ignition.
– Connect the air conditioner service station to the power sup‐
ply.
In addition for vehicles with electrically-actuated valves in the re‐
frigerant circuit that are not open when unenergised:
132 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
On vehicles with high-voltage system and auxiliary air condition‐
ing system functions (“heat pump mode” or “cooling of high-
voltage battery”), valves may be installed in the refrigerant circuit
that are not open when unenergised. These valves are opened
and closed e.g. via incremental motors and are no longer actu‐
ated when the ignition is switched off. To empty completely, for
correct evacuation and charging of the refrigerant circuit, howev‐
er, no areas may be isolated, which is why these valves must be
opened before work is carried out ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
circuit and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode.
AG. Volkswagen AG d
agen oes
olksw not
V
– Using ⇒ Vehicle diagnostic tester, open any valves which ed byare gu
ara
not open in their resting state. horis nte
eo
aut ra
All vehicles ss c
ce
le
un
pt
– Bring the air conditioner service station into operation as in‐
an
d
itte
structed in the associated operating manual.
y li
erm
ab
ility
– Unscrew the sealing caps from the service connections of the
ot p
wit
refrigerant circuit (see vehicle-specific refrigerant circuit) ⇒
is n
h re
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
ole,
System overview - refrigerant circuit .
spec
urposes, in part or in wh
t to the co
– Connect air conditioner service station to refrigerant circuit
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 .
rrectne
– Perform a gas analysis with the air conditioner service station
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
ss o
cial p
f inform
Note
mer
atio
m
♦ If during the gas analysis it is found that the R1234y refrigerant
o
n
c
i
is contaminated, extract the refrigerant from the refrigerant
or
n thi
e
circuit and send it e.g. back to your gas supplier for analysis,
t
sd
va
processing or disposal
i
o
pr
cum
r
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
fo
en
ng
analysis, processing or disposal”, page 25 .
t.
yi Co
Cop py
t. rig
♦ Refill the refrigerant that is contaminated into a recycling cyl‐ gh ht
yri by
inder and return it e.g. to your gas supplier for analysis, pro‐
op Vo
by c lksw
cessing or disposal cted agen
Prote AG.
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
analysis, processing or disposal”, page 25 .
– Evacuate the refrigerant circuit with the air conditioner service
station as instructed in the associated operating manual.
NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.
2. Working with air conditioner service station 133
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Arteon 2018 ➤ , Atlas 2017 ➤ ,hoCC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 n...
ris tee
t or
Air conditioning systems withs refrigerant R1234yf - General information - Edition
a u ac 01.2018
s
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
♦ Sometimes, refrigerant oil is extracted from the refrigerant cir‐
wit
is n
h re
cuit along with the refrigerant and there is no way of stopping
ole,
this. In order to ensure the lubrication of the air conditioner
spec
urposes, in part or in wh
compressor, the refrigerant oil quantity should be topped up
t to the co
with fresh refrigerant oil
⇒ “2.6 Charging refrigerant circuit”, page 141 .
♦ Where vehicles are fitted with an air conditioner compressor
rrectne
without a magnetic clutch (with air conditioner compressor
regulating valve - N280- ) the engine should be run with the
ss
refrigerant circuit empty for no longer than is absolutely nec‐
o
cial p
f
essary, making sure that higher engine speeds are avoided
inform
(since the air conditioner compressor will always run when the
mer
engine is running).
atio
om
n
♦ On vehicles that have an air conditioner compressor without
c
i
or
n thi
magnetic clutch, the engine may only be started with a com‐
te
sd
a
pletely assembled refrigerant circuit, ensuring that higher en‐
iv
o
pr
c
gine speeds are avoided.
um
r
fo
en
ng
t.
yi
♦ Depending on the version of air conditioner compressor, a
Co
op py
valve may be installed on the high-pressure side that prevents
. C rig
ht ht
rig
liquefied refrigerant flowing back into the air conditioner com‐ py by
co Vo
pressor after the air conditioning system is switched off. If an
by lksw
cted agen
Prote
air conditioner compressor with this valve is installed in a ve‐
AG.
hicle with a refrigerant circuit with expansion valve, it could
take some time before the pressure on the high-pressure side
drops (the expansion valve is cold and the pressure on the
low-pressure side rises quickly after switching off, the expan‐
sion valve closes and refrigerant only flows slowly on the low-
pressure side). If the air conditioner compressor is switched
on (or the refrigerant circuit is emptied via the low pressure
side), pressure on the low pressure side drops, the expansion
valve opens and refrigerant can flow on the low pressure side.
If it is necessary after emptying to perform work on the vehicle for
which the air conditioner service station is not required:
– Detach the air conditioner service station from the refrigerant
circuit and switch off
⇒ “2.8 Switching off air conditioner service station and sepa‐
rating from refrigerant circuit”, page 146 .
– Open the refrigerant circuit at a connection point.
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.
– Wear protective gloves.
– Wear protective goggles.
– 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.
– Perform the required measures on the refrigerant circuit.
If, after emptying, the refrigerant circuit is to be evacuated and
recharged ⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
134 Rep. gr.87 - Air conditioning system
. Volkswage
Arteon wa2018
gen AG➤ , Atlas 2017
n AG d
o➤
es n, CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
olks ot g
Air conditioning
d by systems with refrigerant R1234yf
V ua - General information - Edition 01.2018
r
e an
ris tee
tho or
au ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
♦ After opening the connecting points in the refrigerant circuit,
erm
ab
the open lines and component connections must be closed (so
ility
ot p
that the ingress of moisture and dirt in these components is
wit
, is n
prevented).
h re
hole
spec
♦ Sometimes, refrigerant oil is extracted from the refrigerant cir‐
es, in part or in w
cuit along with the refrigerant and there is no way of stopping
t to the co
this. To ensure lubrication of the air conditioner compressor,
the refrigerant oil quantity should be topped up with fresh oil.
rrectness of i
♦ Where vehicles are fitted with an air conditioner compressor
with air conditioner compressor regulating valve - N280- , the
l purpos
engine should be run with the refrigerant circuit empty for no
longer than is absolutely necessary, making sure that higher
engine speeds are avoided (since the air conditioner com‐
nform
ercia
pressor will always run when the engine is running).
m
at
om
i
♦ On vehicles that have an air conditioner compressor with air
on
c
conditioner compressor regulating valve - N280- , the engine
in t
or
his
e
may only be started with a completely assembled refrigerant
at
do
riv
circuit, ensuring that higher engine speeds are avoided.
p
cum
for
en
ng
t.
yi
2.5 Evacuating refrigerant circuit
Co
Cop py
ht. rig
rig ht
• The procedure described in the operating manual for your air
py by
co Vo
by lksw
conditioning service station is to be followed ⇒ Operating Prote
cted AG.
agen
manual for air conditioner service station .
• The refrigerant oil volume in the air conditioner service station
has been checked and, if necessary, adjusted ⇒ Operating
instructions of air conditioner service station .
• The refrigerant volume in the air conditioner service station
has been checked and, if necessary, adjusted ⇒ Operating
manual of air conditioner service station .
Before the refrigerant circuit is filled with refrigerant, it must be
evacuated, i.e. completely emptied of air. In the process, all mois‐
ture is drawn out of the circuit.
Leaks can be determined when evacuating the refrigerant circuit
⇒ “1.4 Investigating leaks”, page 68 .
NOTICE
Risk of damage to air conditioner compressor with negative
pressure in the refrigerant circuit.
– Never start the engine if there is negative pressure in the
refrigerant circuit.
Evacuating:
• The refrigerant circuit is completely assembled.
– On vehicles with high-voltage system, switch off stationary air
conditioning function (deactivate) ⇒ Owner's Manual .
– Switch off ignition.
– Switch off ignition.
– Connect the air conditioner service station to the power sup‐
ply.
In addition for vehicles with electrically-actuated valves in the re‐
frigerant circuit that are not open when unenergised:
2. Working with air conditioner service station 135
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ On vehicles with high-voltage system and auxiliary air condi‐
tioning system functions (“heat pump mode” or “cooling of
high-voltage battery”), valves may be installed in the refriger‐
ant circuit that are not open when unenergised. These valves
are opened and closed e.g. via incremental motors and are no
longer actuated when the ignition is switched off. To empty
completely, to evacuate correctly and to charge the refrigerant
circuit, however, no areas may be isolated, which is why these
valves must be opened before work is carried out A⇒
G. VHeating,
olkswagen
agen(vehicle-spe‐ AG does
air conditioning; Rep. gr. 87 ; Refrigerantolcircuit
ksw not
cific workshop manual) and ⇒ Vehicle d bdiagnostic tester in
yV gu
ara
“Guided Fault Finding” mode. orise nte
e h
ut or
♦ Non-return valves in the refrigerant
ss
a
circuit have a certain hold‐ ac
ing pressure in the direction of flow (approx. 0.1 bar or
ce
e
nl
pt
100 mbar). To ensure that the refrigerant circuit can be evac‐
du
an
itte
uated completely (residual pressure below 5 mbar), all of the
y li
erm
ab
electrically actuated valves must therefore be open.
ility
ot p
wit
, is n
– Use the vehicle diagnostic tester to open the electrically-ac‐
h re
hole
tuated valves that are not open when unenergised ⇒ Vehicle
spec
diagnostic tester in “Guided Fault Finding” mode.
es, in part or in w
t to the co
All vehicles
– Bring the air conditioner service station into operation as de‐
rrectness of i
scribed in the instructions ⇒ Operating instructions air condi‐
tioner service station .
l purpos
– Unscrew the sealing caps from the service connections of the
refrigerant circuit (see vehicle-specific refrigerant circuit) ⇒
nform
ercia
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
m
cuit (vehicle-specific workshop manual).
at
om
ion
c
– Check service connections of refrigerant circuit for contami‐
in t
or
his
e
nation or corrosion, clean if necessary.
at
do
priv
cum
for
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
Dirt or a rough surface on the service connections caused by cor‐ yri
p by
o Vo
rosion can cause damage to the seals and thereby premature
by c lksw
cted agen
failure of the quick-release couplings.
Prote AG.
– Connect the air conditioner service station to the refrigerant
circuit
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 .
– Switch on the air conditioner service station , evacuate the re‐
frigerant circuit and perform the vacuum test (for a period of
e.g. 10 minutes with the vacuum pump on to remove any air,
remains of refrigerant and moisture and 20 minutes for the
vacuum/pressure increase check).
136 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The vacuum at the end of the evacuating process (running of
vacuum pump of air conditioner service station ) must be less
than 5 mbar absolute pressure. Should pressure during the
evacuating process in the refrigerant circuit not be less than
5 mbar, this could have various causes. For example, leaks in
the refrigerant circuit or in the connection to the air conditioner
service station , the time for the evacuating process is set too
short, the vacuum pump of the air conditioner service station
does not generate the necessary vacuum or the vacuum sen‐
sor of the air conditioner service station is not calibrated prop‐
erly ⇒ Operating instructions air conditioner service station .
♦ An absolute pressure of 5 mbar equates to a vacuum of
975 mbar at an ambient pressure e.g. of 980 mbar.
♦ At the end of the vacuum/pressure increase check, pressure
in the refrigerant circuit should not be greater than 20 mbar
absolute. Should the pressure in the refrigerant circuit be
greater than 20 mbar during the vacuum/pressure increase
check, the vacuum pump is switched on and the process is
repeated from the beginning ⇒ Operating instructions air con‐
ditioner service station . Should pressure in the refrigerant
circuit still not be less than 20 mbar even after the process has
been repeated twice, this could have various causes. For ex‐
ample, there could be leaks in the refrigerant circuit, a leak in
the connection from the refrigerant circuit to the air conditioner
service station or in the air conditioner service station itself,
the time set for the evacuating process is too short and the
time set for the vacuum/pressure increase check is too long.
♦ If there is reason to suspect a leak in the refrigerant circuit,
switch off the air conditioner service station if necessary and
allow it to stand for as long as possible (e.g. for at least 1 hour AG. Volkswagen AG d
agen oes
ksw
to check the leak-tightness of the refrigerant circuit) ⇒ by Oper‐
Vol not
gu
ating instructions air conditioner service station . rised ara
nte
tho eo
♦ Depending on the version of air conditioner sservice
sa
u
station , ra
c
the pressure in the refrigerant circuit is displayed directly.
ce
le
However, there is also a chance that the current pressure is
un
pt
an
d
only displayed while the vacuum pump is running ⇒ Operating
itte
y li
erm
instructions air conditioner service station . In the event of an
ab
ility
air conditioner service station only displaying the ambient
ot p
pressure, the display of the pressure in the refrigerant circuit wit
is n
will depend on the ambient pressure during activation (ambi‐ h re
ole,
spec
ent pressure at 980 mbar, a vacuum of 975 mbar equates to
urposes, in part or in wh
a residual pressure of 5 mbar absolute).
t to the co
♦ If the refrigerant circuit was opened, small quantities of mois‐
ture may have entered the refrigerant circuit. In this case, the
rrectne
refrigerant circuit is to be evacuated for at least 30 minutes
(pressure in the refrigerant circuit before charging must be less
than 20 mbar).
ss o
cial p
♦ If the refrigerant was extracted (to check the fill volume) and
f in
the refrigerant circuit was only evacuated so that it could be
form
mer
recharged (the refrigerant circuit was not opened and is leak-
atio
m
tight), it is sufficient to evacuate the refrigerant circuit for 5
o
n
c
minutes and to set no time or only a short time (e.g. 1 minute)
i
or
n thi
for the vacuum/pressure increase check (no air or moisture
te
sd
a
entered the refrigerant circuit).
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 137
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Depending on the volume of refrigerant oil in the refrigerant
circuit, the age and mileage of the vehicle, the layout of the
refrigerant circuit etc., there is a chance with a leak-tight re‐
frigerant circuit of the specified absolute pressure in the re‐
frigerant circuit not rising above the prescribed 20 mbar owing
to refrigerant evaporating out of the refrigerant oil. Should this
be the case, repeat the process again if necessary and / or
adapt the preset times accordingly.
If the vacuum display does not change (and the pressure stays
below 20 mbar), the system is leak-tight and can be recharged.
Note
♦ Depending on the version of air conditioner service station ,
the current pressure in the refrigerant circuit is permanently
displayed or only displayed after switching on e.g. the “Evac‐
uate” function ⇒ Operating instructions air conditioner service
station .
. Volkswagen AG
gen AG
♦ Due to the high degree of evacuation, there is a chance
ksw that
a does
not
Vol
refrigerant - which evaporates from the refrigerant ed by oil - could gu
ara
elevate the pressure in the refrigerant circuit hoduring
ris the vac‐ nte
eo
uum test from 20 to 40 mbar (absolute pressure).
aut
This is no ra
c
ss
indication of a leak in the refrigerant circuit, though depending
ce
e
on the version of air conditioner service station it could trigger
nl
pt
du
an
a fault. If necessary, evacuate the refrigerant circuit again and
itte
y li
observe the vacuum display for an extended period. Only if the
erm
ab
vacuum remains steady and you are certain that the refriger‐
ility
ot p
ant circuit is leak-tight is it permissible to charge the system.
wit
, is n
h re
hole
spec
– Charge the refrigerant circuit with air conditioner service sta‐
es, in part or in w
tion ⇒ “2.6 Charging refrigerant circuit”, page 141 .
t to the co
If the vacuum does not remain or sufficient pressure cannot be
built-up, the following action is required:
rrectness of i
♦ If pressure in the refrigerant circuit only rises slowly after evac‐
l purpos
uating e.g. owing to refrigerant (or moisture) evaporating from
the refrigerant oil, evacuate the refrigerant circuit again and
observe the vacuum gauge for an extended period. nform
ercia
– If there is any doubt as to whether the refrigerant circuit is ac‐
m
at
om
tually leak-tight, evacuate again and observe the vacuum
ion
c
gauge for an extended period. Only when a vacuum is main‐
in t
or
tained can charging commence.
his
ate
do
riv
– Only if you are really sure that the refrigerant circuit is leak-
p
cum
or
tight should the system be charged
f
en
ng
t.
yi
⇒ “2.6 Charging refrigerant circuit”, page 141 .
Co
Cop py
t. rig
gh
Further action if a leak is detected during evacuation:
ht
pyri by
Vo
co lksw
by
♦ If there is a leak so major that it causes air to escape to such
cted agen
Prote AG.
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.
– Investigate the leak in the refrigerant circuit as follows:
138 Rep. gr.87 - Air conditioning system
AG. Volkswagen AG d
agen oes
olksw not
V
d by Arteon 2018 ➤ , Atlas 2017 ➤g,uaCC ran 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
e
ris te
Airutconditioning
ho systems with refrigerant R1234yfe o-r General information - Edition 01.2018
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 139
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ A larger leak in the refrigerant circuit can be detected, for ex‐
ample, by pressurising the circuit to a maximum of 15 bar using
cleaned and dried compressed air or nitrogen ⇒ page 119 . If
the leak is large enough, the leakage point can be detected by
sound as the gas escapes.
♦ The compressed air or nitrogen is introduced to the closed,
empty refrigerant circuit via the service connection -B- to which
through a quick-release coupling adapter -A- has been con‐
nected.
♦ Screw the handwheel -C- into the quick-release coupling
adapter -A- until the valve in the service connection -B- is
completely open - do not over tighten the valve.
♦ The quick-release coupling adapter for service connection can
be fitted e.g. with a modified charging hose -A- (for example
with a M12 x 1.5-6G thread in accordance with SAE J639)
depending on the thread of the quick-release coupling adapter
and a suitable adapter -B- to connect to the workshop com‐
pressed air system ⇒ page 254 . To ensure that no moisture,
oil and dirt from the workshop compressed air system enter gen AG
. Volkswagen AG
does
the refrigerant circuit of the air conditioning system, use e.g. a Volkswa not
combination fine filter unit for compressed air systems with san d by gu
ara
i e
oil, dirt and water separator, which is commonly used inthpaint
or
nte
eo
spraying facilities. Install this between the compresseds aair sys‐
u ra
c
tem and the charge hose -A- ⇒ Electronic parts catalogue .
s
ce
le
un
pt
♦ Using the manifold gauge with pressure reducer for nitrogen
an
d
itte
y li
(maximum reduced pressure: 15 bar) -1- you can connect a
rm
ab
full nitrogen gas cylinder -3- via a charge hose -2- (e.g. with
pe
ility
ot
M12 x 1.5-6G thread in accordance with SAE J639) to the
wit
, is n
service connection - to which a quick-release coupling adapter
h re
hole
is connected - of a closed, empty refrigerant circuit
spec
⇒ page 253 .
es, in part or in w
t to the co
– Slowly increase the pressure in the refrigerant circuit to a max‐
imum of 15 bar.
rrectness of i
CAUTION
l purpos
Risk of injury from nitrogen escaping under high pressure.
nform
ercia
– Use pressure limiter for nitrogen tank.
m
a
com
tio
– Search for the leak by sound, which can be heard as gas es‐
n in
r
te o
capes from this point.
thi
s
iva
do
– Repair the leak.
r
rp
cum
fo
en
g
– Evacuate refrigerant circuit and observe the vacuum gauge
n
t.
yi Co
over a period of hours. Only when a vacuum is maintained can Cop py
t. rig
charging commence. gh ht
pyri by
Vo
co lksw
by
♦ If a leak is present of a size where no or very little air is drawn Prote
cted AG.
agen
in - with the refrigerant circuit evacuated - and the air condi‐
tioner service station can create sufficient vacuum. The vac‐
uum 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.
140 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Charge the circuit with 100 g of refrigerant and search for the
possible leak using an electronic leak tester
⇒ “1.4.2 Searching for leaks in refrigerant circuits using an
electronic leak detector”, page 69 or add an approved UV
contrast substance to the refrigerant and search for the pos‐
sible leak in the circuit using the leak detector system
⇒ “1.4.3 Searching for leaks with UV leak detection system”,
page 71 .
– Evacuate refrigerant circuit if necessary
⇒ “2.4 Emptying refrigerant circuit”, page 132
– Rectify the problem in the refrigerant circuit ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
– Evacuate the refrigerant circuit and observe thewvacuum
gen AG
. Volkswagen AG
does
s a
gauge over an extended period. Only whenyaV vacuum is main‐
olk not
gu
tained can charging commence risedb ara
nte
⇒ “2.5 Evacuating refrigerant circuit”,
ut page 135 .
ho eo
r
sa ac
If it is necessary after evacuating to perform
s
work on the vehicle
ce
e
nl
for which the air conditioner service station is not required:
pt
du
an
itte
y li
– Detach the air conditioner service station from the refrigerant
erm
ab
circuit and switch off
ility
ot p
⇒ “2.8 Switching off air conditioner service station and sepa‐
wit
, is n
rating from refrigerant circuit”, page 146 .
h re
hole
spec
NOTICE
es, in part or in w
t to the co
Risk of damage to air conditioner compressor with negative
pressure in the refrigerant circuit.
rrectness of i
– Never start the engine if there is negative pressure in the
refrigerant circuit.
l purpos
– Ensure that, until the refrigerant circuit is charged, the engine
nf
ercia
cannot be started.
orm
m
atio
If after emptying and evacuating the refrigerant circuit is to be
om
n in
recharged ⇒ “2.6 Charging refrigerant circuit”, page 141 .
or c
thi
te
sd
iva
2.6 Charging refrigerant circuit
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
♦ The whole amount of refrigerant can be charged either on the
cted agen
Prote AG.
high pressure side or the low pressure side. Charging of the
refrigerant circuit is described as follows for the high pressure
side.
♦ Fill capacities of refrigerant and refrigerant oil ⇒ Heating, air
conditioning; Rep. gr. 00 ; Technical data .
• The procedure described in the instruction manual for the air
conditioning service station is to be followed ⇒ Operating in‐
structions of air conditioner service station .
• Before charging the system with refrigerant, the amount of re‐
frigerant oil must be adjusted ⇒ Heating, air conditioning; Rep.
gr. 00 ; Technical data .
• Ensure when charging the refrigerant circuit that the air con‐
ditioner service station is at the same level as the vehicle
whose refrigerant circuit is to be charged (no greater than 50
cm difference). If the height difference is too great, deviations
may occur between the amount of refrigerant displayed and
the amount actually charged (depending on the version of air
2. Working with air conditioner service station 141
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
conditioner service station ). The filling accuracy of the air
conditioner service station may be affected.
• The refrigerant circuit is completely assembled ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - refrigerant circuit .
– On vehicles with high-voltage system, switch off stationary air
conditioning function (deactivate) ⇒ Owner's Manual .
– Switch off ignition.
– Connect the air conditioner service station to the power sup‐
ply.
– Check the volume of refrigerant, the volume of refrigerant oil
and the amount of UV leak detection additive in the air condi‐
tioner service station and replenish as necessary ⇒ Operating
instructions air conditioner service station .
In addition for vehicles with electrically-actuated valves in the re‐
frigerant circuit that are not open when unenergised:
Note
On vehicles with high-voltage system and auxiliary air condition‐
ing system functions (“heat pump mode” or “cooling of high-
voltage battery”), valves may be installed in the refrigerant circuit
that are not open when unenergised. These valves are opened
and closed e.g. via incremental motors and are no longer actu‐ en AG. V
olkswagen AG
ated when the ignition is switched off. To empty the refrigerant Volkswag does
not
circuit completely or to evacuate and charge it correctly, however, d by gu
ara
no areas must be isolated. Therefore, these valves must be rise nte
ho eo
opened before performing these types of work ⇒ Heating, s a air
ut ra
c
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
s
ce
e
workshop manual) and ⇒ Vehicle diagnostic tester in “Guided
nl
pt
du
an
Fault Finding” mode.
itte
y li
erm
ab
ility
ot p
– Use the vehicle diagnostic tester to open the electrically-ac‐
wit
, is n
tuated valves that are not open when unenergised ⇒ Vehicle
h re
diagnostic tester in “Guided Fault Finding” mode.
hole
spec
es, in part or in w
All vehicles
t to the co
– Bring the air conditioner service station into operation as de‐
scribed in the instructions ⇒ Operating instructions air condi‐
tioner service station .
– Unscrew the sealing caps from the service connections of the rrectness of i
l purpos
refrigerant circuit (see vehicle-specific refrigerant circuit) ⇒
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐
nf
ercia
cuit (vehicle-specific workshop manual).
orm
m
atio
– Connect quick-release couplings to the service connections of
om
the refrigerant circuit
n in
or c
⇒ “2.2 Connecting air conditioner service station to refrigerant
thi
te
sd
circuit”, page 126 .
iva
o
r
rp
cu
– Evacuate the refrigerant circuit with the air conditioner service
o
m
f
en
ng
station ⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
t.
yi Co
Cop py
t. rig
– Adjust the requisite amount of refrigerant, the amount of re‐ yri
gh by
ht
frigerant oil to be replenished if necessary and the amount of cop Vo
by lksw
UV leak detection additive in the air conditioner service station
cted agen
Prote AG.
⇒ Operating instructions air conditioner service station , ⇒
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-
specific workshop manual).
– Choose the relevant setting on the air conditioner service sta‐
tion for charging on the high pressure side ⇒ Operating
instructions air conditioner service station .
142 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
When charging the refrigerant circuit on the low pressure side,
liquefied refrigerant could accumulate in the compression cham‐
ber of the air conditioner compressor.
– Should it be necessary to charge the refrigerant circuit on the
low pressure side, turn the air conditioner compressor 10
times by hand before bringing into operation for the first time
after charging (if necessary, remove e.g. the drive belt to fa‐
cilitate this).
Note
♦ Refrigerant and refrigerant oil are charged in the refrigerant
circuit on the high pressure side.
♦ If a vehicle has no service connection on the high pressure
side of the refrigerant circuit, refrigerant can also be charged
via the service connection on the low pressure side. To do sthis, agen
AG. Volkswagen AG d
oes
however, always observe the setting and the operating olk w
in‐ not
y V gu
structions of the air conditioner service station . rised b ara
nt ee
tho or
♦ If on an air conditioner service station the charging
sa
u device ac
cannot be adjusted, unscrew (close) the handwheel
s
on the
ce
le
quick-release coupling adapter on the low pressure side if
un
pt
an
d
necessary.
itte
y li
rm
ab
pe
ility
– Charge the refrigerant circuit with the requisite amount of re‐
ot
wit
, is n
frigerant, the amount of refrigerant oil that needs to be replen‐
h re
ished if necessary and the amount of UV leak detection
hole
spec
additive.
es, in part or in w
t to the co
– Bring the air conditioning system into operation after charging
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Bringing air conditioning system into operation after charging
rrectness of i
refrigerant circuit (vehicle-specific workshop manual) and
⇒ “2.7 Bringing air conditioning system into service after
l purpos
charging”, page 144
Bringing air conditioning system with electrical air conditioning
nform
ercia
compressor into operation
m
a
com
t
– Bring the air conditioner compressor into operation via “Basic
ion in
setting, compressor run-in” function in guided fault finding
r
te o
thi
⇒ Vehicle diagnostic tester.
s
iva
do
r
rp
In addition for vehicles with electrically-actuated valves in the re‐
um
fo
frigerant circuit that are not open when unenergised:
en
ng
t.
yi Co
op
– Use the vehicle diagnostic tester to enable (open or close) the
C py
t. rig
gh
electrically-actuated valves - that are not open when unener‐
ht
pyri by
Vo
o
gised - for operation of the air conditioning system via the
c by lksw
cted agen
respective control unit ⇒ Vehicle diagnostic tester in “Guided Prote AG.
Fault Finding” mode.
2. Working with air conditioner service station 143
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
On vehicles with high-voltage system and auxiliary air condition‐
ing system functions (“heat pump mode” or “cooling of high-
voltage battery”), valves may be installed in the refrigerant circuit
that are not open when unenergised. These valves are opened
and closed e.g. via incremental motors and are no longer actu‐
ated when the ignition is switched off. To completely empty,
correctly evacuate and charge the refrigerant circuit, however, no
areas may be isolated. Therefore, these valves must be opened
before these measures are carried out. On completion of the
work, enable actuation of these valves again via the respective
control unit ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual) and ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode.
All vehicles agen
AG. Volkswagen AG d
oes
olksw not
V
If it is necessary to perform a function check afteredcharging
by the gu
ara
refrigerant circuit: thoris nte
eo
au ra
– Check the pressures in the refrigerant scircuit ⇒ page 165 .
s c
ce
e
nl
pt
If it is not necessary to perform a function check after charging
du
an
itte
the refrigerant circuit:
y li
erm
ab
ility
– Detach the air conditioner service station from the refrigerant
ot p
wit
circuit and switch off
, is n
h re
⇒ “2.8 Switching off air conditioner service station and sepa‐
hole
rating from refrigerant circuit”, page 146 .
spec
es, in part or in w
t to the co
2.7 Bringing air conditioning system into
service after charging
rrectness of i
l purpos
Note
♦ If the mechanical air conditioner compressor was removed,
nf
ercia
o
turn it approx. 10 times by hand before initial operation (during
rm
m
atio
installation or after installation e.g. before fitting the belt) so
om
that no damage is caused from a fluid shock when it is switch‐
n in
or c
ed on the first time (if there is refrigerant oil in the cylinder of
thi
te
sd
the air conditioner compressor, this will be forced out by turn‐
iva
o
r
ing) ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner
rp
cu
o
compressor; Removing and installing air conditioner compres‐
f
en
ng
t.
yi
sor .
Co
Cop py
t. rig
gh
♦ If the electrical air conditioner compressor was removed, be‐
ht
pyri by
fore bringing the air conditioning system into operation for the
co Vo
by lksw
cted agen
first time and after charging, the air conditioner compressor is Prote AG.
to be brought into operation via the “Basic setting, compressor
run-in” function in guided fault finding ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode - air conditioning system
and battery regulation. This prevents damage to the air con‐
ditioner compressor, e.g. from a fluid shock, during initial
activation (if there is refrigerant oil in the compression cham‐
ber of the air conditioner compressor, this will be forced out).
♦ The mechanical air conditioner compressor is driven by the
engine via a belt or a shaft. The electrical air conditioner com‐
pressor is driven by an electric motor mounted directly on the
air conditioner compressor (e.g. on vehicles with hybrid drive)
⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing and installing air conditioner compressor .
144 Rep. gr.87 - Air conditioning system
AG. Volkswagen AG d
agen oes
olksw not
V
Arteon 2018 ➤ed, bAtlas 2017 ➤ , CC 2012 ➤ , Caddy
y gu 2016 ➤ , Crafter 201 ...
ara
is nte
Air conditioning systemsthowith refrigerant R1234yf - General information
r e o - Edition 01.2018
au ra
ss c
Bringing air conditioning system with mechanical air conditioning
ce
le
un
pt
compressor into operation
an
d
itte
y li
– Switch on ignition.
rm
ab
pe
ility
ot
– Set the air conditioning system to the lowest output possible
wit
, is n
(e.g. select operating mode “A/C OFF”).
h re
hole
spec
– Switch off actuation of the air conditioner compressor (e.g.
es, in part or in w
select operating mode “A/C OFF”).
t to the co
– Start the engine with the air conditioner compressor switched
off (e.g. operating mode “A/C OFF” selected).
rrectness of i
– Wait until idling speed has stabilised:
l purpos
– Switch air conditioner compressor on and let system run for at
least 2 minutes with engine idling.
nform
ercia
– If necessary, check the pressures in the refrigerant circuit us‐
m
a
ing the air conditioner service station ⇒ page 124 .
com
tion in
r
– Switch off engine.
te o
thi
s
iva
do
– Detach the air conditioner service station from the refrigerant
r
rp
cum
circuit and switch off
fo
en
g
⇒ “2.8 Switching off air conditioner service station and sepa‐
n
t.
yi Co
op
rating from refrigerant circuit”, page 146 . C py
t. rig
gh ht
yri
Bringing air conditioning system with electrical air conditioning
p by
co Vo
by lksw
compressor into operation Prote
cted AG.
agen
– Switch on ignition.
– Bring the air conditioner compressor into operation via the
“Basic settings, compressor run-in” function of guided fault
finding ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system and battery regulation.
In addition for vehicles with electrically-actuated valves in the re‐
frigerant circuit that are not open when unenergised:
– Use the vehicle diagnostic tester to enable (open or close) the
electrically-actuated valves - that are not open when unener‐
gised - for operation of the air conditioning system via the
respective control unit ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
Note
On vehicles with high-voltage system and auxiliary air condition‐
ing system functions (“heat pump mode” or “cooling of high-
voltage battery”), valves may be installed in the refrigerant circuit
that are not open when unenergised. These valves are opened
and closed e.g. via incremental motors and are no longer actu‐
ated when the ignition is switched off. To completely empty,
correctly evacuate and charge the refrigerant circuit, however, no
areas may be isolated. Therefore, these valves must be opened
before these measures are carried out. On completion of the
work, enable actuation of these valves again via the respective
control unit ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit and ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode.
All air conditioning systems with electrical air conditioning com‐
pressor
– After the basic setting, check the pressures in the refrigerant
circuit if necessary using the air conditioner service station .
– On vehicles with high-voltage system, switch off “stationary air
conditioning” function (deactivate)⇒ Owner's Manual .
2. Working with air conditioner service station 145
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Switch off ignition.
– Detach the air conditioner service station from the refrigerant
circuit and switch off
⇒ “2.8 Switching off air conditioner service station and sepa‐
rating from refrigerant circuit”, page 146
wage
n A.G. Volkswagen AG do
e ks s no
Vol t gu
Vehicles with electrical air conditioning
ed
by compressor ara
is nte
or
• The engine may only abe
ut started when the refrigerant
h circuit eo
ra
has been fully assembled.
ss c
ce
le
un
pt
• On vehicles with battery cooling, hybrid operation is only pos‐
an
d
itte
sible with the air conditioning system charged and no faults
y li
rm
ab
stored in connection with the air conditioning system ⇒ Vehicle
pe
ility
diagnostic tester in “Guided Fault Finding” mode - air condi‐
ot
wit
, is n
tioning system and battery regulation.
h re
hole
• First bring the electrical air conditioner compressor into oper‐
spec
es, in part or in w
ation after installing the air conditioner compressor and charg‐
t to the co
ing the refrigerant circuit via the “Compressor run-in” function
in basic settings. Should there be an accumulation of refriger‐
ant oil in the compression chamber of the air conditioner
rrectness of i
compressor before installation owing to unfavourable storage,
damage could be caused to the air conditioner compressor
l purpos
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system and battery regulation.
nform
ercia
• An electrically driven air conditioner compressor may only be
activated when the refrigerant circuit is charged. Running the
m
a
com
ti
air conditioner compressor with the refrigerant circuit empty
on in
could lead to compressor damage ⇒ Vehicle diagnostic tester
r
te o
thi
in “Guided Fault Finding” mode - air conditioning system and s
iva
do
battery regulation.
r
rp
cum
fo
en
g
– To minimise the number of automatic engine starts when the
n
t.
yi Co
vehicle's drive system is active (READY) during test and . Cop py
measurement work, charge the vehicle batteries e.g. with the
ht rig
rig ht
by
battery charger 60 A - VAS 5904- in battery standby mode ⇒ copy Vo
by lksw
Electrical system - General information; Rep. gr. 27 ; Charging cted agen
Prote AG.
battery and ⇒ Electrical system; Rep. gr. 93 ; General warning
instructions for work on the high-voltage system .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake and arrange the tools needed so that they can‐
not come into contact with moving components of the engine
and so that they cannot even come near to components that
turn when the engine is running.
2.8 Switching off air conditioner service sta‐
tion and separating from refrigerant cir‐
cuit
– Finish the requisite work with the air conditioner service sta‐
tion .
– Switch off ignition.
– Unscrew (close) the handwheels of both service couplings.
146 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant. AG. Volkswagen AG d
agen o s
There is a risk of injury to theVoskin
lksw and parts of the bodyedue not to
gu
freezing. ed by ara
nte
ris
– Wear protective agloves.
ut
ho eo
ra
s c
– Wear protective s goggles.
ce
le
un
pt
– If, when loosening the handwheel of the service coupling,
an
d
itte
refrigerant escapes from the refrigerant line for longer then
y li
erm
ab
1 second, screw in the handwheel and renew the defective
ility
ot p
valve.
wit
is n
– Extract refrigerant and open the refrigerant circuit immedi‐
h re
ole,
ately afterwards.
spec
urposes, in part or in wh
– If more than 10 minutes have passed since the refrigerant
t to the co
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.
rrectne
Different versions of service couplings
ss o
♦ On one version of service coupling, the space between the
cial p
f in
valve in the service connection of the refrigerant circuit and the
form
mer
valve in the service coupling is vented externally when the
atio
m
handwheel is unscrewed. On these service couplings, the
o
n
c
valve in the service connection of the vehicle is closed first,
i
or
n thi
followed by the valve in the service coupling for the charge
te
sd
a
hose of air conditioner service station when the handwheel of
iv
o
pr
the service coupling is unscrewed. As it is unscrewed further, cum
r
fo
en
ng
the pressure still present between the two valves is released
t.
yi Co
via an additional valve (approx. 2 cm3 of refrigerant). Should Cop py
t. rig
one of these two valves (the valve in the service connection of gh ht
yri by
the vehicle or the valve in the service coupling for the charge
op Vo
by c lksw
hose) not close properly, the whole refrigerant could escape
cted agen
Prote AG.
out of the refrigerant circuit of the vehicle or the charge hose.
♦ On another version of service coupling, the space between the
valve in the service connection of the refrigerant circuit and the
valve in the service coupling is not vented externally when the
handwheel is unscrewed. This version features a valve that is
open when the service coupling is connected, which facilitates
pressure compensation between the space to the valve in the
service connection of the refrigerant circuit and the charge
hose connected to the service coupling. On this version, no
refrigerant escapes when the handwheel of the service cou‐
pling is unscrewed, which is why the refrigerant has to be
extracted from the charge hoses into the air conditioner serv‐
ice station here before the service couplings are disconnected.
If a large amount of refrigerant is recovered here, for example,
after a pressure test or after charging the refrigerant circuit
(more than approx. 50 g), this is an indication that a valve in
one of the service connections of the refrigerant circuit could
be leaking and refrigerant is escaping from the refrigerant cir‐
cuit of the vehicle (extract refrigerant and renew the defective
valve)
Before extracting the refrigerant from the charge hoses into the
air conditioner service station , unscrew the handwheels of both
service couplings as far as they will go.
2. Working with air conditioner service station 147
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Stored in the air conditioner service station is a function via
which it is switched to a specific operating mode when deac‐
tivated. The whole refrigerant is extracted from the charge
hoses into the air conditioner service station with this function.
♦ If the handwheels of the two service couplings are not un‐
screwed when this function is activated, refrigerant could be
extracted from the vehicle's refrigerant circuit.
– Extract the refrigerant from the two charge hoses using the air
conditioner service station as instructed in the relevant oper‐
ating manual ⇒ Operating instructions of air conditioner serv‐
ice station .
Note
♦ If, on an air conditioner service station with a service coupling
that does not vent to the outside, this process takes longer
than approx. 2 minutes or quite a large amount of refrigerant
is extracted, this suggests that there is a fault in one of the
valves in a service connection.
♦ If, on an air conditioner service station with a service coupling
that does vent to the outside, this process takes longer than
approx. 2 minutes, this suggests that there is a fault in one of
the valves in a service coupling.
Note
Erroneous extraction from vehicle's refrigerant circuit.
– First unscrew (close) the handwheels of the quick-release
coupling adapters. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
– Then extract the refrigerant from the two charge hoses using ir se
d b ua
ran
the air conditioner service station. tho tee
or
au ac
s
– Switch off the air conditioner service station (and isolate it from
s
ce
e
the power supply if necessary) ⇒ Operating instructions air
nl
pt
du
an
conditioner service station .
itte
y li
erm
ab
– Separate the quick-release couplings from the service con‐
ility
ot p
nections of the refrigerant circuit.
wit
, is n
h re
– Screw the sealing caps on the service connections (see vehi‐
hole
spec
cle-specific refrigerant circuit) ⇒ Heating, air conditioning;
es, in part or in w
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
t to the co
circuit .
2.9 Charging refrigerant in reservoir
rrectness of i
– Connect the cylinder with fresh R1234yf refrigerant to the
l purpos
service coupling on the high pressure side of the air condi‐
tioner service station ⇒ Operating instructions air conditioner
nf
service station .
ercia
orm
m
– Perform a gas analysis on the refrigerant (from the cylinder
atio
m
supplied) with which the system is to be charged using the air
o
n in
c
conditioner service station
or
thi
e
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
t
sd
iva
o
r
rp
cu
• The procedure described in the operating manual for your air
o
m
f
en
ng
conditioning service station is to be followed ⇒ Operating
t.
yi Co
manual for air conditioner service station . Cop py
t. rig
gh ht
pyri by
Vo
co
148
by lksw
cted agen
Rep. gr.87 - Air conditioning system Prote AG.
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
CAUTION
Risk of explosion from overfilling refrigerant reservoirs.
Refrigerant can expand and cause reservoirs to burst if they are
overfilled.
– Use a refrigerant tank with safety valve.
– Never exceed the permissible fill level of the refrigerant tank.
Note AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Depending on the version of air conditioner service station ised and ara
nte
the measures to be performed, there is a minimum volumeut
hor
of re‐ eo
frigerant, refrigerant oil and UV leak detection additive
ss a that must ra
c
be in the respective supply tank of the air conditioner service sta‐
ce
e
nl
tion ⇒ Operating instructions air conditioner service station
pt
du
an
itte
y li
erm
ab
2.10 Emptying air conditioner service station
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ If it is necessary to discharge the air conditioner service station
(e.g. because contaminated refrigerant was extracted), all fil‐
ters and dryers must be renewed (do not remove filter and
rrectness of i
dryer from the air-tight transport package until immediately
before installation to keep absorption of moisture as low as
l purpos
possible).
nf
ercia
♦ If it is necessary to empty the air conditioner service station
or
(e.g. because certain measures have to be performed on the
m
m
atio
air conditioner service station and the refrigerant that has been
om
or is to be extracted from the air conditioner service station
n in
or c
complies with the specifications (is not contaminated), it can
thi
te
sd
a
be filled into a recycling cylinder, if necessary, and then reused
iv
o
r
rp
⇒ Operating instructions air conditioner service station .
cu
o
m
f
en
ng
t.
♦ Refrigerant cylinders that have been charged with contamina‐
yi Co
op
ted or used refrigerant are referred to as “recycling cylinders”
C py
t. rig
gh
or “R cylinders”.
ht
pyri by
Vo
o
by c lksw
cted
♦ Always evacuate recycling cylinders before the first filling (re‐
agen
Prote AG.
frigerant cylinders containing air must not be filled with refrig‐
erant).
♦ Different types of refrigerant must not be mixed together (mix‐
tures of refrigerant cannot be recycled, but must be disposed
of instead). If the composition of the contents in the cylinder is
not clear, the gas processing / gas disposal company must be
informed of this
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder
for analysis, processing or disposal”, page 156 and
⇒ “6.2.17 Returning contaminated R1234yf refrigerant for
analysis, processing or disposal”, page 25 .
CAUTION
Risk of explosion from overfilling refrigerant reservoirs.
Refrigerant can expand and cause reservoirs to burst if they are
overfilled.
– Use a refrigerant tank with safety valve.
– Never exceed the permissible fill level of the refrigerant tank.
There are various ways to empty an air conditioner service sta‐
tion , observe the operating instructions of the air conditioner
2. Working with air conditioner service station 149
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
service station ⇒ Operating instructions air conditioner service
station .
– Drain the refrigerant from the air conditioner service station to
be emptied into a different air conditioner service station , ob‐
serving the operating instructions of the air conditioner service
station to do so ⇒ Operating instructions air conditioner serv‐
ice station and
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder
for analysis, processing or disposal”, page 156 .
2.11 Cleaning electrical air conditioning com‐
pressor
Vehicles with high-voltage system
Observe the additional warning instructions for working on vehi‐
cles with high-voltage system ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .
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, and observe the warnings ⇒
Electrical system; Rep. gr. 93 ; General warnings for work on the
. Volkswagen AG
high-voltage system . swagen AG does
k not
Vol gu
by
If repair work on high-voltage components is necessary, de-en‐ ara
ed nte
ergise the high-voltage system oris⇒ Electrical system; Rep. gr. 93 ; eo
th
De-energising high-voltagess
ausystem , and “observe the general ra
c
warning instructions for work on the high-voltage system” ⇒ Elec‐ ce
le
un
trical system; Rep. gr. 93 ; General warning instructions for work
pt
an
d
on the high-voltage system .
itte
y li
rm
ab
pe
Flushing air conditioner compressor
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ On an electrical air conditioning compressor, the refrigerant oil
cannot be poured out (as there is no oil drain plug), i.e. the
design makes no allowance for the drainage of oil
rrectness of i
♦ With an electrical air conditioning compressor, the refrigerant
l purpos
oil is to be removed in the direction of flow by flushing (flushing
in the opposite direction of flow is not possible due to the in‐
tegrated valves).
nform
ercia
♦ The air conditioner compressor must be positioned for flushing
m
a
com
so that the connection for the refrigerant line on the high pres‐
ion in
sure side is at the lowest point possible.
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.
150 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
1 - Air conditioner service sta‐
tion
❑ With electronics and
flushing program, air
conditioner service sta‐
tion with flushing device
⇒ Electronic parts cata‐
logue .
❑ If an air conditioner
service station without
flushing program is
used, the sequence has
to be carried out man‐
ually (evacuate, flush
4 times with at least 2 kg
of refrigerant each time
and extract refrigerant
again, evacuate).
2 - Refrigerant hose of air con‐
ditioner service station
❑ From high pressure side
of air conditioner service
station (normally col‐
oured red) for connect‐
ing low pressure side of
air conditioner compres‐ n AG. Volkswagen AG do
sor to refrigerant lkswage
circuit es n
Vo ot g
(larger diameter)
ed
by ua
ra
is nte
or
3 - Adapter ato
ut connection for
h eo
ra
low pressure
ss side on air condi‐ c
tioner compressor
ce
le
un
pt
an
d
❑ Different versions de‐
itte
y li
pending on vehicle
rm
ab
pe
ility
⇒ “1.6.8 Adapters for
ot
wit
setting up flushing cir‐
, is n
h re
cuits”, page 106
hole
spec
❑ The item to be used be‐
es, in part or in w
tween the refrigerant
t to the co
hose -2- and adapter -3- is adapter - VAS 6338/48- .
❑ From adapter case VW/Audi passenger vehicle set
rrectness of i
4 - Refrigerant line
l purpos
❑ For connection of air conditioner compressor to adapter ⇒ Item 3 (page 151)
5 - Electrical air conditioner compressor
nform
ercia
❑ Flush the air conditioner compressor in normal direction of flow (from low pressure inlet to high pressure
m
outlet)
a
com
tion in
❑ In order to flush as much refrigerant oil out of the air conditioner compressor as possible, make sure that
r
te o
thi
the high pressure outlet of the air conditioner compressor is in the lowest position possible
s
iva
do
r
rp
cum
Note
fo
en
ng
t.
yi Co
op
♦ Depending on the air conditioner
C py
t. rig
gh
compressor, a new air condition‐
ht
pyri by
er compressor might be filled
co Vo
by lksw
cted agen
with quite a large amount of re‐
Prote AG.
frigerant oil (see manufacturer
plate on air conditioner compres‐
sor and
⇒ “5.2 Refrigerant oil capacities”,
page 15 ).
2. Working with air conditioner service station 151
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ On a new air conditioner com‐
pressor filled with more than
150 cm3, pour out as much re‐
frigerant oil as possible before
flushing.
♦ Reason: The oil volume to be
displaced in one work step may
be restricted depending on the
version of air conditioner service
station .
Note
AG. Volkswagen AG d
agen oes
If the clean refrigerantyV
olkoil
sw is poured not
gu
out of a new airiseconditioner
d b com‐ ara
nte
pressor into tahorclean container and eo
this is subsequently
ss
au sealed air-tight, ra
c
the refrigerant oil can be re-used to
ce
le
un
top-up the refrigerant oil volume in
pt
an
d
the circuit.
itte
y li
rm
ab
pe
ility
6 - Refrigerant line
ot
wit
, is n
❑ For connection of air conditioner compressor to adapter ⇒ Item 7 (page 152)
h re
hole
spec
❑ Use a refrigerant line e.g. with part number 7L6 820 721 BF to set-up the flushing circuit ⇒ Electronic
es, in part or in w
parts catalogue
t to the co
7 - Adapter for connection on high pressure side of air conditioner compressor
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
rrectness of i
❑ From adapter case VW/Audi passenger vehicle set
l purpos
8 - Charging hose of flushing device for refrigerant circuits
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐
nform
ercia
ameter) to inlet of flushing device for refrigerant circuits.
m
a
com
9 - Flushing device for refrigerant circuits
ion in
r
❑ Different versions and different design of flushing devices for refrigerant circuits ⇒ Electronic parts cata‐
te o
thi
logue (Tools; Workshop equipment/tools; Air conditioning/heating)
s
iva
do
r
rp
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
um
fo
en
ng
❑ Depending on the layout of the air conditioner service station and the flushing device for refrigerant
t.
yi Co
op
circuits, there may be a service coupling for refrigerant circuits fitted at the outlet and in some cases at
C py
ht. rig
the inlet of the flushing device. If a service connection with a valve is installed to the outlet of the flushing
rig ht
py by
device, this valve must be opened completely when the service coupling is connected. If the valve is not
co Vo
by lksw
cted
opened completely, it restricts the refrigerant flow.
agen
Prote AG.
❑ If there is a connection for a service coupling fitted at the inlet of the flushing device, the inlet must be
adapted to allow for the refrigerant hose coming from the vehicle to be connected directly.
Note
A service coupling and a valve in the
inlet of the flushing device restrict
the refrigerant flow from the vehicle
into the flushing device.
10 - 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.
2.12 Cleaning refrigerant circuit
– Perform preparatory measures for cleaning (flushing with
R1234yf refrigerant)
152 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
⇒ “1.6.2 Preparations for cleaning refrigerant circuit (flushing
with R1234yf refrigerant)”, page 94
– Check the refrigerant volume in the air conditioner service sta‐
tion . There must be at least 6 kg of R1234yf refrigerant ⇒
Operating instructions of air conditioner service station .
– Empty container for used oil of air conditioner service station
⇒ Operating instructions of air conditioner service station .
– Connect the supply hose (high pressure side) of the air con‐
ditioner service station with an adapter to the low pressure line
leading to the air conditioner compressor (line with larger di‐
ameter)
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106 .
– Connect the return hose (low pressure or suction side) of the
air conditioner service station to the outlet of the flushing de‐
vice for refrigerant circuits.
– Connect the inlet of the flushing device for refrigerant circuits
with an adapter to the high pressure line leading to the air
conditioner compressor (line with smaller diameter)
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106 .
♦ Principle circuit diagrams for various flushing circuits
⇒ “1.6 Cleaning refrigerant circuit”, page 92
♦ Adapters for setting up flushing circuits
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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atio
om
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or c
thi
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o
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Cop py
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gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 153
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Air conditioning systems with refrigerant AG. Volkswa
gen R1234yf - gGeneral
en AG
doesinformation - Edition 01.2018
swa k not
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Note au ra
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ss
ce
e
nl
pt
♦ The components are almost always flushed against the direc‐
du
an
itte
tion of refrigerant flow when the air conditioning system is in
y li
erm
ab
operation. (Exception: electrically-actuated air conditioner
ility
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compressor) ⇒ page 92 .
wit
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h re
♦ When flushing, contaminants from the refrigerant circuit enter
hole
the flushing device for refrigerant circuits and the air condi‐
spec
tioner service station and are retained in the filters and dryers
es, in part or in w
t to the co
installed within. Depending on the contamination, these com‐
ponents must be renewed at shorter intervals than prescribed
as per the operating instructions of the air conditioner service
rrectness of i
station or flushing device for refrigerant circuits ⇒ Operating
instructions of air conditioner service station .
l purpos
♦ The filter in the flushing device for refrigerant circuits should
be changed (depending on the type and severity of contami‐
nf
ercia
nation in the flushed refrigerant circuits) after about 5 to 10
orm
flushing cycles (flushed vehicles). If a heavily contaminated
m
atio
m
refrigerant circuit is flushed (the refrigerant oil from the refrig‐
o
n in
c
erant circuit is black and viscous or there are large amounts
or
thi
e
of swarf in the refrigerant circuit), renew the filter after flushing
t
sd
iva
this refrigerant circuit. After such heavy contamination of the
o
r
rp
cu
refrigerant circuit, it is a good idea to flush the system again
o
m
f
en
ng
after replacing the filter.
t.
yi Co
Cop py
♦ Depending on the type of contamination, deposits (old refrig‐
t. rig
gh ht
yri by
erant oil and friction dust from the air conditioner compressor) cop Vo
by lksw
will gather in the sight glass of the rinsing device for refrigerant cted agen
Prote AG.
circuits. If necessary, clean this sight glass after flushing and
flush the refrigerant circuit through again to make sure it is
clean (one pass is sufficient in this instance).
♦ Liquid refrigerant cannot be routed through the expansion
valve, restrictor and desiccant bag of certain receivers at the
necessary rate. Therefore remove these components and re‐
place them with adapters if applicable ⇒ page 92 and ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit (vehicle-specific work‐
shop manual).
♦ Adapters to connect air conditioner service station and to
bridge certain components of the refrigerant circuit
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 106 .
Perform flushing (the procedure runs automatically as per the
program in the air conditioner service station ⇒ Operating in‐
structions of air conditioner service station )
– Switch on the air conditioner service station ⇒ Operating in‐
structions of air conditioner service station .
– Select the flushing program on the air conditioner service sta‐
tion ⇒ Operating instructions of air conditioner service station .
– Flush the refrigerant circuit (duration approx. 1 to 1.5 hours for
one flushing cycle with 4 cycles) ⇒ Operating instructions of
air conditioner service station .
154 Rep. gr.87 - Air conditioning system
AG. Volkswagen AG d
agen oes
olksw no
d by
V
Arteon 2018 ➤ , Atlast g2017
ua
ran ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
e
oris Air conditioning systems with refrigerant teeR1234yf - General information - Edition 01.2018
h
aut or
ac
ss
ce
e
nl
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du
Note
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♦ Flushing procedure
ility
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⇒ “1.6.3 Refrigerant circuit cleaning procedure”, page 97 .
wit
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♦ Perform flushing as instructed in the operating manual of the
hole
spec
air conditioning service station ⇒ Operating instructions of air
es, in part or in w
conditioner service station .
t to the co
♦ Depending on the type of air conditioning service station , the
used oil tank has a capacity of about 125 cm 3 of refrigerant
rrectness of i
oil. If a system with a greater amount of refrigerant oil has to
be flushed, it may be necessary to empty the used oil tank after
l purpos
the first flushing process of a flushing cycle.
♦ Observe the refrigerant flowing back into the air conditioning
nf
ercia
o
service station from the refrigerant circuit. Once the refrigerant
rm
m
atio
flows clear and completely colourless through the inspection
om
window of the flushing device for refrigerant circuits in the air
n in
or c
conditioning service station , the refrigerant circuit is cleaned.
thi
te
sd
iva
♦ When flushing, the whole amount of refrigerant oil from the
o
r
rp
cu
refrigerant circuit is washed out (except for a very small
o
m
f
en
ng
amount, e.g. in the evaporator, but this is negligible).
t.
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Cop py
t. rig
♦ Where contamination is particularly high, it may be necessary
gh ht
yri by
to carry out the flushing process twice (two flushing cycles with
op Vo
by c lksw
4 flushing processes each).
cted agen
Prote AG.
– At the end of the flushing process, check the inspection win‐
dow or windows of the flushing device for refrigerant circuits.
If dirty, clean as per the instructions of the flushing device for
refrigerant circuits or air conditioner service station and per‐
form the flushing process again to be safe (running through
once over a period of approx. 30 min. is sufficient) ⇒ Operating
instructions air conditioner service station .
– Check the pressure in the refrigerant circuit. There must be no
overpressure in the refrigerant circuit (evacuate twice briefly if
necessary).
– Remove the connections to the air conditioning service station
from the refrigerant circuit of the vehicle (there should be no
overpressure in the refrigerant circuit)
– Renew these vehicle-specific components (restrictor and res‐
ervoir, expansion valve and receiver / dryer cartridge in the
reservoir) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refriger‐
ant circuit; System overview - refrigerant circuit (vehicle-spe‐
cific workshop manual) and ⇒ Electronic parts catalogue .
– Depending on the complaint, renew the air conditioner com‐
pressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit (vehicle-specific
workshop manual) and ⇒ Electronic parts catalogue or drain
the remaining refrigerant oil from the removed air conditioner
compressor ⇒ “1.5 Renewing components”, page 79 and fill
with the requisite amount of fresh refrigerant oil again ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Technical data (vehicle-
specific workshop manual) and ⇒ Heating, air conditioning;
Rep. gr. 00 ; Technical data; Refrigerant oil .
2. Working with air conditioner service station 155
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Replacement compressors contain a certain specified quantity
of refrigerant oil. On vehicles with two evaporators, a certain
amount of refrigerant oil may also have to be filled in the circuit
if necessary ⇒ Heating, air conditioning; Rep. gr. 00 ; Tech‐
nical data; Refrigerant oil .
♦ If the air conditioner compressor does not need to be renewed,
replenish the refrigerant oil accordingly up to the prescribed fill
level (empty or flush refrigerant oil and pour Athe prescribed
G. Volkswagen AG
agen
volume back into the air conditioner ocompressor or refrigerant
does
lksw not
circuit) ⇒ “1.5 Renewing components”,db
y V
page 79 and ⇒ Heat‐ gu
ara
ing, air conditioning; Rep. gr. oris00 ; Technical data; refrigerant
e nte
eo
oil .
h
aut ra
s s c
ce
le
un
pt
– Completely reassemble the refrigerant circuit again ⇒ Heat‐
an
d
itte
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
y li
erm
ab
overview - refrigerant circuit (vehicle-specific workshop man‐
ility
ot p
ual).
wit
is n
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– Evacuate and charge the refrigerant circuit in accordance with
ole,
the specifications
spec
urposes, in part or in wh
⇒ “2.5 Evacuating refrigerant circuit”, page 135 ,
t to the co
⇒ “2.6 Charging refrigerant circuit”, page 141 and ⇒ Heating,
air conditioning; Rep. gr. 00 ; Technical data .
– Bring the air conditioning system into operation in the prescri‐
rrectne
bed manner ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; Bringing air conditioning system into operation
ss
after charging refrigerant circuit (vehicle-specific workshop
o
cial p
f
manual) and
inform
⇒ “2.7 Bringing air conditioning system into service after
mer
charging”, page 144 atio
om
2.13 Filling contaminated refrigerant in a re‐
c
i
or
n thi
e
cycling cylinder for analysis, processing
t
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o
pr
or disposal
um
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en
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⇒ “2.13.1 Filling contaminated refrigerant in a recycling cylinder Cop py
t. rig
using technical equipment”, page 156 opyri
gh by
Vo
ht
by c lksw
⇒ “2.13.2 Filling undercooled contaminated refrigerant in a recy‐ Prote
cted agen
cling cylinder”, page 159
AG.
2.13.1 Filling contaminated refrigerant in a re‐
cycling cylinder using technical equip‐
ment
Note
♦ Some manufacturers may provide accessory devices (extract‐
ing or disposal units) that they claim to be approved for the
extraction of gases of unknown composition. These devices,
however, have not been tested or approved by Volkswagen
so that we cannot draw any conclusions about their operation
or suitability.
♦ In order to be filled into an evacuated recycling cylinder without
any auxiliary equipment, the contaminated refrigerant must be
supercooled. The corresponding procedure has been ap‐
proved by Volkswagen and described accordingly
⇒ page 159 .
156 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
CAUTION
Risk of explosion if non-approved equipment is used
Refrigerant of unknown composition may expand due to a
chemical reaction or overheating causing the used device to
burst.
– Make sure to use only devices and accessories that have
been authorised and approved by the manufacturer for be‐
ing suitable for operation with gases of unknown composi‐
tion in accordance with the relevant rules and regulations.
– Always read the owner's manual of these devices before
using them.
– Make sure to comply with all instructions given in the re‐
spective owner's manual when using the devices.
CAUTION
Risk of explosion from overfilling refrigerant reservoirs.
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swa are does
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– Use a refrigerant tank with safety valve. tho r eo
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– Never exceed the permissible fill level of
s the refrigerant tank.
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CAUTION
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Chemical reactions from contaminated refrigerant. Mixing
wit
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gases of unknown composition can cause different chemical
h re
reactions.
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Risk of injuries.
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t to the co
– Never mix together refrigerants of different origins.
rrectness of i
Extract refrigerant of unknown composition from refrigerant circuit
and collect it in a recycling cylinder.
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– Connect the extracting and charging unit to the refrigerant cir‐
cuit of the vehicle and to a recycling cylinder observing the
nf
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corresponding owner's manual.
orm
m
atio
– Operate the extracting and charging unit according the in‐
om
n in
structions in the corresponding owner's manual.
or c
thi
te
– Monitor the extraction process using a suitable pressure
sd
iva
gauge.
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op py
Note
. C rig
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by lksw
♦ You can use your own pressure gauge or the pressure gauge cted agen
Prote AG.
of the air conditioner service station to monitor the extraction
process.
♦ As it will take some time until the entire contaminated refrig‐
erant has been extracted from the refrigerant circuit, make
sure that you do not switch off the extracting and charging unit
until the refrigerant circuit has been drained completely. To be
absolutely sure about this, watch the display of the connected
pressure gauge.
After the entire contaminated refrigerant has been extracted from
the circuit:
– Switch off unit.
– Close the manual shut-off valve of the recycling cylinder.
2. Working with air conditioner service station 157
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Wait a certain amount of time (e.g. 20 minutes), then check if
pressure started building up again in the vehicle’s refrigerant
circuit.
Note
If pressure started building up in the refrigerant circuit due to
evaporation of refrigerant, fill the refrigerant responsible for this
increase in pressure into the recycling cylinder.
A n AG d G. Volkswage
agen
– Remove the charge hose and adapter olfrom
ksw the recycling cyl‐
oes
not
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inder, and seal the connection ofethe
d b recycling cylinder with ara
nte
is
the sealing cap. thor eo
au ra
– The paperwork required forss analysis, processing (or disposal) c
ce
le
of contaminated refrigerant must be filled in completely (dis‐
un
pt
posal record, acceptance certificate etc.).
an
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itte
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ility
ot
Note
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♦ All of the information and documents for analysis, processing
es, in part or in w
(or disposal) can be obtained from your gas processing / gas
t to the co
disposal company.
♦ Included with the recycling cylinder is a form. Kindly fill this in
rrectness of i
accordingly and attach it to the recycling cylinder.
♦ If it is not possible to weigh the recycling cylinder before and
l purpos
after filling with contaminated refrigerant, the fill volume speci‐
fied for the vehicle in question can be quoted as the amount
nform
ercia
of refrigerant that was filled in the recycling cylinder. This is
permissible as only the amount of refrigerant from a vehicle is
m
a
com
t
filled in a recycling cylinder. ion in
r
te o
thi
– Take the recycling cylinder to a suitable location for storage
s
iva
do
until it is ready to be collected by the gas processing / gas
r
rp
cum
fo
disposal company.
en
ng
t.
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op
– Fill out the data sheet for the recycling cylinder (R-cylinder) if C py
t. rig
the refrigerant is contaminated, and firmly attach it to the re‐
gh ht
yri by
cycling cylinder.
op Vo
by c lksw
cted agen
Prote AG.
Note
♦ In the “Other comments” section, details can be provided re‐
garding e.g. who is to receive the analysis results and in which
way.
♦ Example for recycling cylinder (R-cylinder) data sheet
⇒ page 164 .
– Evacuate the refrigerant circuit with the air conditioner service
station for at least 1 hour
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
158 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note n AG. Volkswagen AG do
lkswage es n
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♦ Subsequent evacuation results in the last remnants ir se of conta‐
d b ran
tee
minated refrigerant, which could still be in the refrigerant
utho oil, or
being removed at an absolute pressure of less ss than 10 mbar.
a ac
ce
e
♦ If, after the unit has been switched off, a pressure that is higher
nl
pt
du
an
than the maximum permissible pressure for the function
itte
y li
“Evacuate” to be started on the air conditioner service station
erm
ab
ility
builds up in the refrigerant circuit, release this pressure (drain
ot p
refrigerant) into the workshop extraction unit.
wit
, is n
h re
hole
♦ The next steps depend on the complaint with the refrigerant
spec
circuit es, in part or in w
t to the co
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
2.13.2 Filling undercooled contaminated refrig‐
rrectness of i
erant in a recycling cylinder
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Note
orm
m
atio
m
♦ To ensure that the contaminated refrigerant is filled automat‐
o
n in
c
ically without supporting equipment into an evacuated recy‐
or
thi
cling cylinder, the cylinder must be supercooled.
te
sd
iva
o
r
♦ To cool down the evacuated recycling bottle, use an insulated
rp
cu
o
m
f
container and dry ice.
en
ng
t.
yi Co
op
♦ Dry ice is solid carbon dioxide (CO2) that changes from a solid
C py
t. rig
gh ht
directly to a gaseous state at -78°C. pyri by
Vo
co lksw
by
cted agen
♦ Most of the gases used as refrigerant have only a low vapour Prote AG.
pressure at very low temperatures (less than 0.6 bar absolute
pressure at -50°C). When an extremely cooled recycling cyl‐
inder is connected to a refrigerant circuit, the refrigerant liq‐
uefies in the cold recycling cylinder and the pressure in the
refrigerant circuit drops below ambient pressure
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17 .
♦ Commercially available recycling cylinders are usually made
of common mild steel. These are not always suitable for low
temperatures (down to -78°C in this case), which is why only
recycling cylinders suitable for this application should be used
and why the cylinder should be allowed to reach ambient tem‐
perature slowly (e.g. by placing the insulated container with
recycling cylinder in a secure, well-ventilated location where
the dry ice can evaporate safely).
Special tools and workshop equipment required
♦ Extraction unit - VAS 581 007- ⇒ Electronic parts
catalogue (ETKA)
♦ At least 10 kg of commercially available dry ice (pellets or
granules)
♦ Evacuated recycling cylinder from gas supplier for contami‐
nated R1234yf refrigerant, which is suitable for very low tem‐
peratures (e.g. with a permissible fill capacity greater than
3.0 kg).
♦ Commercially available bottle adapter with seal (for connect‐
ing charge hose to recycling bottle, internal W 21.8 x 1/14 LH
left-hand thread and M 12 x 1.5-6G in accordance with SAE
J639)
2. Working with air conditioner service station 159
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Commercially available charge hose for R1234yf refrigerant
with seals (2m charge hose with external M12 x 1.5-6G thread
in accordance with SAE J639)
♦ Commercially available low-pressure service coupling in nac‐
AG. Volkswagen AG d
cordance with SAE J639 olks
wage oes
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tho eo
Note au ra
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ss
ce
le
Dry ice evaporates at ambient temperature even from the insu‐
un
pt
an
d
lated container (about 20 to 30% per day depending on the itte
y li
rm
ambient conditions). Therefore, only order the dry ice once all of
ab
pe
ility
the necessary tools are ready and the measures can be per‐
ot
wit
formed immediately after receipt of the dry ice (e.g. do not order
, is n
h re
the dry ice on a Friday if work is not going to be carried out at the
hole
spec
weekend).
es, in part or in w
t to the co
CAUTION
rrectness of i
Risk of frost-bite and suffocation from dry ice.
Frost-bite on the skin and other body parts possible and risk of
l purpos
suffocation in gaseous state.
– Wear protective gloves.
nform
ercia
– Wear protective goggles.
m
a
– Only work with dry ice in well ventilated areas.
com
tion in
– Never work in or near cellars or other low lying areas.
r
te o
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s
iva
do
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fo
CAUTION
en
ng
t.
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op
Risk of explosion from incorrectly stored dry ice. C py
t. rig
gh ht
yri
As dry ice evaporates, pressure builds up in the container. Un‐ p by
o Vo
by c
suitable containers could burst.
lksw
cted agen
Prote AG.
– Only transport and store dry ice in dedicated containers.
Refilling refrigerant using a supercooled recycling cylinder
• All requisite tools, equipment and a sufficient quantity of dry
ice ready
– Remove seal on recycling cylinder and unscrew sealing cap
from connection.
160 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Sealed recycling cylinders from your gas supplier usually
come pre-evacuated.
♦ Should the recycling cylinder not be evacuated, evacuate it as
necessary using a vacuum pump or an air conditioner service
station . n AG. Volkswagen AG ge does
swa
♦ Recycling cylinders are clearlybmarked
yV
olk as such and, unlike not
gu
refrigerant cylinders, do notrishave
ed a non-return valve thereby ara
nte
making them suitable forutfilling.
ho eo
ra
a c
ss
♦ Recycling cylinders are designed for international use, which
ce
le
is why the “O” on the handwheel means “Open” (cylinder valve
un
pt
an
d
= open) and not “0” (zero = closed).
itte
y li
erm
ab
♦ If an absolute pressure greater than 100 mbar but less than
ility
ot p
900 mbar is measured in the recycling cylinder, evacuate the
wit
is n
recycling cylinder using a vacuum pump (or an air conditioner
h re
ole,
service station ) (residual pressure less than 50 mbar)
spec
urposes, in part or in wh
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
t to the co
♦ If an absolute pressure greater than 900 mbar is measured in
the recycling cylinder, this could be due to a number of rea‐
sons. The manual shut-off valve was opened and not closed
rrectne
properly or the recycling cylinder had previously been used to
store refrigerant and then was not evacuated properly
s
⇒ “2.10 Emptying air conditioner service station”, page 149
s o
cial p
(evacuate recycling cylinder). The recycling cylinder is leaking
f in
(return the recycling cylinder to the supplier).
form
mer
atio
m
– Connect a vacuum metre (or air conditioner service station )
o
n
c
i
or
n
to the recycling cylinder.
thi
te
sd
va
– Carefully open the manual shut-off valve of the recycling cyl‐
i
o
pr
cum
r
inder to check the vacuum and then check the vacuum in the
fo
en
ng
cylinder.
t.
yi Co
Cop py
– If necessary, evacuate the recycling cylinder with the air con‐
t. rig
gh ht
yri
ditioner service station .
p by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Should there be any air trapped in the recycling cylinder, it can
be evacuated using an air conditioner service station for
R1234yf. To do this, unscrew the low pressure service cou‐
pling from the charge hose of the air conditioner service station
and connect the charge hose directly to the recycling cylinder
adapter for the extraction device (for R1234yf refrigerant) - dry
ice box .
♦ If air is trapped in the recycling cylinder and there is no air
conditioner service station for R1234yf available, the recycling
cylinder can also be evacuated with an air conditioner service
station for R134a using a relevant flushing container and
adapter -VAS 6338/38- along with the charge hose from ex‐
traction device (for R1234yf refrigerant) - dry ice box .
• Residual pressure in the recycling cylinder less than 10 mbar
absolute pressure.
2. Working with air conditioner service station 161
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Recycling cylinders are pre-evacuated by the supplier, though
it is not always possible to ensure that the vacuum will remain
intact in storage.
♦ To reliably determine the type and scope of the contamination
of the refilled refrigerant during analysis of the contaminated
refrigerant, the recycling cylinder must be evacuated before
refilling to a residual pressure less than 50 mbar.
– Switch off ignition. . Volkswagen AG
gen AG does
swa
– Ensure that the workplace y V is well ventilated. Switch onoaddi‐
olk n t
gu
tional workshop extraction
edb systems if fitted. ara
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ho eo
– Connect the charge
aut hose with a suitable adapter to the evac‐ ra
s c
uated recycling cylinder.
s
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e
nl
pt
du
an
itte
CAUTION
y li
erm
ab
ility
Risk of explosion from overfilling refrigerant reservoirs.
ot p
wit
, is n
Refrigerant can expand and cause reservoirs to burst if they are
h re
overfilled.
hole
spec
– Use a refrigerant tank with safety valve.
es, in part or in w
t to the co
– Never exceed the permissible fill level of the refrigerant tank.
rrectness of i
Note
l purpos
♦ Since contaminated refrigerant is only filled into a recycling
nform
ercia
cylinder from a vehicle in the following work routine, there is
no danger of a recycling cylinder being overfilled with a fill vol‐
m
at
om
ume exceeding 3.0 kg.
ion
c
in t
or
♦ If contaminated refrigerant is filled into a recycling cylinder e.g.
his
ate
from an air conditioner service station , measures must be
do
priv
taken to ensure that the recycling cylinder is not overfilled due
cum
for
to the larger volume. Use a recycling cylinder with an appro‐
en
ng
t.
yi
priate permissible fill capacity and when refilling ensure by
Co
Cop py
means of weighing that the maximum permissible fill volume
t. rig
gh ht
yri
is not exceeded. p by
o Vo
by c lksw
cted agen
Prote AG.
CAUTION
Chemical reactions from contaminated refrigerant. Mixing
gases of unknown composition can cause different chemical
reactions.
Risk of injuries.
– Never mix together refrigerants of different origins.
162 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
– Connect the service coupling for R1234yf refrigerant -5- to the
charge hose -4-.
– Connect the charge hose -4- with cylinder adapter -3- (and
seal -2-) to the recycling cylinder -1-.
– Place the spacer -6- in the insulated container -7-.
– Cover the base of the insulated container -7- with dry ice.
– Place the recycling cylinder -1- in the insulated container -7-
extraction device (for R1234yf refrigerant) - dry ice box .
– Pour the remainder of the dry ice in the insulated container
-7-.
– Cool down the recycling container -1- with dry ice (for approx.
15 minutes).
– Connect the recycling cylinder -1- via the service coupling
-5- to the connection of the air conditioner service station (or
the vehicle's refrigerant circuit).
– Open the manual shut-off valve of the recycling cylinder -1-.
AG. Volkswagen AG d
agen oes
olksw not
Note ed b y V gu
ara
ris nte
tho eo
Recycling
s a cylinders are designed for international use, which
u
is ra
c
why the “O” on the handwheel means “Open” (cylinder valve =
s
ce
le
open) and not “0” (zero = closed).
un
pt
an
d
itte
y li
erm
ab
– Connect a pressure gauge to the refrigerant circuit (or use the
ility
ot p
pressure gauge of the air conditioner service station ) and
wit
is n
check the pressure in the refrigerant circuit.
h re
ole,
spec
– Carefully open the service coupling -5- on the charge hose for
urposes, in part or in wh
the recycling cylinder and allow the refrigerant to flow out
t to the co
slowly into the recycling cylinder -1-.
– Wait until the refrigerant in the recycling cylinder -1- has liq‐
rrectne
uefied (watch the display on the connected pressure gauge).
ss
Note
o
cial p
f inform
mer
♦ You can use your own pressure gauge or the pressure gauge
atio
of the air conditioner service station to monitor the extraction
om
process.
c
i
or
n thi
te
♦ As soon as the displayed pressure is less than 0.3 bar after
sd
iva
o
r
approx. 60 minutes, it is safe to assume that the whole refrig‐
p
cum
r
fo
erant in the recycling cylinder is liquefied.
en
ng
t.
yi Co
op
♦ Complete evaporation of the contaminated refrigerant from the
C py
t. rig
refrigerant circuit takes some time. After 60 minutes, it is safe
gh ht
pyri by
to assume that the whole refrigerant has evaporated.
co Vo
by lksw
cted agen
Prote AG.
– Close the service coupling -5- and manual shut-off valve of the
recycling cylinder -1-.
– Remove the charge hose -4- and cylinder connecting piece
-3- from the recycling cylinder -1- and close the recycling cyl‐
inder with the cap.
– The paperwork required for analysis, processing (or disposal)
of contaminated refrigerant must be filled in completely (dis‐
posal record, acceptance certificate etc.).
2. Working with air conditioner service station 163
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Arteon 2018 ➤ , Atlas
auth 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter or
ac 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition
ss
01.2018
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ All of the information and documents for analysis, processing
h re
hole
(or disposal) can be obtained from your gas processing / gas
spec
disposal company.
es, in part or in w
t to the co
♦ Included with the recycling cylinder is a form. Kindly fill this in
accordingly and attach it to the recycling cylinder.
rrectness of i
♦ If it is not possible to weigh the recycling cylinder before and
after filling with contaminated refrigerant, the fill volume speci‐
l purpos
fied for the vehicle in question can be quoted as the amount
of refrigerant that was filled in the recycling cylinder. This is
permissible as only the amount of refrigerant from a vehicle is
nf
ercia
o
filled in a recycling cylinder.
rm
m
atio
om
n in
c
– Move the insulated box -7- with recycling cylinder -1- and dry
or
thi
ice to a secure, well ventilated area outside the building.
te
sd
iva
o
r
rp
cu
– Open the lid of the insulated box -7- or remove and allow the
o
m
f
dry ice to evaporate.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
Do not take the recycling cylinder -1- out of the insulated container
-7- until the dry ice has evaporated and the recycling cylinder has
adjusted to ambient temperature.
– Remove the recycling cylinder -1- from the insulated container
-7-.
– Take the recycling cylinder -1- to a suitable location for storage
until it is ready to be collected by the gas processing / gas
disposal company.
– Evacuate the refrigerant circuit with the air conditioner service
station for at least 1 hour
⇒ “2.5 Evacuating refrigerant circuit”, page 135 .
Note
♦ Subsequent evacuation results in the last remnants of conta‐
minated refrigerant, which could still be in the refrigerant oil,
being removed at an absolute pressure of less than 10 mbar.
♦ The next steps depend on the complaint with the refrigerant
circuit
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 .
– Fill out the data sheet for the recycling cylinder (R-cylinder) if
the refrigerant is contaminated and firmly attach it to the recy‐
cling cylinder -1-.
Note
In the “Other comments” section, details can be provided regard‐
ing e.g. who is to receive the analysis results and in which way.
Example for recycling cylinder (R-cylinder) data sheet
164 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Data sheet for R-cylinder if refrigerant is contaminated
Service contact
Dealership contact:
Email address:
Customer information:
Surname, first name:
Street:
Town/city:
Vehicle model
Identification
Vehicle identification
number:
Mileage:
Gas analysis performed
on:
Information about R-cylinder
Cylinder number:
Cylinder weight with
contents:
(gross weight)
Fill volume
(net weight)
AG. Volkswagen AG d
Other comments agen oes
olksw not
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rise nte
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au ra
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2.14 Checking pressures
ce
e
nl
pt
du
an
itte
y li
⇒ “2.14.1 General information on checking pressures in the re‐
erm
ab
frigerant circuit”, page 165
ility
ot p
wit
, is n
⇒ “2.14.2 Pressures and temperatures in refrigerant circuit”, page
h re
168
hole
⇒ “2.14.3 Checking pressures in the refrigerant circuit with the spec
es, in part or in w
ignition switched off”, page 171 t to the co
⇒ “2.14.4 Checking pressures with air conditioning system switch‐
ed on - vehicles with mechanical air conditioning compressor”,
rrectness of i
page 178 .
l purpos
⇒ “2.14.5 Checking pressures with air conditioning system switch‐
ed on - vehicles with electrical air conditioning compressor”, page
nform
ercia
200
m
at
2.14.1 General information on checking pres‐
om
ion
c
sures in the refrigerant circuit
in t
or
his
ate
do
priv
cum
for
Note
en
ng
t.
yi Co
Cop py
t.
Work on the refrigerant circuit that involves the air conditioner
rig
gh ht
yri by
service station can usually be carried out without the need to de- cop Vo
by lksw
energise the high-voltage system. cted agen
Prote AG.
2. Working with air conditioner service station 165
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Vehicles with electrically-actuated valves in the refrigerant circuit
that are not open when unenergised:
Note
On vehicles with high-voltage system and auxiliary air condition‐
ing system functions (“heat pump mode” or “cooling of high-
voltage battery”), valves may be installed in the refrigerant circuit
that are not open when unenergised. These valves are opened
and closed e.g. via incremental motors and are no longer actu‐
ated when the ignition is switched off. To check the pressures in
the refrigerant circuit with the air conditioning system switched off,
however, no areas may be isolated, which is why these valves
must be opened before work is carried out ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
refrigerant circuit and ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode. gen AG
. Volkswagen AG
d
a oes
ksw not
y Vol gu
b
– Use the vehicle diagnostic tester to open the electrically-ac‐
ris
ed
ara
nte
tuated valves that are not open when unenergised
tho ⇒ Vehicle eo
au
diagnostic tester in “Guided Fault Finding”ssmode.
ra
c
ce
le
All vehicles
un
pt
an
d
itte
y li
rm
ab
NOTICE
pe
ility
ot
Risk of damage to the air conditioner compressor or air condi‐
wit
, is n
h re
tioner service station.
hole
spec
Opening the valves with the air conditioning system switched
es, in part or in w
on can cause a short circuit between the high pressure and low
t to the co
pressure side.
– Never open valves on the high pressure or low pressure side
with the air conditioning system switched on.
rrectness of i
l purpos
Note
nform
mercia
♦ Certain conditions for testing are pertinent to a certain vehicle
a
com
and are described in the vehicle-specific workshop manual ⇒ tion in
r
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
te o
thi
Checking cooling output .
s
iva
do
r
rp
cum
♦ Check the cooling output ⇒ Heating, air conditioning; Rep. gr.
fo
en
g
00 ; Repair instructions; Checking cooling output (vehicle-spe‐
n
t.
yi Co
op
cific workshop manual). C py
t. rig
gh ht
yri by
♦ Connections with valve and service connections for measuring cop Vo
by lksw
and testing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐ cted agen
Prote AG.
erant circuit; System overview - refrigerant circuit (vehicle-
specific workshop manual)
♦ Depending on the version of air conditioner compressor, a
valve may be installed on the high-pressure side that prevents
liquefied refrigerant flowing back into the air conditioner com‐
pressor after the air conditioning system is switched off. If an
air conditioner compressor with this valve is installed in a ve‐
hicle with a refrigerant circuit with expansion valve, it could
take some time before the pressure on the high-pressure side
drops (the expansion valve is cold and the pressure on the
low-pressure side rises quickly after switching off, the expan‐
sion valve closes and refrigerant only flows slowly on the low-
pressure side). If the air conditioner compressor is switched
on, the pressure on the low-pressure side drops, the expan‐
sion valve opens and refrigerant can flow on the low-pressure
side.
166 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Under certain operating conditions, residual moisture in the re‐
frigerant circuit may lead to the formation of ice at the air condi‐
tioner compressor regulating valve. The ice impairs the air
conditioner compressor control and causes the evaporator to be
cooled excessively and to ice up. Icing-up of the evaporator may
give rise to the following problems:
♦ Repeated or sporadic failure of the air conditioner (no cooling/
heat output) after a lengthy journey. After switching off the en‐
gine and waiting for a short period, operation of air conditionerwagen AG. Volkswagen AG doe
returns to normal. yV
olks s no
t gu
b ara
ed
♦ Misting up of the windows on the inside after a long ho journey;
ris nte
e
the windows are initially not cleared even by pressing
aut the De- or
ac
ss
frost button; the air conditioner functions properly again after
ce
e
nl
a short delay following engine shut-off (or after switching off
pt
du
an
the air conditioner).
itte
y li
erm
ab
Remedy:
ility
ot p
wit
, is n
– On vehicles with an air conditioner compressor with air con‐
h re
ditioner compressor regulating valve - N280- , check the
hole
spec
measured value of the evaporator output temperature sender
es, in part or in w
- G263- (via the “Read measured values” function). If the
t to the co
measured value of the sender is too low under the operating
conditions described by the customer (at an ambient temper‐
ature above 0°C, colder than 0°C for an extended period even
rrectness of i
though the -N280- is currently not actuated) or too high (higher
l purpos
than approx. 10°C, even though the air conditioning system is
functioning properly): the evaporator may ice up due to the
incorrect measured value ⇒ Vehicle diagnostic tester in “Gui‐
nf
ercia
ded Fault Finding” mode - air conditioning system and ⇒
orm
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
m
atio
m
Checking cooling output (vehicle-specific workshop manual).
o
n in
or c
– On vehicles without evaporator output temperature sender -
thi
te
sd
a
G263- , use e.g. the footwell vent temperature sender - G192-
iv
o
r
rp
cu
to check the outlet temperature with the temperature set to
o
m
f
“low” or “cold” for the driver and front passenger side with the
en
ng
t.
yi
lowest setting (4 or 5 bars) for the fresh air blower speed, air
Co
Cop py
outlet in the footwell and fresh air mode under the operating ht. rig
rig ht
conditions described by the customer. If the measured value py by
co Vo
by lksw
of the sender is too low (with an ambient temperature higher Prote
cted AG.
agen
than 0°C, colder than 0°C for an extended period), the evap‐
orator could ice up due to the wrong measured value ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air condi‐
tioning system.
– On vehicles with shut-off valves in the refrigerant circuit, check
the function and actuation of these valves ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode - air conditioning sys‐
tem, ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit and ⇒ Heating,
air conditioning; Rep. gr. 00 ; Repair instructions; Checking
cooling output (vehicle-specific workshop manual).
– Check the refrigerant line from the evaporator (or from the in‐
ner heat exchanger) and the air conditioner compressor (thick
pipe, low pressure side) with the engine running. If this line is
very icy when the complaint is encountered (a thin layer of ice
is acceptable), this is also evidence that the temperature in the
evaporator is too low ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific workshop manual).
– Empty the refrigerant circuit, renew the receiver with dryer,
renew the reservoir with dryer or desiccant cartridge and then
evacuate the refrigerant circuit for at least 3 hours ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - refrigerant circuit (vehicle-specific workshop manual)
and ⇒ page 124 .
2. Working with air conditioner service station 167
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ ⇒ “2.14.3 Checking pressures in the refrigerant circuit with the
ignition switched off”, page 171
♦ ⇒ “2.14.4 Checking pressures with air conditioning system
switched on - vehicles with mechanical air conditioning com‐
pressor”, page 178 .
♦ ⇒ “2.14.5 Checking pressures with air conditioning system
switched on - vehicles with electrical air conditioning com‐
pressor”, page 200
2.14.2 Pressures and temperatures in refriger‐
ant circuit wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
General information about pressures and temperatures
db
y in the re‐ ara
frigerant circuit ⇒ page 168 rise nte
ho t eo
au ra
Pressures and temperatures in refrigerantsscircuit with expansion c
valve ⇒ page 169
ce
le
un
pt
an
d
itte
General information about pressures and temperatures in the re‐
y li
erm
ab
frigerant circuit
ility
ot p
wit
♦ The pressures and temperatures in the refrigerant circuit de‐
is n
h re
pend on the current operating conditions (e.g. engine speed,
ole,
radiator running at level 1, 2, or 3, engine temperature, air
spec
urposes, in part or in wh
conditioner compressor actuation on or off) as well as envi‐
t to the co
ronmental influences (e.g. ambient temperature, humidity, re‐
quired cooling output).
♦ On vehicles with air conditioner compressor regulating valve -
rrectne
N280- , the pressure on the low pressure side is varied by
means of -N280- actuation.
ss o
♦ For these reasons, the values given in the following table may
cial p
f in
only be considered guidelines. They occur at an engine speed
form
mer
of 1,500 to 2,000 rpm and an ambient temperature of 20°C
atio
after about 20 minutes.
om
n
c
i
or
n
♦ Refer to the vehicle-specific refrigerant circuit for the pressure
thi
te
sd
gauge set measurement connections ⇒ Heating, air condi‐
iva
o
r
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific work‐
p
cum
r
fo
shop manual).
en
ng
t.
yi Co
op
♦ At 20°C and with the engine stationary, the refrigerant circuit
C py
t. rig
gh
will adjust itself to a pressure of 4.7 bar overpressure
ht
pyri by
Vo
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17 (va‐
co lksw
by
cted agen
pour pressure table). Prote AG.
Note
♦ Pressure is indicated in various units: 1 MPa (Mega-Pascal)
is equal to 10 bar or 145 psi; 1 bar absolute pressure is equal
to 0 bar, which is about the same as ambient pressure (at‐
mospheric pressure).
♦ The pressures and temperatures in refrigerant circuits with re‐
strictor and reservoir are about the same as those in refriger‐
ant circuits with expansion valve. Since Volkswagen/Audi
currently only installs refrigerant circuits with expansion valve,
just this refrigerant circuit is described here.
168 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Pressures and temperatures in refrigerant circuit with expansion
valve
Note
♦ The following log (p), h-diagram (logarithmic pressure, energy
diagram) shows the processes that run during certain operat‐
ing conditions in the refrigerant circuit. These values change
depending on the environmental conditions (engine speed,
ambient temperature, requisite cooling output, etc.).
♦ The log (p), h-diagram shows the pressure (0 to 60 in bar ab‐
solute pressure) and the energy content (100 to 420, specific
enthalpy in kilojoules per kg of R1234yf refrigerant) in the re‐
frigerant circuit cycle.
♦ The arrows indicate the direction of refrigerant flow in the re‐
frigerant circuit.
A - Area with vaporous refrigerant
B - Area with gaseous refrigerant
C - Area with liquefied refrigerant
D - Supercritical pressure and temperature range, physical state
of refrigerant undetermined (no longer a separation between liq‐
uefied and gaseous refrigerant)
1- Low pressure side: output of inner heat exchanger, input of
air conditioner compressor, refrigerant is completely evapo‐
rated and gaseous, temperature of refrigerant is approx. -4°
C
. Volkswagen AG
gen AG d
2- High pressure olksside: output of air conditioner
wa oes
not compressor,
yV
input ofecondenser, refrigerant has been compressed
gu
and is
db ara
gaseous,
thoris temperature of refrigerant is up to approx.
nte
e 80°C
or
au a
3- High
ss pressure side: output of condenser (receiver), input
c of
ce
inner heat exchanger, refrigerant has been cooled down and
le
un
pt
is liquefied, temperature of refrigerant is approx. 55°C
an
d
itte
y li
erm
ab
4- High pressure side: output of inner heat exchanger, input of
ility
ot p
expansion valve, liquefied refrigerant has cooled down fur‐
wit
is n
ther, temperature of refrigerant is approx. 50°C
h re
ole,
5- Low pressure side: expansion valve on evaporator side, in‐
spec
urposes, in part or in wh
put of evaporator, liquefied refrigerant comes to rest and
t to the co
starts to evaporate, temperature of refrigerant approx. -7°C
6- Low pressure side: output of evaporator, expansion valve,
input of inner heat exchanger, refrigerant mainly evapora‐
rrectne
ted, small percentage is still vaporous, temperature of re‐
frigerant approx. -6°C
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 169
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The temperatures given relate to the refrigerant in the refrig‐
erant circuit. The temperatures deviate from this on the sur‐
face of components containing refrigerant
en AG. V
olkowing toGheat
swagen A
absorption and dissipation. olkswag does
not
V gu
by a
♦ The pressure and theristemperature,
ed too, are maintained at ap‐rante
prox. 3 bar absoluteau
thopressure (equates to approx. 2 bar over‐ eo
ra
pressure) in refrigerant
ss circuits with regulated air conditioner c
compressor despite thermal changes and different engine
ce
e
nl
pt
du
speeds. This applies however only within the rated range of
an
itte
the air conditioner compressor; if the rated range of the air
y li
erm
ab
conditioner compressor is exceeded, the pressure will in‐
ility
ot p
crease and so, too, will the temperature
wit
, is n
⇒ “2.14 Checking pressures”, page 165 .
h re
hole
spec
♦ On air conditioner compressors that do not regulate their per‐
es, in part or in w
formance themselves, the pressure on the low pressure side
t to the co
and thereby the evaporator temperature are regulated by the
respective control via the air conditioner compressor regulat‐
ing valve - N280- . Depending on the version and the setting,
rrectness of i
if an air temperature of less than approx. 2°C is measured after
the evaporator, the performance of the air conditioner com‐
l purpos
pressor is lowered. At below 0°C, -N280- actuation is switched
off. This prevents the evaporator from cooling down too much
nf
ercia
and becoming icy.
orm
m
♦ On vehicles with two evaporators and two expansion valves,
atio
m
the temperature and pressure in the refrigerant circuit are the
o
n in
c
same at the second evaporator as those in vehicles with only
or
thi
e
one evaporator and one expansion valve (parallel circuit).
t
sd
iva
o
r
rp
cu
♦ Depending on the version of refrigerant circuit, a component
o
m
f
en
ng
with inner heat exchanger may be installed. In the internal heat
t.
yi Co
op
exchanger, the hot liquid refrigerant flowing on the high pres‐ C py
t. rig
sure side supplies energy to the cold gaseous or vaporous gh ht
yri by
refrigerant flowing on the low pressure side, thus enhancing cop Vo
by lksw
the efficiency of the air conditioner
cted agen
Prote AG.
⇒ “1.2.13 Refrigerant line with internal heat exchanger”, page
51 .
♦ Depending on the version of control unit (e.g. operating and
display unit for front air conditioning system - E87- or Clima‐
tronic control unit - J255- ), the measured ambient conditions
(exterior temperature, moisture in the passenger compartment
etc.) and the control unit setting (passenger compartment tem‐
perature, operating mode etc.), the pressure and thereby also
the temperature at the output of the evaporator can also be
regulated at a higher temperature ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system.
170 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
2.14.3 Checking pressures in the refrigerant
circuit with the ignition switched off
Test prerequisites ⇒ page 171
Checking pressures with the ignition switched off ⇒ page 174
Conditions for testing
Note
♦ Work on the refrigerant circuit that involves the air conditioner
service station (checking the pressures in this case) can usu‐
ally be carried out without the need to de-energise the high-
voltage system.
♦ Only de-energise the high-voltage system if work on the high-
voltage system is necessary ⇒ page 3
All vehicles
Note
♦ Certain conditions for testing are pertinent to a certain vehicle
and are described in the vehicle-specific workshop manual ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output (vehicle-specific workshop manual).
♦ Depending on the version of air conditioner compressor, a
valve may be installed on the high-pressure side that prevents
liquefied refrigerant flowing back into the air conditioner com‐
pressor after the air conditioning system is switched off. If an
air conditioner compressor with this valve is installed in a ve‐
hicle with a refrigerant circuit with expansion valve, it could AG. Volkswagen AG d
agen oes
ksw
take some time before the pressure on the high-pressure byV
ol
side not
gu
drops (the expansion valve is cold and the pressurerised on the ara
nte
low-pressure side rises quickly after switchinguthoff, the expan‐
o eo
ra
sion valve closes and refrigerant only flowss slowly on the low-
s a c
pressure side). If the air conditioner compressor is switched ce
e
nl
on, the pressure on the low-pressure side drops, the expan‐ pt
du
an
itte
sion valve opens and refrigerant can flow on the low-pressure y li
erm
ab
side. ility
ot p
wit
, is n
♦ Check the cooling output ⇒ Heating, air conditioning; Rep. gr.
h re
hole
00 ; Repair instructions; Checking cooling output (vehicle-spe‐
spec
cific workshop manual).
es, in part or in w
t to the co
♦ Connections with valve and service connections for measuring
and testing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
rrectness of i
♦ Connect the air conditioner service station
l purpos
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 .
nform
ercia
Under certain operating conditions, residual moisture in the re‐
m
frigerant circuit may lead to the formation of ice at the air condi‐
at
om
io
tioner compressor regulating valve. The ice impairs the air
n
c
in t
r
conditioner compressor control and causes the evaporator to be
o
his
e
cooled excessively and to ice up. Icing-up of the evaporator may
at
do
riv
give rise to the following problems:
p
cum
for
en
g
♦ Repeated or sporadic failure of the air conditioner (no cooling/
n
t.
yi Co
op
heat output) after a lengthy journey. After switching off the en‐ C py
ht. rig
gine and waiting for a short period, operation of air conditioner rig ht
py by
returns to normal.
co Vo
by lksw
cted agen
Prote AG.
2. Working with air conditioner service station 171
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ Misting up of the windows on the inside after a long journey;
the windows are initially not cleared even by pressing the De- agen
AG. Volkswagen AG d
oes
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frost button; the air conditioner functions properly again after by Vol not
gu
ara
a short delay following engine shut-off (or after switchingorisoff
ed
nte
the air conditioner). auth eo
ra
ss c
Remedy:
ce
le
un
pt
an
d
– On vehicles with an air conditioner compressor with air con‐
itte
y li
ditioner compressor regulating valve - N280- , check the
erm
ab
ility
measured value of the evaporator output temperature sender
ot p
- G263- (via the “Read measured values” function). If the
wit
is n
h re
measured value of the sender is too low under the operating
ole,
conditions described by the customer (at an ambient temper‐
spec
urposes, in part or in wh
ature above 0°C, colder than 0°C for an extended period even
t to the co
though the -N280- is currently not actuated) or too high (higher
than approx. 10°C, even though the air conditioning system is
functioning properly): the evaporator may ice up due to incor‐
rrectne
rect actuation of -N280- or the incorrect measured value of -
G263- ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system and ⇒ Heating, air condition‐
ss
ing; Rep. gr. 00 ; Repair instructions; Checking cooling output
o
cial p
f
(vehicle-specific workshop manual).
inform
mer
– On vehicles without evaporator output temperature sender -
atio
m
G263- , use e.g. the footwell vent temperature sender - G192-
o
n
c
to check the outlet temperature with the temperature set to
i
or
n thi
e
“low” or “cold” for the driver and front passenger side with the
t
sd
va
lowest setting (4 or 5 bars) for the fresh air blower speed, air
i
o
pr
cum
r
outlet in the footwell and fresh air mode under the operating
fo
en
ng
conditions described by the customer. If the measured value
t.
yi Co
op
of the sender is too low (with an ambient temperature higher C py
t. rig
than 0°C, colder than 0°C for an extended period), the evap‐
gh ht
yri by
orator could ice up due to the wrong measured value ⇒ Vehicle
cop Vo
by lksw
cted
diagnostic tester in “Guided Fault Finding” mode - air condi‐
agen
Prote AG.
tioning system.
– On vehicles with shut-off valves in the refrigerant circuit, check
the function and actuation of these valves ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode - air conditioning system
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
ditioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output (vehicle-specific workshop manual).
– Check the refrigerant line from the evaporator (or from the in‐
ner heat exchanger) and the air conditioner compressor (thick
pipe, low pressure side) with the engine running. If this line is
very icy when the complaint is encountered (a thin layer of ice
is acceptable), this is also evidence that the temperature in the
evaporator is too low ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual).
– Empty the refrigerant circuit, renew all reservoirs/receivers
with dryer or desiccant cartridge and then evacuate the refrig‐
erant circuit for at least 3 hours ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
manual) and
⇒ “2 Working with air conditioner service station”, page 124 .
Conditions for testing
♦ Observe the general information on checking pressures in the
refrigerant circuit
⇒ “2.14.1 General information on checking pressures in the
refrigerant circuit”, page 165
172 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
All of the conditions for testing marked with * are pertinent to a
certain vehicle and are described in the vehicle-specific workshop
manual ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
tions; Checking cooling output (vehicle-specific workshop man‐
ual).
General conditions for testing (these only have an influence on
the display of the pressure gauges during this measurement with
the air conditioning system switched on)
• Radiator and condenser are clean (clean them if necessary).*
• The heat insulation on the expansion valve is OK and properly
installed.*
• The poly V-belt is OK and properly tensioned. The belts for air
conditioner compressor and alternator are in good condition
and correctly tensioned.*
• The drive unit for the air conditioner compressor is OK and
properly installed.*
• All air ducts, covers and seals are OK and properly installed.*
• Diagnosis of the air conditioning system finds no faults (with
the engine running and the air conditioning system switched
on), no compressor deactivation conditions are shown in the
measured values (only on vehicles with diagnosis “air condi‐
tioning system”).* ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode of air conditioning system. AG. Volkswagen gen AG do
swa es n
• The air flow rate through the dust and pollen
y V filter is not im‐
olk ot g
ua
paired by dirt.* edb ran
ris tee
tho or
• All dash panel air vents are open.*
sa
u ac
s ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Depending on the engine, the air conditioner compressor is
ot
wit
, is n
driven by different components (belts or drive shaft). To pro‐
h re
tect these components and the engine, the pulley or the air
hole
spec
conditioner compressor drive unit is fitted with an overload
es, in part or in w
protection which is tripped if the air conditioner compressor is
t to the co
not operating smoothly ⇒ Heating, air conditioning; Rep. gr.
00 ; Repair instructions; Checking cooling output (vehicle-spe‐
cific workshop manual) and ⇒ Heating, air conditioning; Rep.
rrectness of i
gr. 87 ; Air conditioner compressor (vehicle-specific workshop
manual).
l purpos
♦ On certain versions, the radiator fan cuts in only after the pres‐
sure in the refrigerant circuit has exceeded a pre-set value
nform
ercia
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
m
air conditioning system.
com
tion in
r
te o
thi
Other conditions for testing (these have an influence on the dis‐
s
iva
do
play of the pressure gauge with this measurement)
r
rp
cum
fo
• The vehicle is not exposed to the sun's rays ⇒ Heating, air
en
ng
t.
yi
conditioning; Rep. gr. 00 ; Repair instructions; Checking cool‐
Co
Cop py
ing output (vehicle-specific workshop manual). ht. rig
rig ht
py by
o Vo
• Ambient temperature is above 15°C. by c lksw
cted agen
Prote AG.
• The ignition is switched off.
• The air conditioner service station is connected to the refrig‐
erant circuit
2. Working with air conditioner service station 173
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 .
♦ ⇒ “2.14.4 Checking pressures with air conditioning system
switched on - vehicles with mechanical air conditioning com‐
pressor”, page 178 .
♦ ⇒ “2.14.5 Checking pressures with air conditioning system
switched on - vehicles with electrical air conditioning com‐
pressor”, page 200
Checking pressures with the ignition switched off
Note
♦ The switching pressures for actuation of the air conditioner
compressor regulating valve - N280- , the air conditioning sys‐
tem magnetic clutch - N25- (if fitted) and the radiator fan (e.g.
radiator fan - V7- / radiator fan 2 - V177- ) are vehicle-specific
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system.
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
♦ Once the planned measures are complete, separate the air
conditioner service station from the refrigerant circuit and
switch it off
⇒ “2.8 Switching off air conditioner service station and sepa‐
rating from refrigerant circuit”, page 146 .
• The engine is at operating temperature (atagan
en Aambient
G. Volkswatem‐
gen AG
does
perature less than 25°C). Volksw not
g by ua
ed ran
oris tee
th or
Note ss
au ac
ce
e
nl
pt
♦ Should the engine not be at operating temperature, take the
du
an
itte
vehicle for a short drive.
y li
erm
ab
ility
♦ To test the cooling output, the engine does not have to be at
ot p
wit
operating temperature. However, to demand a certain cooling
, is n
h re
output from the air conditioning system at an ambient temper‐
hole
spec
ature of less than 25°C, the engine is required to be warm if
es, in part or in w
ambient temperatures are low.
t to the co
♦ Observe the test prerequisites ⇒ page 171 .
rrectness of i
– On vehicles with high-voltage system, switch off “stationary air
conditioning” function (deactivate)⇒ Owner's Manual and ⇒
l purpos
Operating instructions of infotainment / MMI .
– Switch off ignition.
nf
ercia
orm
– Connect the air conditioner service station
m
atio
m
⇒ “2.2 Connecting air conditioner service station to refrigerant
o
n in
c
circuit”, page 126 .
or
thi
te
sd
a
– Check the pressures in the refrigerant circuit with the engine
iv
o
r
rp
cu
stationary.
o
m
f
en
ng
t.
yi
– Take pressure readings from pressure gauges of air condi‐
Co
op py
tioner service station . Two results may be displayed:
. C rig
ht ht
rig by
py
♦ The pressure in the refrigerant circuit is lower than indicated
co Vo
by lksw
cted
in the following table ⇒ page 177 .
agen
Prote AG.
♦ The pressure in the refrigerant circuit is equal to or greater than
that in the following table ⇒ page 178 .
174 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Vapour pressure table for R1234yf refrigerant
⇒ “6.1.3 Vapour pressure table for refrigerant”, page 17
♦ On vehicles with high-voltage system and auxiliary air condi‐
tioning system functions (“heat pump mode” or “cooling of
high-voltage battery”), valves may be installed in the refriger‐
ant circuit that are not open when unenergised. These valves
are opened and closed e.g. via incremental motors and are no
longer actuated when the ignition is switched off. Depending
on the last operating status of the air conditioning system, cer‐
tain areas of the refrigerant circuit could be isolated by these
valves. Depending on the layout of the service connections in
the refrigerant circuit, these could be in an area that is isolated
(e.g. the area with the service connection on the high pressure
side). If necessary, these valves must be opened before the
pressure is tested ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual) and
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
♦ The pressures given in the table are slightly lower than speci‐
fied in the vapour pressure table for the R1234yf refrigerant.
The evaporation pressure of the refrigerant in the refrigerant
circuit is orientated around the coldest component and could
therefore also be slightly lower in a correctly charged refriger‐
ant circuit than that specified for the R1234yf refrigerant in the
. Volkswagen AG
vapour pressure table. sw agen AG does
olk not
yV gu
edb ara
ris nte
Ambient temperature (in de‐ Pressure
tho in the refrigerant cir‐ eo
grees C) aucuit in bar positive pressure ra
c
ss
ce
e
+15 °C 3.5
nl
pt
du
an
+20 °C 4.4
itte
y li
erm
ab
+25 °C 5.3
ility
ot p
+30 °C 6.3 wit
, is n
h re
hole
+35 °C 7.4 spec
es, in part or in w
+40 °C 8.6
t to the co
+45 °C 10.0
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.
2. Working with air conditioner service station 175
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
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 most pressure gauges, a reading
of 0 bar corresponds to an absolute pressure of one bar (which
is confirmed by the existence of a -1 bar marking beneath the
0 scale marking).
♦ On vehicles with pressure senders ( high pressure sender -
G65- , pressure sender for refrigerant circuit - G805- or refrig‐
erant pressure and temperature sender - G395- , etc.) for
which the measured pressure is displayed in the measured
values of the diagnosis, the measured pressure should corre‐
late with the values in the table (or be slightly higher) ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air condi‐ n AG. Volkswagen AG do
tioning system and ⇒ Heating, air conditioning; Rep. ol gr.
ksw
age00 ; es n
ot g
Repair instructions; Checking cooling output (vehicle-specific
d byV ua
ran
workshop manual). horis
e
tee
t or
au
♦ The pressure is given in different units,ss1 MPa (megapascal)
ac
equates to 10 bar overpressure or 145 psi. At 0 bar overpres‐
ce
le
un
pt
sure, 1 bar absolute pressure is approximately the same as
an
d
itte
ambient pressure (atmospheric pressure).
y li
rm
ab
pe
ility
ot
If the measured values are OK and there is no complaint:
wit
, is n
h re
hole
– Unscrew (close) the handwheels of the quick-release coupling
spec
adapters ⇒ Operating instructions air conditioner service sta‐
es, in part or in w
tion .
t to the co
– Extract the refrigerant from the two charge hoses using the air
conditioner service station as instructed in the relevant oper‐
rrectness of i
ating manual ⇒ Operating instructions air conditioner service
station .
l purpos
– Switch off the air conditioner service station (and isolate it from
the power supply if necessary)
nform
ercia
⇒ “2.8 Switching off air conditioner service station and sepa‐
m
rating from refrigerant circuit”, page 146 .
a
com
tion in
If the measured values are OK and there is complaint:
r
te o
thi
s
iva
– Check the cooling output of the air conditioning system ⇒
do
r
rp
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
um
fo
en
g
Checking cooling output (vehicle-specific workshop manual)
n
t.
yi Co
and watch the pressures in the refrigerant circuit. ht. Cop py
rig
rig ht
♦ ⇒ “2.14.4 Checking pressures with air conditioning system py by
co Vo
switched on - vehicles with mechanical air conditioning com‐
by lksw
cted agen
Prote
pressor”, page 178 .
AG.
♦ ⇒ “2.14.5 Checking pressures with air conditioning system
switched on - vehicles with electrical air conditioning com‐
pressor”, page 200
If the measured values are not OK:
– Investigate the cause of the deviation and rectify.
176 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If the pressures are too low, it could be because there is too
little refrigerant in the circuit ⇒ Heating, air conditioning; Rep.
gr. 00 ; Technical data (vehicle-specific workshop manual)
and ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
♦ If the pressures are too high, there may be too much refriger‐
ant or refrigerant oil in the circuit. Empty the refrigerant circuit
using the air conditioner service station
⇒ “2.4 Emptying refrigerant circuit”, page 132 . If the extracted
refrigerant volume is greater than the specified fill capacity for
the R1234yf refrigerant ⇒ Heating, air conditioning; Rep. gr.
00 ; Technical data (vehicle-specific workshop manual), evac‐
uate the refrigerant circuit and recharge with the correct wagen AG. Volkswagen AG doe
amount of R1234yf refrigerant. Then repeat the test. If ythe Vol ex‐
ks s no
t gu
tracted quantity of refrigerant roughly equates to the ise specified
d b ara
nte
fill capacity for the R1234yf refrigerant or is less,ut
hoclean
r
the re‐ eo
frigerant circuit with refrigerant ss a ra
c
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Then add the
ce
e
nl
specified amount of refrigerant oil, evacuate the refrigerant
pt
du
an
circuit, recharge with the correct volume of R1234yf refrigerant
itte
y li
erm
and repeat the test.
ab
ility
ot p
♦ If the pressures are too low or too high and contaminated re‐
wit
, is n
frigerant is found during the gas analysis, this may be the
h re
hole
cause of the deviation (different refrigerants have varying va‐
spec
pour pressures). Empty the refrigerant circuit and then clean
es, in part or in w
t to the co
with R1234yf refrigerant
⇒ “2.3 Performing gas analysis of refrigerant”, page 129 ,
⇒ “2.4 Emptying refrigerant circuit”, page 132 and
rrectness of i
⇒ “1.6 Cleaning refrigerant circuit”, page 92
l purpos
The pressure in the refrigerant circuit is lower than indicated in
the table
nform
ercia
Too little refrigerant in circuit.
m
at
om
i
– Check for leaks in the refrigerant circuit
on
c
in t
⇒ “1.4 Investigating leaks”, page 68 .
or
his
ate
– Check the high pressure safety valve
do
priv
c
⇒ “1.2.17 High-pressure safety valve”, page 53 .
um
for
en
ng
t.
yi
If the high pressure safety valve has blown (check
Co
op py
⇒ “1.2.17 High-pressure safety valve”, page 53 ):
t. C rig
gh ht
pyri by
Vo
– Check radiator fan actuation or the radiator fan ⇒ Vehicle di‐
o
by c lksw
cted agen
agnostic tester in “Guided Fault Finding” mode - air condition‐ Prote AG.
ing system.
– On vehicles with shut-off valves for the refrigerant circuit,
check the actuation and function of these shut-off valves ⇒ Ve‐
hicle diagnostic tester in “Guided Fault Finding” mode - air
conditioning system (and battery control) and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
– Check refrigerant lines and refrigerant hoses for signs of
crushing (bottle-neck), external damage and tight bends ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual) and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
– If no fault can be detected, clean the refrigerant circuit
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
2. Working with air conditioner service station 177
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
The pressure in the refrigerant circuit is equal to or greater than
that in the table
♦ ⇒ “2.14.4 Checking pressures with air conditioning system
switched on - vehicles with mechanical air conditioning com‐
pressor”, page 178 .
♦ ⇒ “2.14.5 Checking pressures with air conditioning system
switched on - vehicles with electrical air conditioning com‐
pressor”, page 200
2.14.4 Checking pressures with air condition‐
ing system switched on - vehicles with
mechanical air conditioning compressor
Checking pressures ⇒ page 178
Specifications for pressures in the refrigerant circuit
⇒ page 182
Checking pressures AG. Volkswagen AG d
agen oes
ksw
Refrigerant circuit with expansion valve, receiver with or withoutby V ol not
gu
ara
air conditioning system magnetic clutch - N25- and air conditioner
rised
nte
compressor regulating valve - N280- (with externally regulated
ut
ho air eo
ra
conditioner compressor) ss a c
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
♦ Connect the air conditioner service station
wit
is n
⇒ “2.2 Connecting air conditioner service station to refrigerant
h re
ole,
circuit”, page 126 .
spec
urposes, in part or in wh
♦ If on vehicles with two evaporators a problem is encountered
t to the co
in just one evaporator, check the pressures in the refrigerant
circuit. If these are OK, check the line connection between the
evaporator that is causing the problem and the outlet of the
rrectne
line connection at the distribution point of the refrigerant lines
(for bottle-neck or blockage). If no fault can be determined,
s
empty the refrigerant circuit and recharge with the prescribed
s o
cial p
amount of refrigerant. Then check the pressures and the cool‐
f in
ing output of the air conditioner again. If the problem persists,
form
mer
replace the expansion valve upstream of the problematic
atio
m
evaporator ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
o
n
c
erant circuit (vehicle-specific workshop manual).
i
or
n thi
te
sd
a
♦ ⇒ “2.14.3 Checking pressures in the refrigerant circuit with the
iv
o
r
ignition switched off”, page 171
p
cum
r
fo
en
ng
t.
yi Co
op
Conditions for testing C py
t. rig
gh ht
yri
• The air conditioner service station is connected to the refrig‐
p by
o Vo
by c lksw
erant circuit Prote
cted AG.
agen
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 .
• Observe the conditions for testing pressures in the refrigerant
circuit with the ignition switched off ⇒ page 171 .
• The pressures in the refrigerant circuit comply with the speci‐
fications with the ignition switched off
⇒ “2.14.3 Checking pressures in the refrigerant circuit with the
ignition switched off”, page 171 .
• Observe the conditions for testing the cooling output ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Repair instructions; Check‐
ing cooling output (vehicle-specific workshop manual).
178 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The switching pressures for actuation of the air conditioner
compressor regulating valve - N280- , the air conditioning sys‐
tem magnetic clutch - N25- (if fitted) and the radiator fan - V7-
are vehicle-specific ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode - air conditioning system.
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
AG. Volkswagen AG d
agen oes
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• The engine is at d byoperating temperature (at an ambient
Vo gu
ara tem‐
perature less ris than 25°C).
e nte
ho eo
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ss c
ce
le
Note
un
pt
an
d
itte
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♦ Should the engine not be at operating temperature, take the
rm
ab
pe
ility
vehicle for a short drive.
ot
wit
, is n
♦ To test the cooling output, the engine does not have to be at
h re
hole
operating temperature. However, to demand a certain cooling
spec
output from the air conditioning system at an ambient temper‐
es, in part or in w
t to the co
ature of less than 25°C, the engine is required to be warm if
ambient temperatures are low.
– Start engine. rrectness of i
l purpos
– Set the air conditioning system to maximum cooling output ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output (vehicle-specific workshop manual).
nform
ercia
• The air conditioner compressor is actually driven with the en‐
m
a
com
gine running (visual check ⇒ Heating, air conditioning; Rep.
ion in
gr. 87 ; Refrigerant circuit (vehicle-specific workshop man‐
r
te o
thi
ual)).
s
iva
do
r
rp
• The air conditioner compressor regulating valve - N280- is ac‐
um
fo
tuated ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
en
ng
t.
yi
mode - air conditioning system.
Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
Note cted agen
Prote AG.
♦ Depending on the engine, the air conditioner compressor is
driven by different components (belts or drive shaft). To pro‐
tect these components and the engine, the pulley or the air
conditioner compressor drive unit is fitted with an overload
protection which is tripped if the air conditioner compressor is
not operating smoothly ⇒ Heating, air conditioning; Rep. gr.
87 ; Air conditioner compressor (vehicle-specific workshop
manual).
♦ On vehicles with air conditioner compressor regulating valve -
N280- , the control current can be gleaned from the measured
values ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system.
If the air conditioner compressor is not driven or the regulating
valve not activated when the engine is running:
– Determine the cause, e.g. by interrogating the event memory
of the air conditioning system, and rectify it ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode - air conditioning
system.
2. Working with air conditioner service station 179
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
Arteon 2018 ➤ , Atlas th 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter
o tee
or 201 ...
u
Air conditioning systems
ss
a
with refrigerant R1234yf - General information ac
- Edition 01.2018
ce
le
un
pt
– If fitted, check the voltage supply for the air conditioning sys‐
an
d
itte
y li
tem magnetic clutch - N25- . If this is OK, repair the magnetic
erm
ab
clutch ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
ility
circuit (vehicle-specific workshop manual). ot p
wit
is n
h re
– Check actuation of the air conditioner compressor regulating
ole,
spec
valve - N280- ⇒ Vehicle diagnostic tester in “Guided Fault
urposes, in part or in wh
Finding” mode - air conditioning system.
t to the co
Note
rrectne
♦ On air conditioner compressors with an air conditioning sys‐
ss
tem magnetic clutch - N25- , the air conditioner compressor
o
cial p
f
only works (delivers refrigerant) if in addition to the air condi‐
inform
tioner compressor regulating valve - N280- , -N25- is actuated
mer
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
atio
m
air conditioning system.
o
n
c
i
or
n thi
♦ -N280- (and -N25- ) is actuated by the air conditioning system
te
sd
a
control unit - J301- , the operating and display unit for front air
iv
o
pr
c
conditioning system - E87- and the Climatronic control unit -
um
r
fo
en
J255- or a downstream control unit ⇒ Vehicle diagnostic tester
ng
t.
yi Co
in “Guided Fault Finding” mode - air conditioning system and Cop py
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
t. rig
gh ht
yri by
(vehicle-specific workshop manual). cop Vo
by lksw
cted agen
Prote
♦ All of the conditions for testing marked with * are pertinent to
AG.
a certain vehicle and are described in the vehicle-specific
workshop manual ⇒ Heating, air conditioning; Rep. gr. 00 ;
Repair instructions (vehicle-specific workshop manual) and ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual).
• The radiator and condenser are clean (clean if necessary) * ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual).
• The heat insulation on the expansion valve is OK and mounted
correctly * ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
• The poly V-belt is OK and properly tensioned. The belts for air
conditioner compressor and alternator are in good condition
and correctly tensioned.* ⇒ Heating, air conditioning system;
Rep. gr. 87 ; Air conditioner compressor (vehicle-specific
workshop manual) and ⇒ Heating, air conditioning system;
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
manual).
• The drive unit for the air conditioner compressor is OK and
mounted properly * ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual) and ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor (vehicle-specific workshop manual).
• The air ducts, covers and seals are OK and mounted correctly
* ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting
locations - air conditioning system (vehicle-specific workshop
manual).
• Diagnosis of the air conditioning system finds no faults (with
the engine running and the air conditioning system switched
on), no compressor deactivation conditions are shown in the
measured values of the respective control unit (only on vehi‐
cles with diagnosis “air conditioning system”).* ⇒ Vehicle di‐
agnostic tester in “Guided Fault Finding” mode of air
conditioning system.
• The air flow rate through the dust and pollen filter is not im‐
paired by dirt.* ⇒ Heating, air conditioning system; Rep. gr.
180 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
87 ; Overview of fitting locations - air conditioning system (ve‐
hicle-specific workshop manual).
• The heater and air conditioner does not draw any secondary
air at highest fresh air blower speed. The evaporator and heat‐
er are not drawing in secondary air at the highest fresh air
blower speed * ⇒ Heating, air conditioning; Rep. gr. 87 ;
Overview of fitting locations - air conditioning system (vehicle-
specific workshop manual).
• The air flaps in the heating and air conditioning unit, in the
heating and in the evaporator reach their end position * ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output (vehicle-specific workshop manual)
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system (vehicle-specific
workshop manual).
• The fresh air intake ducts under the bonnet and in the pas‐
senger compartment and the corresponding water drain
valves are OK * ⇒ Heating, air conditioning; Rep. gr. 00 ;
Repair instructions; Checking cooling output (vehicle-specific
workshop manual) and ⇒ Heating, air conditioning; Rep. gr.
87 ; Overview of fitting locations - air conditioning system (ve‐
hicle-specific workshop manual).
• Engine warm.
• The vehicle is not exposed to the sun's rays ⇒ Heating, air
conditioning; Rep. gr. 00 ; Repair instructions; Checking cool‐
ing output (vehicle-specific workshop manual). en AG. Volkswagen AG
ag does
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• Ambient temperature is above 15°C. y Vol gu
db ara
ise nte
• All dash panel diffusers are open * u⇒thorHeating, air conditioning; eo
Rep. gr. 87 ; Air duct system (vehicle-specific
ss
a workshop man‐ ra
c
ual).
ce
le
un
pt
an
d
Setting e.g. on operating and display unit for front air conditioning
itte
y li
system - E87- and Climatronic control unit - J255- or air condi‐
rm
ab
pe
tioning system control unit - J301- (and operating and display unit
ility
ot
for rear Climatronic - E265- on vehicles with two heating and air
wit
, is n
conditioning units) * ⇒ Heating, air conditioning; Rep. gr. 00 ; h re
hole
Repair instructions; Checking cooling output (vehicle-specific spec
workshop manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ;
es, in part or in w
t to the co
Overview of fitting locations - air conditioning system (vehicle-
specific workshop manual).
Setting on -E87- / -J255- *: ⇒ Heating, air conditioning; Rep. gr.
rrectness of i
00 ; Repair instructions; Checking cooling output (vehicle-specific
l purpos
workshop manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Overview of fitting locations - air conditioning system (vehicle-
specific workshop manual).
nform
ercia
– Select “Auto” mode (air conditioner compressor switched on).
m
a
com
tio
– Set temperature to “cold” or “LO” for the driver and front pas‐
n in
r
senger side (and the rear on the left and right in vehicles with
te o
thi
two heating and air conditioning units).
s
iva
do
r
rp
cum
Setting on -J301- *:
fo
en
ng
t.
yi Co
– Press A/C button and Rec or recirculate buttons. t. Cop py
rig
gh ht
yri
– Turn rotary temperature knob in direction of “cold” stop. p by
co Vo
by lksw
cted agen
– Set rotary fresh air blower switch to “4” (maximum fresh air Prote AG.
blower speed).
The following conditions for testing should then be met in the sys‐
tem:
• The radiator fan - V7- is running or the radiator fan - V7- and
radiator fan 2 - V177- are running (at least stage 1) * ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Repair instructions; Check‐
2. Working with air conditioner service station 181
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
ing cooling output (vehicle-specific workshop manual) and ⇒
Heating, air conditioning; Rep. gr. 87 ; Overview of fitting lo‐
cations - air conditioning system (vehicle-specific workshop
manual).
Note
On certain versions, the radiator fan cuts in only after the pressure
in the refrigerant circuit has exceeded a pre-set value ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air conditioning
system.
• The fresh air blower - V2- (and the rear fresh air blower - V80-
on vehicles with two heating and air conditioning units) is
running at maximum speed.*
• The coolant shut-off valve is closed * ⇒ Heating, air condi‐
tioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output (vehicle-specific workshop manual) and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Overview of fitting locations - air
conditioning system (vehicle-specific workshop manual).
• The valves of the pump-valve unit are closed and the coolant
circulation pump is not delivering * ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking cooling output
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Overview of fitting locations - air
conditioning system (vehicle-specific workshop manual).
• The fresh air blower - V2- (and the rear fresh air blower - V80-
on vehicles with two heating and air conditioning units) is
running at maximum speed.*
• The air recirculation flap/fresh air flap is in “recirculation
mode” (within 1 minute afteragstarting
n AG. Volthe
kswavehicle,
gen AG the air flow
lksw e
flap closes and the airVrecirculation flap
d
opens).*oes not g
o
y ua
db ran
• The coolant shut-off
or
ise valve is closed.* tee
u r th o
• The valves sfor
s a the pump-valve unit are closed and the coolant ac
circulation pump is not delivering.*
ce
e
nl
pt
du
an
Specifications for pressures in the refrigerant circuit
itte
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erm
ab
♦ Observe the conditions for testing and the pressures
ility
ot p
⇒ page 178 .
wit
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h re
Testing:
hole
spec
es, in part or in w
– Raise engine speed to 2000 rpm.
t to the co
– Observe pressure display (e.g. pressure gauge) of air condi‐
tioner service station ⇒ Operating instructions of air condi‐
rrectness of i
tioner service station .
l purpos
Note
nf
ercia
or
♦ The switching pressures for actuation of the air conditioner
m
m
atio
compressor regulating valve - N280- and the radiator fan are
om
n in
vehicle-specific ⇒ Vehicle diagnostic tester in “Guided Fault
or c
Finding” mode - air conditioning system.
thi
te
sd
iva
♦ The pressures must be measured at the service connections;
r
rp
cu
o
the fitting locations of these connections are vehicle-specific
f
en
ng
t.
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
yi Co
op py
(vehicle-specific workshop manual). t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
182 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
High-pressure side:
Rising from starting pressure (when pressure gauge is connec‐
ted) to maximum 20 bar.
Low-pressure side:
From the output pressure (when connecting the pressure gauge)
dropping to a value of between 1.5 and 2.3 bar absolute pressure
(depending on required cooling output).
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Working with air conditioner service station 183
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
n AG. Volkswagen AG do
wage
♦ In the event of a very high cooling output (e.g.y at Vo high outside
lks es n
ot g
temperatures and high fresh air blower speed ir se
d while the engine
b ua
ran
is running slowly), the air conditioner compressor
t ho is initially tee
or
incapable of changing the pressure on ss
au
the low pressure side ac
to the specified level (e.g. for a certain period after switching
ce
le
on the air conditioning system). The air conditioner compres‐
un
pt
an
d
sor is actuated with the maximum specified control current.
itte
y li
rm
However, the delivery volume of the air conditioner compres‐
ab
pe
ility
sor is not enough under these operating conditions and at this
ot
wit
engine speed to lower the pressure on the low pressure side
, is n
h re
to the specification. One way of checking the regulating be‐
hole
spec
haviour of the air conditioner compressor under these condi‐
es, in part or in w
tions is to actuate e.g. the fresh air blower with only approx.
t to the co
40% of the maximum voltage and to check the pressures at
reduced fresh air blower speed ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode - air conditioning system and ⇒
rrectness of i
Heating, air conditioning; Rep. gr. 00 ; Repair information;
Checking cooling output (vehicle-specific workshop manual).
l purpos
♦ If the demand on the cooling output is low (e.g. at an ambient
temperature of 20°C and a low fresh air blower speed), pres‐
nform
ercia
sure on the high pressure side may only increase up to a value
of 6 to 7 bar (the energy exchange is low, the refrigerant is
m
a
com
ti
cooled down quickly in the condenser). To check the regulat‐
on in
ing behaviour and the pressures in the refrigerant circuit under
r
te o
thi
these conditions, e.g. actuate the fresh air blower with maxi‐
s
iva
do
mum voltage, set the air conditioning system to maximum
r
rp
cum
heating output and activate air recirculation ⇒ Vehicle diag‐
fo
en
ng
nostic tester in “Guided Fault Finding” mode - air conditioning
t.
yi Co
op
system and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
C py
t. rig
gh
instructions; Checking cooling output (vehicle-specific work‐
ht
pyri by
shop manual).
co Vo
by lksw
cted agen
Prote AG.
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high atmospheric humidity), the pressure on the high
pressure side can increase to a maximum of 29 bar.
♦ The specified working current for the air conditioner compres‐
sor regulating valve - N280- is displayed as a measured value
by the operating and display unit for front air conditioning sys‐
tem - E87- , the air conditioning system control unit - J301- and
the Climatronic control unit - J255- ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system.
♦ The high pressure measured by the high pressure sender -
G65- , the pressure sender for refrigerant circuit - G805- and
the refrigerant pressure and temperature sender - G395- is
displayed as a measured value by -E87- , -J301- or -J255-
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system.
♦ The low pressure adjusts depending on the control current for
the air conditioner compressor regulating valve - N280- and
the control characteristic of the expansion valve within the
performance band of the air conditioner compressor in the tol‐
erance range ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode - air conditioning system.
♦ In unfavourable conditions (very high ambient temperatures,
high air humidity), the performance of the air conditioner com‐
pressor may not always be enough to reach the specified
pressure value within the given time (it could take slightly lon‐
ger, depending on the engine speed, for the prescribed low
pressure to be reached).
184 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ If the air conditioner compressor's capacity utilisation is above
90%, pressure on the low pressure side could be higher than
the specified tolerance range. The air conditioner compressor
output is no longer sufficient in the prevailing conditions (am‐
bient temperature, air humidity, setting of the air conditioning
system, engine speed, etc.) to change the pressureaon nthe low
AG. Volkswagen AG
pressure side to approx. 2 bar. lksw ge does
not
Vo g y ua
db ran
♦ The specified working current for the airoriconditioner
se compres‐ tee
sor regulating valve - N280- must beauhigher
th than 0.3 A so that or
ac
-N280- can be actuated reliably ⇒ Vehicle diagnostic tester in
ss
ce
“Guided Fault Finding” mode - air conditioning system.
e
nl
pt
du
an
♦ When setting to “maximum cooling output”, the control current itte
y li
erm
ab
for the air conditioner compressor regulating valve - N280- is
ility
ot p
regulated at approx. 0.65 A (to 0.85 A). This measured value
wit
, is n
is vehicle-specific and is displayed in the ⇒ Vehicle diagnostic
h re
tester in “Guided Fault Finding” mode - air conditioning sys‐
hole
spec
tem.
es, in part or in w
t to the co
♦ Absolute pressure means that 0 bar corresponds to an abso‐
lute vacuum. The normal ambient pressure corresponds to 1
bar absolute. On most pressure gauges, a reading of 0 bar
rrectness of i
corresponds to an absolute pressure of 1 bar (which is con‐
firmed by the existence of a -1 bar marking beneath the 0 scale
l purpos
marking). Depending on the respective control unit version,
pressure can be displayed as a measured value based on ab‐
solute or relative pressure (difference between displays 1 bar)
nform
ercia
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
m
at
air conditioning system and ⇒ Heating, air conditioning; Rep.
om
io
gr. 00 ; Repair instructions; Checking cooling output (vehicle-
n
c
in t
r
specific workshop manual).
o
his
ate
do
riv
♦ The temperature of the air after the evaporator, the current air
p
cum
or
conditioner compressor speed and the pressure of the refrig‐
f
en
ng
erant on the high pressure side along with the specified work‐
t.
yi Co
op
ing current for the air conditioner compressor regulating valve C py
t. rig
- N280- are displayed e.g. as a measured value by the oper‐
gh ht
pyri by
ating and display unit, the Climatronic control unit - J255-
co Vo
by lksw
cted agen
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - Prote AG.
air conditioning system.
Possible deviations from specification,
cause and rectification
♦ The required cooling output is not ⇒ page 187
reached.
♦ High pressure remains constant or in‐
creases only slightly (above the pressure
measured when the engine is station‐
ary).
♦ Low pressure drops quickly to the spec‐
ification or lower.
♦ The required cooling output is not ⇒ page 188
reached.
♦ The high pressure equates to the speci‐
fication
♦ The low pressure equates to the specifi‐
cation or is too low
2. Working with air conditioner service station 185
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviations from specification,
cause and rectification
♦ The requisite cooling output is not ⇒ page 189
reached.
♦ High pressure does not increase or only
marginally above the pressure with the
engine stationary
♦ The low pressure does not drop or only
marginally
♦ The requisite cooling output is not ⇒ page 190
reached.
♦ The high pressure increases beyond the
specified value
♦ Low pressure drops quickly to the spec‐ AG. Volkswagen AG d
ification or lower. agen oes
olksw not
byV gu
ara
ed
♦ The requisite cooling output is reached horis
⇒ page 191 nte
eo
ut
initially but after a while or after ans aex‐ ra
c
tended period, the cooling output sis no
ce
e
longer sufficient.
nl
pt
du
an
itte
y li
♦ The high pressure and the low pressure
erm
ab
are normal to start with
ility
ot p
wit
, is n
♦ After some time, the high pressure rises
h re
above the specification, the low pressure
hole
spec
still equates to the specification or it
es, in part or in w
drops below the specification.
t to the co
♦ The requisite cooling output is reached ⇒ page 193
initially but after a short or extended pe‐
rrectness of i
riod, the required level is no longer
reached.
l purpos
♦ The high pressure and low pressure are
nf
ercia
normal to start with but after a while, the or
high pressure rises above the specifica‐
m
m
atio
tion and the low pressure drops to the
om
specification or lower.
n in
or c
thi
e
♦ The high pressure and low pressure are
t
sd
iva
normal to start with. After a while, the low
r
rp
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o
pressure drops to the specification or
f
en
ng
t.
lower and the evaporator ices up.
yi Co
Cop py
ht. rig
rig ht
♦ The requisite cooling output is reached. ⇒ page 194 py by
co Vo
by lksw
cted agen
♦ The high pressure equates to the speci‐ Prote AG.
fication
♦ The low pressure is too low (lower than
the specification)
♦ The air conditioner compressor is noisy ⇒ page 196
(especially immediately after being
switched on),
♦ The requisite cooling output is reached.
♦ High pressure normal or too high
♦ The low pressure is normal or too high
(the specification is not always reached)
186 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviations from specification,
cause and rectification
♦ The required cooling output is not ⇒ page 198
reached.
♦ The high pressure and low pressure
equate to the specification
Possible deviation from specification during pressure test
♦ The required cooling output is not reached.
G. Volkswagen
♦ High pressure remains constant or increases
lksw
agen only slightlyA(above
A G do
es n the pressure measured when the engine
is stationary). by Vo ot g
ua
ed ran
ris tee
♦ The low pressure does not
ut
hdrop
o or only marginally or
a ac
ss
Possible causes for deviation from specification and rectification
ce
le
un
pt
an
d
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
itte
y li
erm
ab
– Check actuation of the air conditioner compressor regulating valve - N280- and repair if necessary ⇒ Vehicle
ility
ot p
diagnostic tester in “Guided Fault Finding” mode - air conditioning system.
wit
is n
♦ Air conditioner compressor regulating valve - N280- or air conditioner compressor defective
h re
ole,
spec
– Check function of -N280- ; if necessary remove -N280- and check for dirt ⇒ Vehicle diagnostic tester in
urposes, in part or in wh
“Guided Fault Finding” mode - air conditioning system and ⇒ page 79
t to the co
– -N280- or renew the air conditioner compressor ⇒ page 79
rrectne
– If dirt is found in the refrigerant circuit, clean the refrigerant circuit (flush with R1234yf refrigerant) and renew
the expansion valve and desiccant bag/desiccant cartridge (or renew the receiver/reservoir) ⇒ page 79 and
s
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual) as well as
s o
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
cial p
f inform
Final measures
mer
atio
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
om
n
c
i
or
– Repeat the test
thi
te
sd
a
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
iv
o
pr
conditioning compressor”, page 178
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Working with air conditioner service station 187
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If this problem is encountered, ensure that the air conditioner
compressor (air conditioner compressor shaft) is actually be‐
ing driven via the pulley/drive unit ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific workshop manual).
♦ If no fault can be found for this complaint, clean the refrigerant
circuit (flush with R1234yf refrigerant) n AG. Volkswagen AG do
swage es n
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . byV
olk ot g
ua
d ran
ir se
♦ Check the measured values of the evaporator output tho temper‐ tee
or
ature sender - G263- and actuation of -N280- .ssIfauthe measured ac
value of -G263- is faulty, the evaporator could ice up or the
ce
e
nl
cooling output may not be reached ⇒ Vehicle diagnostic tester
pt
du
an
in “Guided Fault Finding” mode - air conditioning system.
itte
y li
erm
ab
♦ If, after repeating the test when the expansion valve has been
ility
ot p
renewed, the air conditioning system is not operating correctly,
wit
, is n
clean the refrigerant circuit (flush with R1234yf refrigerant)
h re
hole
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Then renew the
spec
air conditioner compressor and desiccant insert/desiccant car‐
es, in part or in w
t to the co
tridge (or reservoir/receiver) ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ In this case, the evaporator may ice up even though the correct
rrectness of i
volume of refrigerant is present in the refrigerant circuit.
l purpos
♦ If the expansion valve is defective (always closed or not open‐
ing wide enough), -N280- will change to maximum power and
nf
ercia
the low pressure will fall to the diagram value or less (the air
o
conditioner compressor is drawing the refrigerant out of the
rm
m
atio
low pressure side) ⇒ Vehicle diagnostic tester in “Guided Fault
om
Finding” mode - air conditioning system. However, since no
n in
or c
refrigerant can flow through the expansion valve, the required
thi
te
sd
a
cooling output is not reached, the high pressure may also not
iv
o
r
rise or only marginally since no energy exchange is taking
rp
cu
o
m
f
place.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Possible deviation from specification during pressure test
♦ The required cooling output is not reached.
♦ The high pressure equates to the specification
♦ The low pressure equates to the specification or is too low
Possible causes for deviation from specification and rectification
♦ There is too little refrigerant in the refrigerant circuit.
♦ The expansion valve is defective.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
– The extracted refrigerant volume approximately equates to the prescribed fill volume, renew the expansion
valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual)
Final measures
188 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
conditioning compressor”, page 178
Note
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and actuation of -N280- . If the measured
value of -G263- is faulty, the evaporator could ice up or the
cooling output may not be reached ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system.
♦ If, after repeating the test when the expansion valve has been
renewed, the air conditioning system is not operating correctly,
clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Then renew the
air conditioner compressor and reservoir/receiver (or desic‐
cant cartridge) ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshopswmanual).
agen
AG. Volkswagen AG d
oes
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
Possible deviation from specification during pressure test
an
itte
y li
erm
ab
♦ The requisite cooling output is not reached.
ility
ot p
♦ High pressure does not increase or only marginally above the pressure with the engine stationary
wit
, is n
h re
hole
♦ The low pressure does not drop or only marginally
spec
es, in part or in w
t to the co
Possible causes for deviation from specification and rectification
♦ The air conditioner compressor is not driven or not driven at the specified speed
rrectness of i
– Check the drive of the air conditioner compressor (via belts or drive unit) ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor (vehicle-specific workshop manual).
l purpos
♦ Actuation of the air conditioner compressor regulating valve - N280- (the air conditioning system magnetic
clutch - N25- ) is defective.
nf
ercia
– Check actuation of the air conditioner compressor regulating valve - N280- (and the air conditioning system
orm
magnetic clutch - N25- ) and repair if necessary ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
m
atio
m
- air conditioning system.
o
n in
c
♦ Air conditioner compressor regulating valve - N280- or air conditioner compressor defective
or
thi
te
sd
a
– Check function of -N280- ; if necessary remove -N280- and check for dirt ⇒ Vehicle diagnostic tester in
iv
o
r
rp
cu
“Guided Fault Finding” mode - air conditioning system and ⇒ page 79
o
m
f
en
ng
– -N280- or renew the air conditioner compressor ⇒ page 79
t.
yi Co
– If dirt is found in the refrigerant circuit, clean the refrigerant circuit (flush with R1234yf refrigerant) and renew . Cop py
the expansion valve and desiccant bag/desiccant cartridge (or renew the receiver/reservoir) ⇒ page 79 ,
ht rig
rig ht
by
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual) and copy Vo
by lksw
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . cted agen
Prote AG.
♦ Bottle-neck or blockage in refrigerant circuit (e.g. in refrigerant line between service connection on “low
pressure side” and air conditioner compressor).
– Touch the refrigerant circuit by hand to feel for a drop in temperature ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual). If a drop in temperature is felt on a component,
if there is a kink or bottle-neck in the hose or pipeline, renew this component. In the event of a blockage or
if no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver) ⇒ page 79 and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
Final measures
2. Working with air conditioner service station 189
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
conditioning compressor”, page 178
AG. Volkswagen AG d
agen oes
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d b ara
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th
u ra
♦ If this problem is encountered,
ss a
ensure that the air conditioner c
compressor (air conditioner compressor shaft) is actually be‐
ce
le
un
pt
ing driven via the pulley / drive unit (take note of overload
an
d
itte
safety device) ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
y li
erm
ab
frigerant circuit (vehicle-specific workshop manual).
ility
ot p
wit
♦ On certain engines, air conditioner compressors are used that
is n
h re
feature in addition to -N280- an air conditioning system mag‐
ole,
spec
netic clutch - N25- on the belt pulley. In the event of this
urposes, in part or in wh
problem, make sure that -N25- is actually being actuated and
t to the co
that the air conditioner compressor (air conditioner compres‐
sor shaft) is being driven by the pulley ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
rrectne
workshop manual) and ⇒ Electronic parts catalogue .
♦ If no fault can be found for this complaint, clean the refrigerant
ss
circuit (flush with R1234yf refrigerant)
o
cial p
f
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
inform
mer
♦ Check the measured values of the evaporator output temper‐
atio
m
ature sender - G263- and actuation of -N280- . If the measured
o
n
c
value of -G263- is faulty, the evaporator could ice up or the
i
or
n thi
cooling output may not be reached ⇒ Vehicle diagnostic tester
te
sd
a
in “Guided Fault Finding” mode - air conditioning system.
iv
o
pr
cum
r
fo
♦ If, after repeating the test when the expansion valve has been
en
ng
t.
yi
renewed, the air conditioning system is not operating correctly,
Co
op py
clean the refrigerant circuit (flush with R1234yf refrigerant)
t. C rig
gh ht
yri
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Then renew the p by
co Vo
air conditioner compressor and reservoir/receiver (or desic‐
by lksw
cted agen
Prote
cant cartridge) ⇒ Heating, air conditioning; Rep. gr. 87 ;
AG.
Refrigerant circuit (vehicle-specific workshop manual).
♦ If the expansion valve is defective (always closed or not open‐
ing wide enough), -N280- will change to maximum power and
the low pressure will fall to the diagram value or less (the air
conditioner compressor is drawing the refrigerant out of the
low pressure side) ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode - air conditioning system. However, since no
refrigerant can flow through the expansion valve, the required
cooling output is not reached, the high pressure may also not
rise or only marginally since no energy exchange is taking
place.
Possible deviation from specification during pressure test
♦ The requisite cooling output is not reached.
♦ The high pressure increases beyond the specified value
♦ Low pressure drops quickly to the specification or lower.
Possible causes for deviation from specification and rectification
190 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
– Check the actuation of -N280- and, if necessary, repair ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system.
♦ Constriction or obstruction in refrigerant circuit
♦ Expansion valve defective
♦ If a shut-off valve is installed in the refrigerant circuit and it does not open correctly or at all ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
– Touch the refrigerant circuit by hand to feel for a drop in temperature ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual). If a drop in temperature is felt on a component,
if there is a kink or bottle-neck in the hose or pipeline, renew this component. In the event of a blockage or
if no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver) ⇒ page 79 and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
conditioning compressor”, page 178
Note
. Volkswagen AG
wa oe gen AG d
♦ In this case, the evaporator may ice
yV
up
olkseven though the correct s not g
volume of refrigerant is present
ise
d in
b the refrigerant circuit. ua
ran
r tee
tho
♦ If the expansion valve is sdefective
au (always closed or not open‐ or
ac
ing wide enough) the airs conditioner compressor regulating
ce
e
valve - N280- will be set to maximum power and the low pres‐
nl
pt
du
an
sure value will fall to the diagram value or less (the air condi‐
itte
y li
tioner compressor extracts refrigerant from the low pressure
erm
ab
side). Since no refrigerant can flow through the expansion
ility
ot p
valve, however, the cooling output is not reached and the high
wit
, is n
pressure may also not increase or only increase slightly owing
h re
hole
to there being no energy exchange ⇒ Vehicle diagnostic tester
spec
in “Guided Fault Finding” mode - air conditioning system and
es, in part or in w
t to the co
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
♦ If there is too much refrigerant in the refrigerant circuit, the air
rrectness of i
conditioner compressor must be emptied and the desiccant
l purpos
bag (desiccant cartridge) or reservoir/receiver renewed. After
cleaning (flushing with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 the refrigerant cir‐
nform
ercia
cuit, pour the correct volume of refrigerant oil in the refrigerant
circuit ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical
m
at
om
data; Approved refrigerant oils and refrigerant oil fill volumes
ion
c
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
in t
or
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
his
ate
do
riv
workshop manual).
p
cum
for
♦ If the specification is not reached again when the test is re‐
en
ng
t.
yi
peated but no fault can be found in the refrigerant circuit, clean
Co
Cop py
the refrigerant circuit (flush with R1234yf refrigerant)
t. rig
gh ht
yri
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
p by
co Vo
by lksw
cted agen
Prote AG.
2. Working with air conditioner service station 191
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 n AG➤
. Vo, lkCrafter
swagen A201
G do ...
wage es n
Air conditioning systems with refrigerant R1234yf
y Vo - General information - Edition
lks ot g 01.2018
b ua
ed ran
oris tee
Possible deviation from specification during pressure
au
th test or
ac
ss
♦ The requisite cooling output is reached initially but after a while or after an extended period, the cooling
ce
e
nl
pt
output is no longer sufficient.
du
an
itte
y li
♦ The high pressure and the low pressure are normal to start with
erm
ab
ility
ot p
♦ After some time, the high pressure rises above the specification, the low pressure still equates to the
wit
, is n
specification or it drops below the specification.
h re
hole
spec
Possible causes for deviation from specification and rectification
es, in part or in w
t to the co
♦ Radiator, condenser contaminated or actuation of the radiator is not OK
– Check actuation of the radiator fan and repair if necessary ⇒ Vehicle diagnostic tester in “Guided Fault
rrectness of i
Finding” mode - air conditioning system.
– Check condenser for contamination and clean if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ;
l purpos
Refrigerant circuit (vehicle-specific workshop manual) and ⇒ Engine, mechanicals; Rep. gr. 19 ; Radiator/
radiator fan .
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
nform
ercia
– Check actuation of -N280- and the measured value of evaporator output temperature sender - G263- ,
m
at
om
i
repair if necessary ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning system.
on
c
in t
♦ Too much refrigerant in the refrigerant circuit
or
his
ate
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
do
priv
c
– If the extracted refrigerant volume is considerably greater (more than 100 g) than the prescribed fill volume
um
for
en
g
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), there was
n
t.
yi Co
too much refrigerant in the refrigerant circuit Refill the refrigerant circuit with the correct volume of R1234yf . Cop py
and repeat the test.
t rig
gh ht
yri by
♦ Air conditioner compressor regulating valve - N280- or air conditioner compressor defective cop Vo
by lksw
cted agen
Prote
– Check function of -N280- ; if necessary remove -N280- and check for dirt ⇒ Vehicle diagnostic tester in
AG.
“Guided Fault Finding” mode - air conditioning system and ⇒ “1.5 Renewing components”, page 79
– -N280- or renew the air conditioner compressor ⇒ “1.5 Renewing components”, page 79
– If dirt is found in the refrigerant circuit, clean the refrigerant circuit (flush with R1234yf refrigerant) and renew
the expansion valve and desiccant bag/desiccant cartridge (or renew the receiver/reservoir)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual) and ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ Too much refrigerant oil in the refrigerant circuit
♦ Moisture in refrigerant circuit
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), there is too
much refrigerant oil in the refrigerant circuit
– Clean refrigerant circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
conditioning compressor”, page 178
192 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If there is too much refrigerant in the refrigerant circuit, the air
conditioner compressor must be emptied and the desiccant
bag (desiccant cartridge) or reservoir/receiver renewed. After
cleaning (flushing with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 the refrigerant cir‐
cuit, pour the correct volume of refrigerant oil in the refrigerant
circuit ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical
data; Approved refrigerant oils and refrigerant oil fill volumes
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
♦ In this case, the evaporator may ice up even though the correct
volume of refrigerant is present in the refrigerant circuit.
♦ A fault in the evaporator output temperature sender - G263-
could also cause the refrigerant circuit to ice up. With this
complaint, also observe the measured value of -G263- ⇒ Ve‐
hicle diagnostic tester in “Guided Fault Finding” mode - air
conditioning system and ⇒ Heating, air conditioning; Rep. gr.
87 ; Overview of fitting locations - air conditioning system (ve‐
hicle-specific workshop manual).
Possible deviation from specification during pressure test
♦ The requisite cooling output is reached initially but after a short or extended period, the required level is no
longer reached.
♦ The high pressure and low pressure are normal to start with but after a while, the high pressure rises above
the specification and the low pressure drops to the specification or lower.
n AG. Volkswagen AG
♦ The high pressure and low pressure are normal to start with.oAfter
ksw a while, the low pressure
age does
not drops to the
specification or lower and the evaporator ices up. y V l gu
db ara
e
ris nte
tho eo
Possible causes for deviation from specification and rectification
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
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Working with air conditioner service station 193
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Radiator, condenser contaminated or actuation of the radiator is not OK
– Check actuation of the radiator fan and repair if necessary ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode - air conditioning system.
– Check condenser for contamination and clean if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual) and ⇒ Engine, mechanicals; Rep. gr. 19 ; Radiator/
radiator fan .
♦ Measured value of evaporator output temperature sender - G263- faulty.
– Check measured value and installation of -G263- ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
function - air conditioning system and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting locations
- air conditioning system .
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
– Check actuation of the air conditioner compressor regulating valve - N280- and repair if necessary ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air conditioning system.
♦ Air conditioner compressor regulating valve - N280- or air conditioner compressor defective
– Check function of -N280- ; if necessary remove -N280- and check for dirt ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode - air conditioning system and ⇒ “1.5 Renewing components”, page 79
– -N280- or renew the air conditioner compressor ⇒ “1.5 ARenewing
G. Volkswagecomponents”,
n AG d page 79
agen
– If dirt is found in the refrigerant circuit, clean the Vorefrigerant
lksw circuit (flush with
oes
nR1234yf
ot refrigerant) and renew
the expansion valve and desiccant bag/desiccant e d by cartridge (or renew the receiver/reservoir)
gu
ara
⇒ “1.6 Cleaning refrigerant circuit”, page tho
ris 92 , ⇒ “1.5 Renewing components”, page nte
e79
or
and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant au circuit (vehicle-specific workshop manual). ac
♦ Moisture in refrigerant circuit ss
ce
le
un
pt
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
an
d
itte
y li
erm
ab
– Clean refrigerant circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
ility
ot p
wit
is n
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver)
h re
ole,
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
spec
urposes, in part or in wh
(vehicle-specific workshop manual).
t to the co
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
rrectne
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air ss
conditioning compressor”, page 178
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
♦ In this case, the evaporator may ice up even though the correct
thi
te
sd
a
volume of refrigerant is present in the refrigerant circuit.
iv
o
pr
cum
r
fo
♦ A fault in the evaporator output temperature sender - G263-
en
ng
t.
could cause the refrigerant circuit to ice up. With this com‐
yi Co
op
plaint, also observe the measured value of -G263- .
C py
t. rig
gh ht
yri by
♦ If there is too much moisture in the circuit, the air conditioner
cop Vo
by lksw
cted
compressor must be emptied and the desiccant bag/desiccant
agen
Prote AG.
cartridge (or reservoir/receiver) renewed. After cleaning
(flushing with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 the refrigerant cir‐
cuit, pour the correct volume of refrigerant oil in the refrigerant
circuit ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
194 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ The requisite cooling output is reached.
♦ The high pressure equates to the specification
♦ The low pressure is too low (lower than the specification)
Possible causes for deviation from specification and rectification
♦ Measured value of evaporator output temperature sender - G263- faulty.
– Check measured value and installation of -G263- ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
function - air conditioning system and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting locations
- air conditioning system (vehicle-specific workshop manual).
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
♦ If a shut-off valve is installed in the refrigerant circuit and it does not open correctly or at all ⇒ Heating, air
conditioning; Rep. gr. 87 ; Overview of fitting locations - air conditioning system (vehicle-specific workshop
manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop man‐
ual).
– Check actuation of the air conditioner compressor regulating valve - N280- and repair if necessary ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air conditioning system.
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview
of fitting locations - air conditioning system and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit .
♦ Air conditioner compressor regulating valve - N280- or air conditioner compressor defective
– Check function of -N280- ; if necessary remove -N280- and check for dirt ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode - air conditioning system and ⇒ “1.5 Renewing components”, page 79
– -N280- or renew the air conditioner compressor ⇒ “1.5 Renewing components”, page 79
– If dirt is found in the refrigerant circuit, clean the refrigerant circuit (flush with R1234yf refrigerant) and renew
the expansion valve and desiccant bag/desiccant cartridge (or
nAG. Vrenew
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en Areceiver/reservoir)
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⇒ “1.6 Cleaning refrigerant circuit”, page 92 , ⇒ “1.5 lkswage
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conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
d by workshop manual). ara
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Final measures utho eo
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– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
s
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– Repeat the test
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conditioning compressor”, page 178
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2. Working with air conditioner service station 195
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ In the event of the following fault “High pressure normal, low
pressure too low”, please note the following: With this fault,
there is a chance that the evaporator could ice up even though
the refrigerant volume in the circuit is OK.
♦ If the fault exists in a shut-off valve that may be installed in the
system (shut-off valve does not open), the refrigerant circuit
needs to be cleaned (flushed with R1234yf refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ). With this fault,
it is sufficient to check actuation of the shut-off valve. If this is
OK, renew the shut-off valve.
♦ If the fault is in the air conditioner compressor regulating valve
- N280- (the regulating valve is not activated, but the air con‐
ditioner compressor still runs), it is not necessary to clean the
refrigerant circuit (flush with R1234yf refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ). In this case it is
sufficient to renew the air conditioner compressor (observe
quantity of refrigerant oil in compressor).
♦ If the expansion valve is defective (always closed or not open‐
ing wide enough) the air conditioner compressor regulating
valve - N280- will be set to maximum power and the low pres‐
sure value will fall to the diagram value or less (the air condi‐
tioner compressor extracts refrigerant from the low pressure
side). However, since no refrigerant can flow through the ex‐
pansion valve, the required cooling output is not reached, the
high pressure may also not rise or only marginally since no
energy exchange is taking place. With this fault, it is not nec‐
essary to clean the refrigerant circuit (flush with R1234yf re‐
frigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 ). . Volkswagen AG
Renewing the expansion valve is sufficient. swa
gen AG does
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♦ Check the measured values of the evaporator output
ise
d b temper‐ ara
nte
ature sender - G263- and actuation of the air thconditioner
or eo
compressor regulating valve - N280- . If thess
ameasured
u
value ra
c
of -G263- is faulty, the evaporator could ice up or the cooling ce
le
output may not be reached ⇒ Vehicle diagnostic tester in “Gui‐
un
pt
an
d
ded Fault Finding” mode - air conditioning system.
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urposes, in part or in wh
Possible deviation from specification during pressure test
t to the co
♦ The air conditioner compressor is noisy (especially immediately after being switched on),
rrectne
♦ The requisite cooling output is reached.
♦ High pressure normal or too high
ss o
♦ The low pressure is normal or too high (the specification is not always reached)
cial p
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Possible causes for deviation from specification and rectification
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Prote AG.
196 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
– Check actuation of the air conditioner compressor regulating valve - N280- and repair if necessary ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air conditioning system.
♦ Check function of -N280- ; if necessary remove -N280- and check for dirt ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode - air conditioning system and ⇒ “1.5 Renewing components”, page 79 and ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (workshop manual for specific vehicle).
♦ Renew -N280- or air conditioner compressor ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-specific workshop manual).
♦ If dirt is found in the refrigerant circuit, clean the refrigerant circuit (flush with R1234yf refrigerant) and renew
the expansion valve and desiccant bag/desiccant cartridge (or renew the receiver/reservoir)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 , ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ Too much refrigerant or refrigerant oil in the refrigerant circuit
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably greater (more than 100 g) than the prescribed fill volume
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), there was
too much refrigerant in the refrigerant circuit Recharge refrigerant circuit and repeat test.
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally higher than the
prescribed fill volume (less than 100 g) ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-
specific workshop manual), there is too much refrigerant oil in the refrigerant circuit Clean the refrigerant
circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 , recharge with the correct
volume of refrigerant and refrigerant oil and repeat the test.
♦ Expansion valve defective
olkswagen AG
en AG. V
♦ If a shut-off valve is installed in the refrigerant circuit and
olks it does not open correctly
wag does
noor at all ⇒ Heating, air
t gu
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
ed byV workshop manual). ara
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or
– If fitted, check the function of the installed shut-off
au
th valve ⇒ Heating, air conditioning; Rep. gr.
eo
r a 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
ss c
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver)
ce
le
un
pt
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
an
d
itte
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(vehicle-specific workshop manual).
rm
ab
♦ The air conditioner compressor is defective.
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– If it is not possible to find a fault on any of the components and the extracted refrigerant volume equates
h re
to the specifications, clean the refrigerant circuit (flush with R1234yf refrigerant)
hole
spec
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . If when cleaning the refrigerant circuit no overly high volume
es, in part or in w
of refrigerant is found, renew the air conditioner compressor ⇒ “1.5 Renewing components”, page 79 , ⇒
t to the co
Heating, air conditioning; Rep. gr. 00 ; Repair instructions; Checking cooling output (vehicle-specific work‐
shop manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-specific
workshop manual).
Final measures rrectness of i
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– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
nform
ercia
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
m
conditioning compressor”, page 178
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2. Working with air conditioner service station 197
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The cause for this fault could also be too much refrigerant oil
in the refrigerant circuit. Overfilling with refrigerant oil can oc‐
cur if the refrigerant oil level was not checked after the air
conditioner compressor was renewed. If there is too much re‐
frigerant oil in the refrigerant circuit, clean the refrigerant circuit
(flush with R1234yf refrigerant).
⇒ “1.6 Cleaning refrigerant circuit”, page 92
♦ If the expansion valve (or a shut-off valve that may be installed
in the system) is defective (always closed or not opening wide
enough) the air conditioner compressor regulating valve -
N280- will be set to maximum power and the low pressure
value will fall to the diagram value or less (the air conditioner
compressor extracts refrigerant from the low pressure side).
Since no refrigerant can flow through the expansion valve,
however, the cooling output is not reached and the high pres‐
sure may also not increase or only increase slightly owing to
there being no energy exchange ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
Possible deviation from specification during pressure test
♦ The required cooling output is not reached.
♦ The high pressure andwlow
agenpressure equate
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198 Rep. gr.87 - Air conditioning system
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Arteon 2018 ➤ , AtlasVol 2017 ➤ , CC 2012 ➤ , Caddy
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Possible deviation from specification
ss
during pressure test
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♦ There is too little refrigerant in the refrigerant circuit.
du
an
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– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
ab
ility
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
ot p
wit
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
, is n
h re
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
hole
spec
– The extracted refrigerant volume roughly equates to the prescribed fill volume, measured value of evapo‐
es, in part or in w
rator output temperature sender - G263- , actuation of air conditioner compressor regulating valve - N280- ,
t to the co
function of expansion valve faulty or fault in a different component (see below).
♦ Measured value of evaporator output temperature sender - G263- faulty.
rrectness of i
– Check measured value and installation of -G263- ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
function - air conditioning system and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting locations
l purpos
- air conditioning system ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific workshop manual).
♦ Actuation of the air conditioner compressor regulating valve - N280- is defective.
nform
ercia
– Check the actuation of -N280- and, if necessary, repair ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
m
at
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mode - air conditioning system.
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♦ Expansion valve defective
in t
or
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ate
♦ If a shut-off valve is installed in the refrigerant circuit and it does not open correctly or at all ⇒ Heating, air
do
riv
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
p
cum
for
en
ng
t.
– Touch the refrigerant circuit by hand to feel for a drop in temperature ⇒ Heating, air conditioning; Rep. gr.
yi Co
op
87 ; Refrigerant circuit (vehicle-specific workshop manual). If a drop in temperature is felt on a component,
C py
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if there is a kink or bottle-neck in the hose or pipeline, renew this component. In the event of a blockage or
ht
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if no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant)
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⇒ “1.6 Cleaning refrigerant circuit”, page 92 Prote AG.
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
♦ Too much refrigerant oil in the refrigerant circuit
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally higher than the
prescribed fill volume (less than 100 g) ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-
specific workshop manual), there is too much refrigerant oil in the refrigerant circuit Clean the refrigerant
circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 , recharge with the correct
volume of refrigerant and refrigerant oil and repeat the test.
♦ Expansion valve defective
♦ If a shut-off valve is installed in the refrigerant circuit and it does not open correctly or at all ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat the test
⇒ “2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air
conditioning compressor”, page 178
2. Working with air conditioner service station 199
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
AG. Volkswagen AG d
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♦ Check the measured
utho values of the evaporator output temper‐ e or
ature sender -ssG263-
a
and actuation of -N280- . If the measured ac
value of -G263- is faulty, the evaporator could ice up or the
ce
e
nl
pt
cooling output will not be reached ⇒ Vehicle diagnostic tester
du
an
itte
in “Guided Fault Finding” mode - air conditioning system and
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ab
⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting
ility
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locations - air conditioning system (vehicle-specific workshop
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manual).
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spec
♦ Overfilling with refrigerant oil can occur if the refrigerant oil
es, in part or in w
level was not checked after the air conditioner compressor
t to the co
was renewed.
♦ If the expansion valve is defective (always open) the evapo‐
rrectness of i
rator temperature will no longer be controlled so that only
gaseous refrigerant exits the evaporator. It is then possible
l purpos
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).
nf
ercia
orm
♦ If there is too much refrigerant oil in the circuit, empty the air
m
atio
m
conditioner compressor and, if fitted, renew the reservoir/re‐
o
n in
c
ceiver (or desiccant cartridge) ⇒ Heating, air conditioning;
or
thi
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
te
sd
a
manual). After cleaning the refrigerant circuit (flushing with
iv
o
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rp
cu
R1234yf refrigerant)
o
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en
ng
⇒ “1.6 Cleaning refrigerant circuit”, page 92 , pour the correct
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amount of refrigerant oil in the circuit ⇒ Heating, air condi‐ Cop py
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shop manual). cop Vo
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2.14.5 Checking pressures with air condition‐
ing system switched on - vehicles with
electrical air conditioning compressor
Checking pressures ⇒ page 200
Specifications for pressures in refrigerant circuit on vehicles with‐
out heat pump ⇒ page 205
Specifications for pressures in refrigerant circuit on vehicles with
heat pump ⇒ page 229
Checking pressures
Note
Work on the refrigerant circuit that involves the air conditioner
service station (checking the pressures in this case) can usually
be carried out without the need to de-energise the high-voltage
system.
– To minimise the number of automatic engine starts during
testing and measuring while operational readiness is active,
charge the vehicle batteries e.g. with battery charger 60A -
VAS 5904- in battery back-up mode ⇒ Electrical system; Rep.
gr. 27 ; Battery; Charging battery and ⇒ Electrical system;
Rep. gr. 93 ; General warning instructions for work on the high-
voltage system .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
200 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
parking brake and arrange the tools needed so that they can‐
not come into contact with moving components of the engine
and so that they cannot even come near to components that
turn when the engine is running.
Note
♦ Also move the selector lever to position “P”, and activate the
parking brake before performing test and measurement work
for which the ignition must be switched on but where the ve‐
hicle's drive system does not need to be active (READY).
♦ Operational readiness (vehicle’s drive system) is displayed in
the control unit in dash panel insert - J285- via the “Powerme‐
ter” ⇒ owner's manual .
♦ Activating and deactivating vehicle drive system ⇒ Owner's
manual (observe display in control unit in dash panel insert -
J285- while doing so).
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– On vehicles with high-voltage system, switch
Vol
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conditioning” function (deactivate)⇒ed bOwner's Manual and ⇒
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Operating instructions of infotainment
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– Switch off ignition. ss c
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– Connect the air conditioner service station
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⇒ “2.2 Connecting air conditioner service station to refrigerant
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circuit”, page 126 .
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If a problem is encountered in just one evaporator on vehicles with
two evaporators (one evaporator in the heater and air conditioning
unit and one evaporator on the heat exchanger for high-voltage
battery), check the pressures in the refrigerant circuit Check the
rrectness of i
line connection between the evaporator that is causing the prob‐
l purpos
lem and the end of the line at the distribution point for the refrig‐
erant lines (for a bottle-neck or blockage). If no fault can be found,
empty the refrigerant circuit and recharge it with the prescribed
nform
ercia
amount of refrigerant. Then check the pressures and the cooling
output of the air conditioning system again. If the problem per‐
m
at
om
sists, check / renew the following components: If the problem is
on
c
only encountered at the evaporator in the heating and air condi‐
in t
or
his
e
tioning unit, check the evaporator in the heating and air condi‐
at
do
riv
tioning unit (it is open in unactuated state and allows refrigerant
p
cum
or
to flow through). Renew the expansion valve on the evaporator in
f
en
g
the heater and air conditioning unit if no fault can be found in the
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shut-off valve. If the problem is only encountered on the evapo‐ C py
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rator in the heat exchanger for high-voltage battery, check actua‐
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in the heat exchanger for high-voltage battery (it is closed in un‐
agen
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actuated state and does not allow refrigerant to flow through) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
Conditions for testing
• The air conditioner service station is connected to the refrig‐
erant circuit
⇒ “2.2 Connecting air conditioner service station to refrigerant
circuit”, page 126 .
• Observe the conditions for testing pressures in the refrigerant
circuit with the ignition switched off ⇒ page 171 .
• The pressures in the refrigerant circuit comply with the speci‐
fications with the ignition switched off
2. Working with air conditioner service station 201
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
⇒ “2.14.3 Checking pressures in the refrigerant circuit with the
ignition switched off”, page 171 .
• Observe the conditions for testing the cooling output ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Repair instructions; Check‐
ing cooling output (vehicle-specific workshop manual).
Note
♦ The switching pressures for actuation of the electrical air con‐
ditioner compressor - V470- and the radiator fan - V7- are
vehicle-specific ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode - air conditioning system and battery regulation.
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
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(vehicle-specific workshop manual). lksw
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• The engine is at operating temperature (at an ambientthtem‐
oris nte
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perature less than 25°C). s au ra
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♦ Should the engine not be at operating temperature, take the
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vehicle for a short drive.
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♦ To test the cooling output, the engine does not have to be at
spec
operating temperature. However, to demand a certain cooling
es, in part or in w
t to the co
output from the air conditioning system at an ambient temper‐
ature of less than 25°C, the engine is required to be warm if
ambient temperatures are low.
rrectness of i
• To minimise the number of automatic engine starts during
l purpos
testing and measuring while operational readiness is active,
charge the vehicle batteries e.g. with battery charger 60A -
nform
ercia
VAS 5904- in battery back-up mode ⇒ Electrical system; Rep.
gr. 27 ; Battery; Charging battery and ⇒ Electrical system;
m
at
om
Rep. gr. 93 ; General warning instructions for work on the high-
ion
c
voltage system .
in t
or
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te
– Activate operational readiness (engine must not run) ⇒ own‐
a
do
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er's manual .
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ng
t.
– Set the air conditioning system to maximum cooling output ⇒ op
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Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
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Checking cooling output (vehicle-specific workshop manual).
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• The electrical air conditioner compressor - V470- is actuated
cted agen
Prote AG.
and runs ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system and battery regulation as well
as ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
202 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ Actuation of the electrical air conditioning compressor is initi‐
ated by the vehicle electronics. The engine speed has no
influence on the cooling output of the air conditioning system.
♦ The air conditioner compressor is currently not activated at the
maximum specified speed (of approx. 8500 rpm) when the
vehicle is stationary or driving slowly (up to a vehicle speed of
AG. Volkswagen AG d
45 km/h). The air conditioner compressor speed kswais
genrestricted oes
to approx. 5000 rpm.
not
y Vol gu
b a d ran
ise
♦ Actuation of the electrical air conditioning
ut
ho
r
compressor can be tee
or
monitored by guided fault findingss⇒
a Vehicle diagnostic tester ac
in “Guided Fault Finding” mode - air conditioning system and
ce
le
un
battery regulation.
pt
an
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itte
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♦ All of the conditions for testing marked with * are pertinent to
rm
ab
pe
a certain vehicle and are described in the vehicle-specific
ility
ot
workshop manual ⇒ Heating, air conditioning; Rep. gr. 00 ;
wit
, is n
Repair instructions; Checking cooling output (vehicle-specific
h re
hole
workshop manual).
spec
es, in part or in w
t to the co
If the air conditioner compressor is not actuated with operational
readiness active:
rrectness of i
– Determine the cause, e.g. by interrogating the event memory
of the air conditioning system, and rectify it ⇒ Vehicle diag‐
l purpos
nostic tester in “Guided Fault Finding” mode - air conditioning
system and battery regulation.
nform
ercia
• The radiator and condenser are clean (clean if necessary) * ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
m
a
com
ti
hicle-specific workshop manual) and ⇒ Engine, mechanicals;
on in
Rep. gr. 19 ; Radiator/radiator fan .
r
te o
thi
s
iva
• The heat insulation on the expansion valve is OK and mounted
do
r
rp
c
correctly * ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
um
fo
en
g
erant circuit (vehicle-specific workshop manual).
n
t.
yi Co
op py
• The air ducts, covers and seals are OK and mounted correctly
t. C rig
gh ht
yri
* ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting p by
co Vo
locations - air conditioning system (vehicle-specific workshop
by lksw
cted agen
Prote
manual).
AG.
• No faults are found during diagnosis of the air conditioning
system (with operational readiness (vehicle’s drive system)
active and the air conditioning system switched on). No com‐
pressor deactivation condition is shown in the measured valve
block ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system and battery regulation.
• The various pressure/temperature senders and temperature
sensors on or in the refrigerant circuit supply plausible values
during operation of the air conditioning system, check ⇒ Ve‐
hicle diagnostic tester in “Guided Fault Finding” mode and ⇒
Heating, air conditioning; Rep. gr. 87 ; Overview of fitting lo‐
cations - air conditioning system . If no fault can be found,
extract the refrigerant.
• The rate of air flow through the dust and pollen filter is not
impaired by dirt * ⇒ Heating, air conditioning; Rep. gr. 87 ;
Overview of fitting locations - air conditioning system (vehicle-
specific workshop manual).
• The heater and air conditioner does not draw any secondary
air at highest fresh air blower speed. evaporator and heater
not drawing in secondary air at maximum fresh-air blower
speed * ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair in‐
structions; Checking cooling output (vehicle-specific work‐
shop manual).
2. Working with air conditioner service station 203
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
• The air duct flaps in the heater and air conditioner unit, heater
and evaporator reach their end position * ⇒ Heating, air con‐
ditioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output (vehicle-specific workshop manual).
. Volkswagen AG
a gen AG d
• Fresh-air intake ducts beneath bonnet Vol
ksw and in passenger com‐
oes
not
gu
partment as well as correspondinged by water drain valves OK* ⇒ ara
nte
Heating, air conditioning;thoRep. gr. 87 ; Overview of fitting lo‐
ris
eo
cations - air conditioning
s au system (vehicle-specific workshop ra
c
manual). s
ce
e
nl
pt
du
• The vehicle is not exposed to the sun's rays ⇒ Heating, air
an
itte
y li
conditioning; Rep. gr. 00 ; Repair instructions; Checking cool‐
erm
ab
ing output (vehicle-specific workshop manual).
ility
ot p
wit
, is n
• Ambient temperature is above 15°C.
h re
hole
spec
• All dash panel air vents are open.*
es, in part or in w
t to the co
Setting e.g. on operating and display unit for front air conditioning
system - E87- (and operating and display unit for rear air condi‐
tioning system - E265- on vehicles with two heater and air con‐
rrectness of i
ditioning units) * ⇒ Heating, air conditioning system; Rep. gr. 00 ;
Repair instructions; Checking cooling output (vehicle-specific
l purpos
workshop manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Overview of fitting locations - air conditioning system .
nf
ercia
Setting e.g. on -E87- *:
orm
m
atio
– Select “Auto” mode (air conditioner compressor switched on).
om
n in
or c
– Set temperature to “cold” or “LO” for the driver and front pas‐
thi
e
senger side (and the rear on the left and right in vehicles with
t
sd
iva
two heating and air conditioning units).* o
r
rp
cu
o
m
f
en
ng
Setting on -J301- *:
t.
yi Co
Cop py
– Press A/C button and Rec or recirculate buttons.* ht. rig
rig ht
py by
o Vo
– Turn rotary temperature knob in direction of “cold” stop.*
by c lksw
cted agen
Prote AG.
– Set rotary fresh air blower switch to “4” (maximum fresh air
blower speed).*
The following conditions for testing should then be met in the sys‐
tem:
• The radiator fan - V7- is running or the radiator fan - V7- and
radiator fan 2 - V177- are running (at least stage 1) * ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Repair instructions; Check‐
ing cooling output (vehicle-specific workshop manual) and ⇒
Engine, mechanicals; Rep. gr. 19 ; Radiator/radiator fan .
Note
On certain versions, the radiator fan cuts in only after the pressure
in the refrigerant circuit has exceeded a pre-set value ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air conditioning
system and battery regulation.
• The fresh air blower - V2- (and the rear fresh air blower - V80-
on vehicles with two heating and air conditioning units) is
running at maximum speed.*
• The air recirculation flap/fresh air flap is in “recirculation
mode” (within 1 minute after starting the vehicle, the air flow
flap closes and the air recirculation flap opens).*
• The coolant shut-off valve is closed * ⇒ Heating, air condi‐
tioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output (vehicle-specific workshop manual) and ⇒ Heating, air
204 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
conditioning; Rep. gr. 87 ; Overview of fitting locations - air
conditioning system (vehicle-specific workshop manual).
• The valves of the pump-valve unit are closed and the coolant
circulation pump is not delivering * ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking cooling output
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Overview of fitting locations - air
conditioning system (vehicle-specific workshop manual).
Note
♦ Actuation of the electrical air conditioning compressor is initi‐
ated by the vehicle electronics. The engine speed has no
influence on the cooling output of the air conditioning system
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system and battery regulation.
♦ The air conditioner compressor is currently not activated at the
maximum specified speed (of approx. 8500 rpm) when the
vehicle is stationary or driving slowly (up to a vehicle speed of
45 km/h). The air conditioner compressor speed is restricted
to approx. 5000 rpm.
♦ Actuation of the electrical air conditioning compressor can be
monitored by guided fault finding ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and
battery regulation.
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
Specifications for pressures in the refrigerant circuit
♦ Specifications for pressures in refrigerant
swa
gcircuit
en AG. Von vehicles
olkswagen AG
does
without heat pump ⇒ page 205 by V olk not
gu
ara
is ed nte
♦ Specifications for pressuresthin
or refrigerant circuit on vehicles e or
with heat pump ⇒ page 229 s au ac
s
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
♦ The specified and actual speeds for actuation of the electrical
wit
, is n
air conditioner compressor - V470- and the radiator fan - V7-
h re
are vehicle-specific ⇒ Vehicle diagnostic tester in “Guided
hole
spec
Fault Finding” mode - air conditioning system and battery reg‐
es, in part or in w
ulation.
t to the co
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific
rrectness of i
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
l purpos
Specifications for pressures in refrigerant circuit on vehicles with‐
nf
ercia
out heat pump
orm
m
atio
♦ Observe the test prerequisites ⇒ page 200 .
om
n in
or c
– Watch the pressure display (e.g. pressure gauge) of the air
thi
e
conditioner service station .
t
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.
2. Working with air conditioner service station 205
. Volkswagen AG
gen AG d
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 olks➤ , Caddy 2016 ➤ , Crafter
wa oes
not 201 ...
yV gu
Air conditioning systems with refrigerant
ised b R1234yf - General information -arEdition
an 01.2018
r tee
ho
aut or
ac
ss
ce
le
Note
un
pt
an
d
itte
y li
erm
♦ The switching pressures for actuation of the electrical air con‐
ab
ility
ditioner compressor - V470- and the radiator fan -V7- / -V177-
ot p
wit
are vehicle-specific ⇒ Vehicle diagnostic tester in “Guided
is n
h re
Fault Finding” mode - air conditioning system and battery reg‐
ole,
spec
ulation.
urposes, in part or in wh
t to the co
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
rrectne
(vehicle-specific workshop manual).
s
High-pressure side:
s o
cial p
f
From the output pressure (when the pressure gauge is connec‐
inform
ted) rising up to a maximum overpressure of 20 bar (depending
mer
on the ambient temperature and operating conditions of the air
atio
m
conditioning system).
o
n
c
i
or
n thi
e
Low-pressure side:
t
sd
iva
o
pr
c
From the output pressure (when connecting the pressure gauge)
um
r
fo
dropping to a value of between 1.5 and 2.3 bar absolute pressure
en
ng
t.
yi Co
(depending on required cooling output). t. Cop py
rig
gh ht
Speed of air conditioner compressor: yri
p by
o Vo
by c lksw
cted
Between 800 and 8500 rpm depending on the required cooling
agen
Prote AG.
output (currently maximum 5000 rpm with vehicle stationary).
206 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The temperature of the air after the evaporator, the current air
conditioner compressor speed and the pressure of the refrig‐
erant on the high-pressure side are displayed as a measured
value from various control units depending on the vehicle (e.g.
operating and display unit, -E87- , -J255- , thermal manage‐
ment control unit - J1024- and air conditioning system control
unit - J301- ) ⇒ Vehicle diagnostic tester in “Guided Fault Find‐
ing” mode - air conditioner compressor and battery regulation.
AG. Volkswagen AG d
♦ In the event of a very high cooling output (e.g. at high outsidelkswagen oes
not
temperatures and high fresh air blower speed), the air condi‐ db
yV
o gu
ara
tioner compressor is initially incapable of changing the ir sepres‐ nte
tho
sure on the low pressure side to the required levelau(e.g. for a eo
ra
certain period after switching on the air conditioning
ss system). c
The air conditioner compressor is not activated with the max.
ce
e
nl
pt
du
specified (of approx. 8500 rpm), if the vehicle stands still or
an
itte
y li
drives slowly (up to a vehicle speed of 45 km/h). The air con‐
erm
ab
ditioner compressor speed is then limited to 5000 rpm. The
ility
ot p
maximum permissible air conditioner compressor speed limit
wit
, is n
is not lifted until a vehicle speed greater than approx. 45 km/
h re
h is reached. The output (delivery rate) of the air conditioner
hole
spec
compressor at an air conditioner compressor speed of
es, in part or in w
5000 rpm, a high ambient temperature and high fresh air blow‐
t to the co
er speed (unfavourable ambient conditions) is initially no lon‐
ger sufficient to bring the pressure on the low pressure side
down to the specified value. To check the regulating behaviour
rrectness of i
of the air conditioner compressor under these conditions, e.g.
l purpos
only actuate the fresh air blower with approx. 40% of the max‐
imum voltage and check the pressures at reduced fresh air
blower speed ⇒ Vehicle diagnostic tester in “Guided Fault
nform
ercia
Finding” mode - air conditioning system and battery regulation
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
m
at
om
tions; Checking cooling output (vehicle-specific workshop
ion
c
manual).
in t
or
his
ate
♦ If the demand on the cooling output is low (e.g. at an ambient
do
priv
c
temperature of 20°C and a low fresh air blower speed), pres‐
um
for
sure on the high pressure side may only increase up to a value
en
ng
t.
yi
of 6 to 7 bar (the energy exchange is low, the refrigerant is
Co
Cop py
cooled down quickly in the condenser). To check the regulat‐
t. rig
gh ht
yri
ing behaviour and the pressures in the refrigerant circuit under
p by
co Vo
by lksw
these conditions, e.g. actuate the fresh air blower with maxi‐ Prote
cted AG.
agen
mum voltage, set the air conditioning system to maximum
heating output and activate air recirculation ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode - air conditioning
system and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking cooling output (vehicle-specific work‐
shop manual).
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high atmospheric humidity), the pressure on the high
pressure side can increase to a maximum of 29 bar.
♦ The specified speed of the air conditioner compressor is dis‐
played by various control units depending on the vehicle (e.g.
operating and display unit, -E87- , -J255- and air conditioning
system control unit - J301- ⇒ Vehicle diagnostic tester) in
“Guided Fault Finding” mode - air conditioning system.
♦ The high-pressure measured by various senders (e.g. high-
pressure sender - G65- , pressure sender for refrigerant circuit
- G805- or refrigerant pressure and temperature sender -
G395- ) is displayed as a measured value depending on the
vehicle (e.g. by -E87- , -J301- , thermal management control
unit - J1024- or -J255- ) ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode - air conditioner compressor.
2. Working with air conditioner service station 207
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ The low pressure adjusts itself depending on the speed of the
air conditioner compressor and the regulating characteristic of
the expansion valve within the performance band of the air
conditioner compressor in the tolerance range (1.5 to 2.3 over‐
pressure).
. Volkswagen AG
gen AG
♦ For this test, the specified speed of the airVconditioner
olks
wa com‐ does
not
pressor must be greater than 1500 rpm e d b⇒ Vehicle diagnostic
y gu
ara
tester in “Guided Fault Finding” mode horis - air conditioning sys‐ nte
eo
tem. s aut ra
c
s
♦ For the “maximum cooling output” setting, the specified speed
ce
e
nl
pt
du
of the air conditioner compressor is regulated at approx. 4000
an
itte
y li
to 5000 rpm. This value is vehicle-specific and is displayed as
erm
ab
a measured value by the respective control unit (e.g. operating
ility
ot p
and display unit, -E87- , -J255- or thermal management control
wit
, is n
unit - J1024- ⇒ Vehicle diagnostic tester) in “Guided Fault
h re
Finding” mode - air conditioning system and battery regulation.
hole
spec
es, in part or in w
♦ Absolute pressure means that 0 bar corresponds to an abso‐
t to the co
lute vacuum. The normal ambient pressure corresponds to 1
bar absolute. On the scales of most pressure gauges, 0 bar
corresponds to an absolute pressure of 1 bar (can be seen
rrectness of i
from -1 bar mark below 0) ⇒ Vehicle diagnostic tester in “Gui‐
ded Fault Finding” mode - air conditioning system.
l purpos
♦ If, on a vehicle with 2 evaporators (one in the heater and air
conditioner unit and one for battery cooling), the temperature
nf
ercia
o
measured at one evaporator meets the specification or falls
rm
m
below the specification, while on the other evaporator, how‐
atio
m
ever, the requisite specification is not reached, regulation
o
n in
or c
works as follows: the respective control unit (e.g. battery reg‐
thi
e
ulation control unit or thermal management control unit )
t
sd
iva
o
makes the electrical air conditioner compressor run at a higher
r
rp
cu
o
m
speed via additional controls units (e.g. power and control
f
en
ng
t.
electronics for electric drive and control unit for air conditioning
yi Co
op py
compressor ) (which results in the cooling output of the air t. C rig
gh ht
conditioning system rising and pressure on the low pressure yri
p by
o Vo
side falling along with the evaporator temperature). If the spec‐ by c lksw
cted agen
ification then falls below the minimum level at one evaporator,
Prote AG.
the respective control unit (e.g. battery regulation control unit )
actuates the shut-off valves (e.g. refrigerant shut-off valve 1
or refrigerant shut-off valve 2 ) in such a way that the evapo‐
rator that is too cold no longer has refrigerant flowing through
it ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
- air conditioning system and battery regulation as well as ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output (vehicle-specific workshop manual)
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system (vehicle-specific
workshop manual).
♦ Since the output of the evaporator in the battery cooling mod‐
ule is considerably lower than the output of the evaporator in
the heating and air conditioning unit, the requisite specified
temperature in the battery cooling module may still be reached
if there is insufficient refrigerant in the circuit but the specified
temperature in the evaporator of the heating and air condi‐
tioning unit will no longer be reached (even though the air
conditioner compressor is actuated at a higher speed) ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output (vehicle-specific workshop manual)
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit (vehicle-specific workshop manual).
208 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviations from specification,
cause and rectification
♦ The requisite cooling output in the evap‐ ⇒ page 211
orator of the heating and air conditioning
unit (and in the evaporator for the battery
cooling module) is not reached.
♦ High pressure remains constant or in‐
creases only slightly (above the pressure
measured when the engine is stopped).
♦ High pressure drops quickly to the spec‐
ification or lower.
♦ The requisite cooling output in the evap‐ ⇒ page 213
orator in the heating and air conditioning
unit (and in the evaporator for battery
cooling) is reached initially. However, af‐
ter a while or after an extended period of
operation, the cooling output is no longer
adequate.
♦ The high pressure and the low pressure
are normal to start with
♦ After some time, the high pressure rises
above the specification, the low pressure
still equates to the specification or it
drops below the specification.
AG. Volkswagen AG d
agen oes
♦ The requisite cooling outputy Vin olkthe
sw evap‐ ⇒ page 215 not
gu
orator of the heating and edair conditioning
b ara
nte
ris for the battery
unit (and in the evaporator
tho eo
cooling module) isss anot
u
reached. ra
c
ce
le
♦ The high pressure equates to the speci‐
un
pt
an
fication
d
itte
y li
rm
ab
♦ The low pressure is too low (lower than
pe
ility
the specification)
ot
wit
, is n
h re
hole
♦ The air conditioner compressor is noisy ⇒ page 217
spec
(especially immediately after being
es, in part or in w
t to the co
switched on),
♦ The requisite cooling output in the evap‐
orator of the heating and air conditioning
rrectness of i
unit and / or in the evaporator for battery
cooling is not reached.
l purpos
♦ High pressure normal or too high
nform
ercia
♦ Low pressure too high (specification is
not reached)
m
a
com
tion in
r
♦ The requisite cooling output in the evap‐ ⇒ page 219
te o
thi
orator of the heating and air conditioning
s
iva
do
unit (and in the evaporator for the battery
r
rp
cum
fo
cooling module) is not reached.
en
ng
t.
yi Co
op
♦ High pressure and low pressure normal C py
ht. rig
(equate to specification) rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Working with air conditioner service station 209
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviations from specification,
cause and rectification . Volkswagen AG
gen AG does
swa
♦ The requisite cooling output in the by
Vevap‐
olk ⇒ page 221 not
gu
orator of the heating and air conditioning
rised ara
nte
unit (and in the evaporatorufor
tho the battery eo
ra
cooling module) is not reached.
ss
a c
ce
le
♦ The high pressure equates to the speci‐
un
pt
an
d
fication
itte
y li
rm
ab
♦ The low pressure equates to the specifi‐
pe
ility
ot
cation or is too low
wit
, is n
h re
hole
♦ The requisite cooling output in the evap‐ ⇒ page 222
spec
orator of the heating and air conditioning
es, in part or in w
t to the co
unit (and in the evaporator for the battery
cooling module) is not reached.
♦ The high pressure equates to the speci‐
rrectness of i
fication
l purpos
♦ Low pressure drops quickly to the spec‐
ification or lower.
nform
ercia
♦ The requisite cooling output in the evap‐ ⇒ page 223
m
a
com
t
orator of the heating and air conditioning
ion in
unit (and in the evaporator for the battery
r
te o
thi
cooling module) is not reached.
s
iva
do
r
rp
c
♦ The requisite cooling output is then not
um
fo
reached at the evaporator in the heater
en
ng
t.
yi
and air conditioning unit (the cooling out‐
Co
Cop py
put at the evaporator in the battery cool‐
t. rig
gh ht
yri
ing module is OK). p by
co Vo
by lksw
cted agen
♦ High pressure increases only slightly Prote AG.
(above the pressure measured when the
engine is stationary) or equates to the
specification.
♦ Low pressure drops (possibly quickly) to
the specification or lower.
♦ The requisite cooling output in the evap‐ ⇒ page 224
orator of the heating and air conditioning
unit (and in the evaporator for the battery
cooling module) is not reached.
♦ The high pressure increases beyond the
specified value
♦ Low pressure drops quickly to the spec‐
ification or lower.
♦ The requisite cooling output is then not ⇒ page 227
reached at the evaporator for battery
cooling (the cooling output at the evapo‐
rator in the heater and air conditioning
unit is OK).
♦ High pressure equates to the specifica‐
tion or increases only slightly (above the
pressure measured when the engine is
stationary).
♦ Low pressure drops to the specification
or lower.
210 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviations from specification,
cause and rectification
♦ The requisite cooling output in the evap‐ ⇒ page 228
orator of the heating and air conditioning
unit (and in the evaporator for the battery
cooling module) is not reached.
♦ High pressure does not increase or only
marginally above the pressure with the
engine stationary
♦ The low pressure does not drop or only
marginally
Possible deviation from specification during pressure test
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
for the battery cooling module) is not reached.
♦ High pressure remains constant or increases only slightly (above the pressure measured when the air
conditioner compressor is stationary).
♦ High pressure drops quickly to the specification or lower.
Possible causes for deviation from specification and rectification
♦ There is too little refrigerant in the refrigerant circuit.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
. Volkswagen AG
the leak and rectify the cause ⇒ “1.4 Investigating
wagen AG leaks”, page do68
es n
olks
– The extracted refrigerant volume approximately equates to the prescribed
ot g fill volume, check actuation of
byV ua
the air conditioner compressor rand ise the installed shut-off valves. If no fault
d ran is found, renew the expansion
tee
valve for the evaporator in the ut heater and air conditioning unit ⇒ Heating, air
ho or conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific
ss
a
workshop manual) ac
♦ Actuation of air conditioner compressor (and if fitted refrigerant shut-off valve 1 and refrigerant shut-off
ce
le
un
pt
valve 2 ) faulty ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning system and
an
d
itte
battery regulation, ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instructions; Checking cooling output
y li
erm
ab
(vehicle-specific workshop manual), ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting locations
ility
ot p
- air conditioning system (vehicle-specific workshop manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ;
wit
is n
Air conditioner compressor (vehicle-specific workshop manual).
h re
ole,
spec
– Check actuation and the function of the air conditioner compressor (and if fitted the shut-off valves, e.g.
urposes, in part or in wh
refrigerant shut-off valve 1 , refrigerant shut-off valve 2 ) and repair if necessary ⇒ Vehicle diagnostic tester
t to the co
in “Guided Fault Finding” mode - air conditioning system and battery regulation. If this is OK, extract the
refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
♦ The expansion valve for the evaporator in the heater and air conditioning unit is defective and must be
rrectne
renewed ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ One of the refrigerant shut-off valves (if fitted) is defective (closed). Check the function and renew if nec‐
ss
essary ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning system and battery
o
cial p
regulation and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
inform
circuit
mer
atio
m
♦ Bottle-neck or blockage in refrigerant circuit (e.g. in refrigerant line between service connection on “low
o
n
c
pressure side” and air conditioner compressor) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
i
or
n thi
(vehicle-specific workshop manual).
te
sd
iva
o
pr
– If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
um
r
fo
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
en
ng
t.
yi
– If a hose or pipe is kinked or crushed, renew this component ⇒ Heating, air conditioning; Rep. gr. 87 ;
Co
Cop py
Refrigerant circuit (vehicle-specific workshop manual).
t. rig
gh ht
yri
♦ The expansion valve for the evaporator in the heater and air conditioning unit is defective and must be
p by
co Vo
by lksw
renewed ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual). Prote
cted AG.
agen
♦ A refrigerant shut-off valve is defective (closed). Check the function and renew ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and battery regulation and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
2. Working with air conditioner service station 211
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Arteon 2018 thor ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016
e o ➤ , Crafter 201 ...
u ra
Air conditioning
ss a systems with refrigerant R1234yf - General c information - Edition 01.2018
ce
e
nl
pt
Possible deviation from specification during pressure test du
an
itte
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erm
ab
Final measures
ility
ot p
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
wit
, is n
h re
hole
– Repeat test
spec
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
es, in part or in w
t to the co
tioning compressor”, page 200
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
212 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If, with this problem, no fault is found during diagnosis, check
the refrigerant circuit for a bottle-neck or blockage (a bottle-
neck or blockage in the refrigerant circuit can also lead to one
of these complaints). If nothing is found here either, clean the
refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and, if fitted, temperature sensor before
evaporator for hybrid battery and temperature sensor after
evaporator for hybrid battery as well as actuation of air condi‐
tioner compressor via the respective control unit ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air condi‐
tioning system and battery regulation.
♦ If there is a fault in the measured value of -G263- , temperature
sensor before evaporator for hybrid battery or temperature
sensor after evaporator for hybrid battery (depending on the
vehicle ⇒ Vehicle diagnostic tester in “Guided Fault Finding” -
air conditioning system and battery regulation), problems may
also be encountered in the cooling output or the evaporator
could ice up.
♦ In the event of a fault in a temperature sensor, the evaporator
may ice up even though the correct quantity of refrigerant is
present in the refrigerant circuit.
♦ If, after repeating the test when the expansion valve has been
renewed, the air conditioning system is not operating correctly,
clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Then renew the
air conditioner compressor and desiccant cartridgesw(or agereser‐
n AG. Volkswagen AG do
es n
voir/receiver) ⇒ Heating, air conditioning; Rep. by
Vgr. 87 ; Re‐
olk ot g
ua
frigerant circuit (vehicle-specific workshoprismanual).
ed ran
t ee
tho or
♦ If the expansion valve on the evaporator
s a in the heater and air
u ac
conditioning unit or the shut-off valves is defective (always ce
le
closed or does not open sufficiently), the air conditioner com‐
un
pt
an
d
pressor is actuated at the maximum output and low pressure
itte
y li
drops to the specification or lower (the air conditioner com‐
erm
ab
ility
pressor draws in refrigerant from the low pressure side). Since
ot p
no refrigerant can flow through the expansion valve, however,
wit
is n
h re
the cooling output is not reached and the high pressure may
ole,
also not increase or only increase slightly owing to there being
spec
urposes, in part or in wh
no energy exchange ⇒ Vehicle diagnostic tester in “Guided
t to the co
Fault Finding” mode - air conditioning system and battery reg‐
ulation and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
rrectne
♦ The evaporator in the heater and air conditioning unit has a
considerably higher output than the evaporator for battery
ss
cooling. Depending on the way the drive battery - A2- is cooled
o
cial p
(depending on the vehicle ⇒ Vehicle diagnostic tester in “Gui‐
inform
ded Fault Finding” - air conditioning system and battery regu‐
mer
lation), the refrigerant shut-off valve 2 on the expansion valve
atio
m
in the battery cooling module is currently only actuated from a
o
n
c
certain battery temperature by the respective control unit (e.g.
i
or
n thi
e
by battery regulation control unit ) so that the power consumed
t
sd
va
by the evaporator for battery cooling is not or barely increased
i
o
pr
cum
r
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
fo
en
ng
air conditioning system and battery regulation as well as ⇒
t.
yi Co
op
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐ C py
t. rig
hicle-specific workshop manual).
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 213
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ The requisite cooling output in the evaporator in the heating and air conditioning unit (and in the evaporator
for battery cooling) is reached initially. However, after a while or after an extended period of operation, the
cooling output is no longer adequate.
♦ The high pressure and the low pressure are normal to start with
♦ After some time, the high pressure rises above the specification, the low pressure still equates to the
specification or it drops below the specification.
Possible causes for deviation from specification and rectification . Volkswagen AG
gen AG does
♦ Radiator, condenser contaminated or actuation of the radiator Volksis
wanot OK not
y gu
db a
– Check actuation of the radiator fan and repair if necessary
or
ise ⇒ Vehicle diagnostic tester in “Guided ran
teeFault
Finding” mode - air conditioning system. uth or
a
sa
– Check condenser for contamination and clean if snecessary ⇒ Heating, air conditioning; Rep. gr. 87 c;
ce
Refrigerant circuit (vehicle-specific workshop manual) and ⇒ Engine, mechanicals; Rep. gr. 19 ; Radiator/
e
nl
pt
du
radiator fan .
an
itte
y li
♦ Actuation or the function of the air conditioner compressor (or, if fitted, the refrigerant shut-off valve 1 or
erm
ab
refrigerant shut-off valve 2 ) is faulty.
ility
ot p
wit
, is n
♦ Moisture in refrigerant circuit
h re
hole
– Check the actuation of the air conditioner compressor (and if fitted the refrigerant shut-off valve 1 and
spec
es, in part or in w
refrigerant shut-off valve 2 ) and check the measured value of the evaporator output temperature sender
t to the co
- G263- ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
– If actuation of the air conditioner compressor (and, if fitted, the refrigerant shut-off valve 1 and refrigerant
shut-off valve 2 ) as well as the measured value of -G263- are OK, extract the refrigerant from the refrigerant
rrectness of i
circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
♦ Too much refrigerant in the refrigerant circuit
l purpos
♦ Expansion valve defective
nform
ercia
♦ If a shut-off valve is installed in the refrigerant circuit and it does not open correctly or at all ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
m
at
om
io
♦ Moisture in refrigerant circuit
n
c
in t
or
his
e
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
at
do
priv
cum
or
– If the extracted refrigerant volume is considerably greater (more than 100 g) than the prescribed fill volume
f
en
ng
t.
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), there was op
yi Co
too much refrigerant in the refrigerant circuit Recharge refrigerant circuit and repeat test.
C py
t. rig
gh ht
pyri by
Vo
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally higher than the
co lksw
by
cted agen
prescribed fill volume (less than 100 g) ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle- Prote AG.
specific workshop manual), there is too much refrigerant oil in the refrigerant circuit Clean the refrigerant
circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 , recharge with the correct
volume of refrigerant and refrigerant oil and repeat the test.
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
– Renew the expansion valve and desiccant bag/desiccant cartridge (or reservoir/receiver)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
214 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If there is too much refrigerant oil in the circuit, empty the air
conditioner compressor and renew the reservoir/receiver (or
desiccant cartridge) ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual). After
cleaning the refrigerant circuit (flushing with R1234yf refriger‐
ant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 , pour in the
correct amount of refrigerant oil in the refrigerant circuit ⇒
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-
specific workshop manual).
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and actuation of the air conditioner
compressor. If the measured value of -G263- or actuation of
the air conditioner compressor is faulty, the evaporator could
ice up or the cooling output will not be reached AG. Vol⇒ Vehicle
kswagen AG di‐
agnostic tester in “Guided Fault Finding” agen mode - air condition‐
does
olksw not
ing system and battery regulationd b as well as ⇒ Heating, air
y V gu
ara
conditioning; Rep. gr. 87 h;orOverview
ise
of fitting locations - air nte
eo
conditioning system ⇒ sHeating,
au
t
air conditioning; Rep. gr. 87 ; ra
Air conditioner compressor (vehicle-specific workshop man‐
s c
ce
le
ual).
un
pt
an
d
itte
♦ In this case, the evaporator may ice up even though the correct
y li
erm
ab
volume of refrigerant is present in the refrigerant circuit.
ility
ot p
wit
♦ A fault in -G263- or / and, if fitted, in the refrigerant shut-off
is n
h re
valve for hybrid battery can also cause the refrigerant circuit
ole,
spec
to ice up. With this complaint, also take note of the measured
urposes, in part or in wh
value of -G263- and the temperature sensor after evaporator
t to the co
for hybrid battery (on vehicles with a battery cooling module)
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system and battery regulation and ⇒ Heating,
rrectne
air conditioning; Rep. gr. 87 ; Overview of fitting locations - air
conditioning system (vehicle-specific workshop manual).
ss o
cial p
f inform
mer
atio
om
n
c
Possible deviation from specification during pressure test
i
or
n thi
te
sd
a
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
iv
o
r
for the battery cooling module) is not reached.
p
cum
r
fo
en
ng
t.
♦ The high pressure equates to the specification
yi Co
Cop py
t. rig
♦ The low pressure is too low (lower than the specification) gh ht
pyri by
Vo
o
by c lksw
cted
Possible causes for deviation from specification and rectification
agen
Prote AG.
2. Working with air conditioner service station 215
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ There is too little refrigerant in the refrigerant circuit.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
– The extracted refrigerant volume approximately equates to the prescribed fill volume, check actuation of
the air conditioner compressor and the installed shut-off valves. If no fault is found, renew the expansion
valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual)
♦ Actuation or the function of the air conditioner compressor or, if fitted, the refrigerant shut-off valve 1 /
refrigerant shut-off valve 2 is faulty.
– Check actuation and the function of the air conditioner compressor and, if fitted, the refrigerant shut-off
valve 1 / refrigerant shut-off valve 2 ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air con‐
ditioning system and battery regulation.
– Clean refrigerant circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ The expansion valve in the heater and air conditioning unit or, if fitted, in the evaporator for battery cooling
is defective.
– Renew the expansion valve for the evaporator in the heater and air conditioning unit (and for the evaporator
for battery cooling) as well as the desiccant bag/desiccant cartridge (or reservoir/receiver).
♦ Air conditioner compressor is defective AG. Volkswagen A gen G do
swa es
– Renew air conditioner compressor ⇒ “1.5 bRenewing
yV
olk components”, page 79
notand ⇒ Heating, air conditioning;
gu
Rep. gr. 87 ; Air conditioner compressor
ris
ed (vehicle-specific workshop manual).ara
nte
ho eo
ut r
– If dirt is found in the refrigerant circuit,
ss
a clean the refrigerant circuit (flush with R1234yf arefrigerant)
c and renew
the expansion valve and desiccant bag/desiccant cartridge (or receiver/reservoir)
ce
e
nl
pt
⇒ “1.5 Renewing components”, page 79 and ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
du
an
itte
y li
Final measures
erm
ab
ility
ot p
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
wit
, is n
h re
– Repeat test
hole
spec
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
es, in part or in w
tioning compressor”, page 200
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
216 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ In the event of the following fault “High pressure normal, low
pressure too low”, please note the following: With this fault,
there is a chance that the evaporator could ice up even though
the refrigerant volume in the circuit is OK.
♦ If the fault exists in the air conditioner compressor (it is not
actuated but still works), it is not necessary to clean (flush with
R1234yf refrigerant) the refrigerant circuit
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . With this fault, it
is sufficient to renew the air conditioner compressor (take note
of refrigerant oil in air conditioner compressor)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Technical data (vehicle-specific
workshop manual).
♦ If the problem is with the air conditioner compressor (the air
conditioner compressor is actuated at excessively n AG. Vhigh
olkswspeed
agen AG
wage
by the control unit for air conditioning Vcompressor ), the refrig‐ does not
olks
erant circuit does not have to be cleaneded
by (by flushing with gu
ara
R1234yf refrigerant horis nte
eo
⇒ “1.6 Cleaning refrigerant scircuit”,
au
t
page 92 ). With this fault, ra
c
it is sufficient to renew the sair conditioner compressor (take
ce
le
note of refrigerant oil in air conditioner compressor) ⇒ Heating,
un
pt
an
d
air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific
itte
y li
workshop manual) and ⇒ Heating, air conditioning; Rep. gr.
erm
ab
87 ; Air conditioner compressor (vehicle-specific workshop
ility
ot p
manual).
wit
is n
h re
ole,
♦ If the expansion valve (or one of the two expansion valves) is
spec
defective (always closed or does not open sufficiently), the air
urposes, in part or in wh
conditioner compressor is also actuated at the maximum out‐
t to the co
put and pressure drops on the low pressure side to the spec‐
ification or lower (the air conditioner compressor draws in
refrigerant from the low pressure side). However, since no re‐
rrectne
frigerant can flow through the defective expansion valve, the
required cooling output in the downstream evaporator is not
reached, the high pressure may also not rise or only marginally ss o
cial p
f
since no energy exchange is taking place. The air conditioner
inform
compressor can be actuated at a higher speed, however,
mer
since the requisite cooling output in one evaporator is not
atio
m
reached. The same also applies if operation or actuation of the
o
n
c
refrigerant shut-off valve 1 or refrigerant shut-off valve 2 is
i
or
n thi
faulty ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
te
sd
va
mode - air conditioning system and battery regulation and ⇒
i
o
pr
cum
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
r
fo
en
ng
hicle-specific workshop manual).
t.
yi Co
Cop py
♦ Check the measured values of the evaporator output temper‐
t. rig
gh ht
yri
ature sender - G263- (and, if fitted, the measured values of the
p by
o Vo
by c lksw
temperature sensor before evaporator for hybrid battery and Prote
cted AG.
agen
temperature sensor after evaporator for hybrid battery ) as well
as actuation of the air conditioner compressor by the control
unit for air conditioning compressor . If the measured value of
-G263- (of the temperature sensor before evaporator for hy‐
brid battery , the temperature sensor after evaporator for
hybrid battery - G757- ) or actuation of the air conditioner com‐
pressor are faulty, the evaporator can ice up or the requisite
cooling output will not be reached ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioner compressor
and battery regulation and ⇒ Heating, air conditioning; Rep.
gr. 87 ; Overview of fitting locations - air conditioning system
(vehicle-specific workshop manual).
2. Working with air conditioner service station 217
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ The air conditioner compressor is noisy (especially immediately after being switched on),
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit and / or in the evap‐
orator for battery cooling is not reached.
♦ High pressure normal or too high
♦ Low pressure too high (specification is not reached)
Possible causes for deviation from specification and rectification
♦ Actuation or the function of the air conditioner compressor or, if fitted, the refrigerant shut-off valve 1 /
refrigerant shut-off valve 2 is faulty. swagen AG. Volkswagen AG does
k not
Vol gu
♦ Too much refrigerant or refrigerant
se
db
y
oil in the refrigerant circuit. ara
nte
i
or e
– Check the actuation andautfunction
h
of the air conditioner compressor and,orifa fitted,
the refrigerant shut-off
valve 1 / refrigerant shut-off
ss
valve 2 ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air con‐ c
ce
le
ditioning system and battery regulation. Repair if necessary. If no fault can be found, extract the refrigerant
un
pt
from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
an
d
itte
y li
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
rm
ab
– If the extracted refrigerant volume is considerably greater (more than 100 g) than the prescribed fill volume
pe
ility
ot
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), there was
wit
, is n
too much refrigerant in the refrigerant circuit Recharge refrigerant circuit and repeat test.
h re
hole
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally higher than the
spec
prescribed fill volume (less than 100 g) ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-
es, in part or in w
t to the co
specific workshop manual), there is too much refrigerant oil in the refrigerant circuit Clean the refrigerant
circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 , recharge with the correct
volume of refrigerant and refrigerant oil and repeat the test.
♦ Expansion valve defective
rrectness of i
– Renew the expansion valve for the evaporator in the heater and air conditioning unit (and for the evaporator
l purpos
for battery cooling) as well as the desiccant bag/desiccant cartridge (or reservoir/receiver)
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
nform
ercia
(vehicle-specific workshop manual).
♦ Air conditioner compressor is defective
m
a
com
tio
– Renew air conditioner compressor ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning;
n in
r
te o
Rep. gr. 87 ; Air conditioner compressor (vehicle-specific workshop manual).
thi
s
iva
do
r
– If dirt is found in the refrigerant circuit, clean the refrigerant circuit (flush with R1234yf refrigerant) and renew
rp
cum
fo
the expansion valve and desiccant bag/desiccant cartridge (or receiver/reservoir)
en
ng
t.
yi
⇒ “1.5 Renewing components”, page 79 and ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
Co
Cop py
t. rig
Final measures gh ht
pyri by
Vo
co
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
by lksw
cted agen
Prote AG.
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
218 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The cause for this fault could also be too much refrigerant oil
in the refrigerant circuit. Overfilling with refrigerant oil can oc‐
cur if e.g. the refrigerant oil level was not checked after the air
conditioner compressor was renewed
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air
conditioning; Rep. gr. 00 ; Technical data (vehicle-specific
workshop manual). If there is too much refrigerant oil in the
refrigerant circuit, clean the refrigerant circuit (flush with
R1234yf refrigerant) n AG. Volkswagen AG do
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . olks
wage es n
o V t gu
by
♦ If the expansion valve on the evaporator in the heaterriseand air
d ara
nte
conditioning unit (or for the evaporator for battery ucooling)
tho is eo
ra
defective (always closed or does not open sufficiently),
ss a
the air c
conditioner compressor is actuated at the maximum output
ce
e
nl
pt
and low pressure drops to the specification or lower (the air
du
an
itte
conditioner compressor draws in refrigerant from the low pres‐
y li
erm
ab
sure side). However, since no refrigerant can flow through the
ility
ot p
expansion valve, the required cooling output is not reached,
wit
, is n
the high pressure may also not rise or only marginally since
h re
no energy exchange is taking place. The same also applies if
hole
spec
operation or actuation of the refrigerant shut-off valve 1 or re‐
es, in part or in w
frigerant shut-off valve 2 is faulty ⇒ Vehicle diagnostic tester
t to the co
in “Guided Fault Finding” mode - air conditioning system and
battery regulation and ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
rrectness of i
l purpos
nf
ercia
orm
Possible deviation from specification during pressure test
m
atio
om
n in
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
or c
thi
for the battery cooling module) is not reached.
te
sd
iva
o
r
♦ High pressure and low pressure normal (equate to specification)
rp
cu
o
m
f
en
ng
t.
yi
Possible causes for deviation from specification and rectification
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Working with air conditioner service station 219
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Actuation or the function of the air conditioner compressor and, if fitted, the refrigerant shut-off valve 1 or
refrigerant shut-off valve 2 is faulty.
♦ Insufficient refrigerant in refrigerant circuit.
– Check the actuation and function of the air conditioner compressor and/or, if fitted, the refrigerant shut-off
valve 1 / refrigerant shut-off valve 2 ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air con‐
ditioning system and battery regulation. Repair if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop manual). If no fault can be found, extract the refrigerant from
the refrigerant circuit.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific nworkshop
AG. Volkswamanual),
gen AG
doethe expansion
wage
valve for the evaporator or an installed shut-off valve in the heater Volksand air conditioning unit sisnodefective.
t gu
♦ The expansion valve for the evaporator in the heater and air by
dconditioning unit is defective ⇒ Heating, nte air
ara
ise
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
thor
workshop manual). eo
u ra
sa c
♦ One of the refrigerant shut-off valves (if fitted) is defective
s (closed). Check the function and renew if nec‐
ce
e
essary ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning system and battery
nl
pt
du
an
regulation and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
itte
y li
manual).
erm
ab
ility
ot p
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
wit
, is n
erant circuit (vehicle-specific workshop manual).
h re
hole
– Renew the expansion valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air con‐
spec
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
es, in part or in w
♦ Too much refrigerant oil in the refrigerant circuit.
t to the co
– Clean refrigerant circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
rrectness of i
– Renew the expansion valve for the evaporator in the heater and air conditioning unit (and for the evaporator
for battery cooling) as well as the desiccant bag/desiccant cartridge (or reservoir/receiver)
l purpos
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
nf
ercia
Final measures
orm
m
atio
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
om
n in
or c
– Repeat test
thi
te
sd
a
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
iv
o
r
rp
cu
tioning compressor”, page 200
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
220 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The cause for this fault could also be too much refrigerant oil
in the refrigerant circuit. Overfilling with refrigerant oil can oc‐
cur if e.g. the refrigerant oil level was not checked after the air
conditioner compressor was renewed
⇒ “1.5 Renewing components”, wage
n AGpage 79
. Volksw and ⇒doeHeating,
agen AG
air
conditioning; Rep. bgr. y Vo 00 ; Technical data (vehicle-specific
lks s no
t gu
workshop manual). ris
ed If there is too much refrigerant oil inrathe
a
nte
refrigerant circuit,
utho clean the refrigerant circuit (flush with eo
ra
R1234yf refrigerant)
ss
a c
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
ce
e
nl
pt
du
an
♦ If the expansion valve on the evaporator in the heater and air
itte
y li
conditioning unit (or for the evaporator for battery cooling) is
erm
ab
ility
defective (always closed or does not open sufficiently), the air
ot p
conditioner compressor is actuated at the maximum output
wit
, is n
h re
and low pressure drops to the specification or lower (the air
hole
conditioner compressor draws in refrigerant from the low pres‐
spec
sure side). However, since no refrigerant can flow through the
es, in part or in w
t to the co
expansion valve, the required cooling output is not reached,
the high pressure may also not rise or only marginally since
no energy exchange is taking place. The same also applies if
rrectness of i
operation or actuation of the refrigerant shut-off valve 1 or re‐
frigerant shut-off valve 2 is faulty ⇒ Vehicle diagnostic tester
l purpos
in “Guided Fault Finding” mode - air conditioning system and
battery regulation and ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
Possible deviation from specification during pressure test
um
for
en
ng
t.
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
yi Co
op py
for the battery cooling module) is not reached. t. C rig
gh ht
pyri by
♦ The high pressure equates to the specification
co Vo
by lksw
cted agen
Prote AG.
♦ The low pressure equates to the specification or is too low
Possible causes for deviation from specification and rectification
2. Working with air conditioner service station 221
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Actuation of the air conditioner compressor (and/or if fitted the refrigerant shut-off valve 1 , refrigerant shut-
off valve 2 ) is faulty ⇒ Vehicle diagnostic
wage
n Atester
G. Volksin “Guided
wagen AG
doeFault Finding” mode - air conditioning system
and battery regulation. y Volks s no
t gu b ara
ed
– Check the actuation andthfunction
or
is of the air conditioner compressor (and
nte
e o if fitted the refrigerant shut-off
valve 1 , refrigerant shut-off
au valve 2 ) and repair if necessary ⇒ Vehicle diagnostic
ra
c tester in “Guided Fault
ss
Finding” mode - air conditioning system and battery regulation. If this is OK, extract the refrigerant from the
ce
e
refrigerant circuit.
nl
pt
du
an
♦ There is too little refrigerant in the refrigerant circuit.
itte
y li
erm
ab
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
ility
ot p
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g) ⇒
wit
, is n
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for the
h re
hole
leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
spec
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
es, in part or in w
t to the co
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual) ⇒ Heating,
air conditioning; Rep. gr. 00 ; Technical data . Check the function of the refrigerant shut-off valves ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ The expansion valve for the evaporator in the heater and air conditioning unit is defective ⇒ Heating, air
rrectness of i
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
l purpos
♦ A refrigerant shut-off valve is defective (closed). Check the function and renew ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and battery regulation and ⇒ Heating, air condi‐
nform
ercia
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
m
at
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
om
io
erant circuit (vehicle-specific workshop manual).
n
c
in t
r
– Renew the expansion valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air con‐
o
his
te
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
a
do
riv
♦ Too much refrigerant oil in the refrigerant circuit.
p
cum
for
en
ng
– Clean refrigerant circuit (flush with R1234yf refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
t.
yi Co
Cop py
t. rig
gh
– Renew the expansion valve for the evaporator in the heater and air conditioning unit (and for the evaporator
ht
pyri by
for battery cooling) as well as the desiccant bag/desiccant cartridge (or reservoir/receiver)
co Vo
by lksw
cted agen
⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit Prote AG.
(vehicle-specific workshop manual).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
Note
Observe the information relating to this ⇒ page 213 and
⇒ page 221 .
Possible deviation from specification during pressure test
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
for the battery cooling module) is not reached.
♦ The high pressure equates to the specification
♦ Low pressure drops quickly to the specification or lower.
Possible causes for deviation from specification and rectification
222 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Actuation or function of air conditioner compressor defective.
♦ Constriction or obstruction in refrigerant circuit
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and battery regulation. If no fault can be found,
touch the refrigerant circuit by hand to feel for a temperature drop ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If a temperature drop is determined in a component. If a hose or pipe is kinked or crushed, renew this
component ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
♦ There is too little refrigerant in the refrigerant circuit.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g) ⇒
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for the
leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), check the
function of the expansion valve and shut-off valves ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual).
♦ The expansion valve for the evaporator in the heater and air conditioning unit is defective ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ A refrigerant shut-off valve is defective (closed). Check the function and renew ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and battery regulation and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
– Renew the expansion valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
n AG. Volkswagen AG do
Final measures lkswage es n
ot g
o
yV
– Recharge the refrigerant icircuit
se
d b ⇒ “2.6 Charging refrigerant circuit”,ua
ran page 141
r tee
tho o
– Repeat test ss
au ra
c
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
ce
le
un
tioning compressor”, page 200
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
Observe the information relating to this ⇒ page 213 and
spec
urposes, in part or in wh
⇒ page 221 .
t to the co
rrectne
Possible deviation from specification during pressure test
ss o
cial p
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
inform
for the battery cooling module) is not reached.
mer
atio
m
♦ The requisite cooling output is then not reached at the evaporator in the heater and air conditioning unit
o
(the cooling output at the evaporator in the battery cooling module is OK).
c
i
or
n thi
te
sd
♦ High pressure increases only slightly (above the pressure measured when the air conditioner compressor
iva
o
r
is stationary) or equates to the specification.
p
cum
r
fo
en
ng
♦ Low pressure drops (possibly quickly) to the specification or lower.
t.
yi Co
Cop py
t. rig
gh ht
Possible causes for deviation from specification and rectification yri
p by
co Vo
by lksw
cted agen
Prote AG.
2. Working with air conditioner service station 223
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ There is too little refrigerant in the refrigerant circuit.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g) ⇒
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for the
leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), check the
function of the expansion valve and shut-off valves ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific workshop manual).
♦ The expansion valve for the evaporator in the heater and air conditioning unit is defective ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ One of the refrigerant shut-off valves is defective (closed). Check the function and renew if necessary
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning system and battery regulation
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If fitted, check the function of the installed shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific workshop manual).
– Renew the expansion valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ Bottle-neck or blockage in refrigerant circuit (e.g. in refrigerant line between service connection on “low
pressure side” and air conditioner compressor) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual).
♦ Actuation of the air conditioner compressor is faulty ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode - air conditioning system and battery regulation.
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode - air conditioning system and battery regulation. If no fault can be found,
touch the refrigerant circuit by hand to feel for a temperature drop ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If a temperature drop is determined in a component. If a hose or pipe is kinked or crushed, renew this
component (the defective expansion valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual). If there is a blockage, clean the refrigerant circuit (flush with R1234yf
refrigerant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
en AG. V
olkswagen AG
wag does
olks not
– If there is a blockage, clean the refrigerantecircuit
db
y V (flush with R1234yf refrigerant) gu
ara
⇒ “1.6 Cleaning refrigerant circuit”, page hor92
is . Renew the expansion valve for the evaporator
nte
eo in the heater
and air conditioning unit (and for the evaporator
s aut for battery cooling) as well as the desiccant
ra
c
bag/desiccant
cartridge (or reservoir/receiver) ⇒ “1.5
s Renewing components”, page 79 and ⇒ Heating, air conditioning;
ce
e
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
nl
pt
du
an
itte
Final measures
y li
erm
ab
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
ility
ot p
wit
, is n
– Repeat test
h re
hole
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
spec
tioning compressor”, page 200
es, in part or in w
t to the co
Note
rrectness of i
Observe the information relating to this ⇒ page 213 .
l purpos
nform
mercia
at
om
ion
c
in t
Possible deviation from specification during pressure test
or
his
ate
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
do
priv
for the battery cooling module) is not reached.
um
for
en
ng
t.
yi
♦ The high pressure increases beyond the specified value
Co
Cop py
ht. rig
♦ Low pressure drops quickly to the specification or lower. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
224 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
. Volkswagen AG
Air conditioning systems with refrigerant R1234yf - General
swa
gen AGinformation - Edition
does 01.2018
k not
Vol gu
d by ara
e
Possible deviation from specification during pressurehotest
ris nte
eo
ut ra
Possible causes for deviation from specification and
ss rectification
a c
ce
le
♦ Actuation or function of air conditioner compressor defective.
un
pt
an
d
itte
y li
♦ Constriction or obstruction in refrigerant circuit
erm
ab
ility
ot p
♦ Expansion valve defective
wit
is n
h re
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
ole,
in “Guided Fault Finding” mode - air conditioning system and battery regulation. If no fault can be found,
spec
urposes, in part or in wh
touch the refrigerant circuit by hand to feel for a temperature drop ⇒ Heating, air conditioning; Rep. gr.
t to the co
87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If a temperature drop is determined in a component. If a hose or pipe is kinked or crushed, renew this
component (the defective expansion valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
rrectne
(vehicle-specific workshop manual).
– If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Renew the expansion valve for the evaporator in the heater
ss
and air conditioning unit (and for the evaporator for battery cooling) as well as the desiccant bag/desiccant
o
cial p
f i
cartridge (or reservoir/receiver) ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning;
nform
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
mer
♦ There is too little refrigerant in the refrigerant circuit.
atio
om
n
c
i
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
or
n thi
te
sd
va
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g) ⇒
i
o
pr
cum
r
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for the
fo
en
ng
leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
t.
yi Co
Cop py
t. rig
– If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
gh ht
pyri by
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), check the
co Vo
by lksw
cted agen
function of the refrigerant shut-off valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐ Prote AG.
hicle-specific workshop manual).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
2. Working with air conditioner service station 225
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ If the function of the air conditioning system is not OK when
the test is repeated, renew the expansion valve and desiccant
bag/desiccant cartridge (or reservoir/receiver) and, if fitted, the
refrigerant shut-off valve ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ In this case, the evaporator may ice up even though the correct
volume of refrigerant is present in the refrigerant circuit.
♦ If the expansion valve on the evaporator in the heater and air
conditioning unit or the refrigerant shut-off valve 1 is defective
(always closed or does not open sufficiently), the air condi‐
tioner compressor is actuated at the maximum output and low
pressure drops to the specification or lower (the air conditioner
compressor draws in refrigerantAfrom olthe
kswalow
gen Apressure side).
Since no refrigerant can flow wagen G. V the expansion
through G do valve (the
e
olks s n
refrigerant shut-off valve
db
y V ), however, the cooling output
ot g
uis
aranot
reached and theorhigh ise pressure may also not increase or only nte
increase slightly
auth owing to there being no energy exchange e or
a
⇒ Vehicle diagnostic
ss tester in “Guided Fault Finding” mode - c
air conditioning system and battery regulation and ⇒ Heating,
ce
le
un
pt
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐
an
d
itte
y li
cific workshop manual).
erm
ab
ility
ot p
♦ If the expansion valve on the evaporator for battery cooling is
wit
is n
defective (or the function or actuation of the refrigerant shut-
off valve 2 is faulty), completely closed or does not open h re
ole,
spec
sufficiently, the air conditioner compressor is likewise actuated
urposes, in part or in wh
with the maximum output (the requisite temperatures in the
t to the co
battery cooling module are not reached). The pressure on the
low pressure side only drops to the specification or lower if, at
the same time, no cooling output is required in the heater and
rrectne
air conditioning unit (the refrigerant shut-off valve 1 is actuated
and is closed). The air conditioner compressor extracts refrig‐
s
erant on the low pressure from both evaporators. Since no
s o
refrigerant can flow through the expansion valve in the heater
cial p
f in
and air conditioning unit (the refrigerant shut-off valve 1 ),
form
mer
however, and the cooling output for battery cooling is not
atio
reached (there is a fault in the area of battery cooling), the
om
electric air conditioning compressor is actuated at a higher
c
i
or
speed. However, since no more refrigerant can flow, the pres‐
thi
te
sd
a
sure on the low pressure side drops below the specified value
iv
o
pr
and the high pressure may also not increase or only increase
um
r
fo
slightly due to the absence of an energy exchange ⇒ Vehicle
en
ng
t.
yi
diagnostic tester in “Guided Fault Finding” mode - air condi‐
Co
Cop py
tioning and battery control ⇒ Heating, air conditioning; Rep.
t. rig
gh ht
yri
gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
p by
co Vo
by lksw
cted agen
♦ Since the output of the evaporator for battery cooling is con‐
Prote AG.
siderably lower than the output of the evaporator in the heating
and air conditioning unit, the requisite specified temperature
for battery cooling may still be reached if there is insufficient
refrigerant in the circuit but the specified temperature in the
evaporator of the heating and air conditioning unit will not be
reached (even though the air conditioner compressor is actu‐
ated at a higher speed).
226 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ If there is too much refrigerant in the refrigerant circuit, the air
conditioner compressor must be emptied and the desiccant
bag (desiccant cartridge) or reservoir/receiver renewed. After
cleaning (flushing with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 the refrigerant cir‐
cuit, pour the correct volume of refrigerant oil in the refrigerant
circuit ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical
data; Approved refrigerant oils and refrigerant oil fill volumes
(vehicle-specific workshop manual) and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual).
♦ Observe the additional information relating to this
⇒ page 213 .
Possible deviation from specification during pressure test
♦ The requisite cooling output is then not reached at the evaporator for battery cooling (the cooling output at
the evaporator in the heater and air conditioning unit is OK).
♦ High pressure equates to the specification or increases only slightly (above the pressure measured when
the engine is stationary).
♦ Low pressure drops to the specification or lower.
Possible causes for deviation from specification and rectification
♦ Actuation or the function of the refrigerant shut-off valve 2 , a control motor, the blower or a temperature
sensor in or on the battery cooling module is defective. Check and repair if necessary ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode - air conditioning system and battery regulation and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ The expansion valve for the evaporator in the battery cooling module is defective.
– Renew the expansion valve for the evaporator nfor
AGbattery
. Volkswacooling
gen AG ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific workshop lkswagemanual). does
not
Vo
– Check the function and actuation eofd the components for battery cooling
by gu
a⇒
ranVehicle diagnostic tester in
“Guided Fault Finding” mode - hair oris conditioning system and battery regulation. tee Check the refrigerant lines
if no fault can be found. s aut or
ac
♦ Bottle-neck or blockage in refrigerant line to or from expansion valve on evaporator for battery cooling.
s
ce
e
nl
pt
du
– If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
an
itte
y li
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Renew the expansion valve for the evaporator in the heater
erm
ab
and air conditioning unit (and for the evaporator for battery cooling) as well as the desiccant bag/desiccant
ility
ot p
cartridge (or reservoir/receiver) ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning;
wit
, is n
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
h re
hole
– If a hose or pipe is kinked or crushed, renew this component ⇒ Heating, air conditioning; Rep. gr. 87 ;
spec
Refrigerant circuit (vehicle-specific workshop manual).
es, in part or in w
♦ Too little refrigerant in circuit.
t to the co
♦ Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
rrectness of i
♦ If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g) ⇒
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for the
l purpos
leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
♦ If the extracted refrigerant volume equates to the prescribed fill volume or is marginally lower (max. 100 g)
nf
ercia
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), check the
orm
refrigerant shut-off valve 1 ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning
m
atio
m
system and battery regulation and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
o
n in
c
specific workshop manual).
or
thi
te
sd
iva
Final measures
r
rp
cu
o
m
f
en
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
ng
t.
yi Co
Cop py
– Repeat test
t. rig
gh ht
yri by
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
cop Vo
by lksw
tioning compressor”, page 200 cted agen
Prote AG.
2. Working with air conditioner service station 227
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ To cool the drive battery - A2- (hybrid battery), the refrigerant
shut-off valve 1 is only actuated by e.g. the battery regulation
control unit from a certain battery temperature. If, at this point,
air conditioning operation has not already been activated, the
electrical air conditioner compressor - V470- is actuated via
the control unit for air conditioning compressor - J842- e.g. by
the battery regulation control unit . The temperature of the air
(or refrigerant) before and after the evaporator for battery cool‐
ing is calculated by the respective control unit (e.g. battery
regulation control unit ). If it is found that cooling down is in‐
sufficient, this is stored in e.g. the battery regulation control
unit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
- air conditioning system and battery regulation.
♦ The temperature of the air (or the coolant) and thereby the
cooling output of the evaporator for battery cooling is deter‐
mined by the integrated temperature sensor (it cannot cur‐
rently be measured during operation with a thermometer) and
can therefore only be checked by means of guided fault finding
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -
air conditioning system and battery regulation.
♦ Observe the additional information relating to this
⇒ page 213 .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
Possible deviation from specification during pressure test
aut or
ac
ss
♦ The requisite cooling output in the evaporator of the heating and air conditioning unit (and in the evaporator
ce
e
nl
pt
du
for the battery cooling module) is not reached.
an
itte
y li
erm
♦ High pressure does not increase or only marginally above the pressure with the engine stationary
ab
ility
ot p
♦ The low pressure does not drop or only marginally
wit
, is n
h re
hole
Possible causes for deviation from specification and rectification
spec
es, in part or in w
♦ No actuation of air conditioner compressor ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
t to the co
♦ If fitted, refrigerant shut-off valve 1 defective (closed)
rrectness of i
– Check the actuation and function of the air conditioner compressor (and the refrigerant shut-off valve 1 ,
refrigerant shut-off valve 2 ) ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air conditioning
l purpos
system and battery regulation. If no fault can be found, renew the expansion valve on the evaporator in the
heating and air conditioning unit ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
nf
ercia
♦ Bottle-neck or blockage in refrigerant circuit (e.g. in refrigerant line between service connection on “low
rm
m
pressure side” and air conditioner compressor).
atio
om
n in
c
– If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
or
thi
e
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Renew the expansion valve for the evaporator in the heater
t
sd
iva
and air conditioning unit (and for the evaporator for battery cooling) as well as the desiccant bag/desiccant
o
r
rp
cu
cartridge (or reservoir/receiver) ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning;
o
m
f
en
ng
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
t.
yi Co
op
– If a hose or pipe is kinked or crushed, renew this component ⇒ Heating, air conditioning; Rep. gr. 87 ; C py
t. rig
Refrigerant circuit (vehicle-specific workshop manual).
gh ht
yri by
♦ The air conditioner compressor is defective.
cop Vo
by lksw
cted agen
Prote AG.
– Renew air conditioner compressor ⇒ “1.5 Renewing components”, page 79 and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor (vehicle-specific workshop manual).
Final measures
228 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
AG. Volkswagen AG d
agen oes
olksw not
V
Specifications for pressuresd by in refrigerant circuit on vehiclesgu with
ara
heat pump rise nte
tho eo
au ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
erm
ab
♦ On vehicles with high-voltage system and heat pump, the re‐
ility
ot p
frigerant circuit is fitted with non-return valves and electrically
wit
is n
actuated valves that regulate the flow of refrigerant in the re‐
h re
frigerant circuit depending on the prevailing operating status.
ole,
spec
These valves come in different versions ⇒ Heating, air con‐
urposes, in part or in wh
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
t to the co
workshop manual) and ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
rrectne
♦ On vehicles with “heat pump” function and/or “high-voltage
battery cooling” function, high pressure is not always at the
service connection on the high pressure side in all operating
ss
conditions of the air conditioning system. On these vehicles,
o
cial p
f
depending on the operating status of the air conditioning sys‐
inform
tem, pressure in the refrigerant circuit on the high pressure
mer
side can only be measured via the pressure/temperature
atio
m
sender installed in the refrigerant circuit ⇒ Heating, air condi‐
o
n
c
i
or
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific work‐
thi
e
shop manual) and ⇒ Vehicle diagnostic tester “Guided Fault
t
sd
iva
Finding” mode.
pr
cum
r
fo
en
ng
♦ The refrigerant circuit of the air conditioning system on these
t.
yi Co
op
vehicles is used not only to cool the passenger compartment C py
t. rig
but also to cool the hybrid battery unit (via the coolant circuit
gh ht
pyri by
for the high-voltage system) and to heat the passenger com‐
co Vo
by lksw
cted
partment (at low ambient temperatures) via the heat pump
agen
Prote AG.
function. To ensure that these functions are effective, various
valves, pressure and temperature senders as well as pumps
in the refrigerant circuit and in the coolant circuit of the high-
voltage system must be installed correctly and be in good
working order ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific workshop manual), ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode and ⇒ En‐
gine, mechanicals; Rep. gr. 19 ; Cooling system/coolant
♦ To localise the potential cause of the malfunction, various rou‐
tines have been stored in the basic settings of the thermal
management control unit with which the “air conditioning cool‐
ing”, “heat pump” and “cooling components of the high-voltage
system” functions can be actuated ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode.
High-pressure side:
Rising from starting pressure (when pressure gauge is connec‐
ted) to maximum 20 bar.
2. Working with air conditioner service station 229
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
Depending on the location of the service connection n Aon
G. Vthe
olkshigh
wagen AG
pressure side and on the operating status, the l wage pressure can
kshigh
does
not
o
yV
only be measured using pressure/temperature ed b sensors installed gu
ara
in the refrigerant circuit ⇒ Heating, air
thor conditioning;
is
Rep. gr. 87 ; nte
eo
Refrigerant circuit (vehicle-specific
s workshop manual).
au ra
c
s
ce
e
nl
pt
Low-pressure side:
du
an
itte
y li
erm
From the output pressure (when connecting the pressure gauge)
ab
ility
dropping to a value of between 1.5 and 2.3 bar absolute pressure
ot p
wit
(depending on required cooling output).
, is n
h re
hole
Speed of air conditioner compressor:
spec
es, in part or in w
Between 800 and 8500 rpm depending on the required cooling
t to the co
output (currently maximum 5000 rpm with vehicle stationary).
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
230 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The temperature of the air after the evaporator, the current air
conditioner compressor speed and the pressure of the refrig‐
erant on the high pressure side are displayed as a measured
by different control units depending on the vehicle (e.g. by the
thermal management control unit , the operating and display
unit for front air conditioning system or the Climatronic control
unit ) ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system (vehicle-specific
workshop manual) and ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
♦ In the event of a very high cooling output (e.g.
swa
gat high
en AG. Vooutside
lkswagen AG
does
temperatures and high fresh air blower yVspeed),
olk the air condi‐ not
gu
tioner compressor is initially incapable
rised b of changing the pres‐ ara
nte
sure on the low pressure side touththeo required level (e.g. for a eo
ra
certain period after switchingsons a the air conditioning system). c
The air conditioner compressor is not activated with the max.
ce
e
nl
pt
specified (of approx. 8500 rpm), if the vehicle stands still or
du
an
itte
drives slowly (up to a vehicle speed of 45 km/h). The air con‐
y li
erm
ab
ditioner compressor speed is then limited to 5000 rpm. The
ility
ot p
maximum permissible air conditioner compressor speed limit
wit
, is n
is not lifted until a vehicle speed greater than approx. 45 km/
h re
h is reached. The output (delivery rate) of the air conditioner
hole
spec
compressor at an air conditioner compressor speed of
es, in part or in w
5000 rpm, a high ambient temperature and high fresh air blow‐
t to the co
er speed (unfavourable ambient conditions) is initially no lon‐
ger sufficient to bring the pressure on the low pressure side
down to the specified value. To check the regulating behaviour
rrectness of i
of the air conditioner compressor under these conditions, e.g.
only actuate the fresh air blower with approx. 40% of the max‐
l purpos
imum voltage and check the pressures at reduced fresh air
blower speed ⇒ Vehicle diagnostic tester in “Guided Fault
nform
ercia
Finding” mode - air conditioning system and battery regulation
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
m
at
tions; Checking cooling output (vehicle-specific workshop
om
manual). ion
c
in t
or
his
te
♦ Under unfavourable conditions (very high ambient tempera‐
a
do
riv
tures, high atmospheric humidity), the pressure on the high
p
cum
or
pressure side can increase to a maximum of 29 bar.
f
en
ng
t.
yi Co
op
♦ The specified speed of the air conditioner compressor is dis‐ C py
ht. rig
played as a measured value e.g. by the thermal management rig ht
py by
control unit ⇒ Vehicle diagnostic tester in “Guided Fault Find‐
co Vo
by lksw
cted
ing” mode.
agen
Prote AG.
♦ The pressure measured by various pressure/temperature
senders in the refrigerant circuit (low or high pressure) de‐
pending on the respective operating status is displayed as a
measured value by the respective control unit ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐
cific workshop manual).
♦ The low pressure adjusts itself depending on the speed of the
air conditioner compressor and the regulating characteristic of
the expansion valve (on the evaporator of the front heating and
air conditioning unit) within the performance band of the air
conditioner compressor in the tolerance range (1.5 to 2.3 over‐
pressure).
♦ The specified speed of the air conditioner compressor must
be greater than 1500 rpm for this test.
2. Working with air conditioner service station 231
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ For the “maximum cooling output” setting, the specified speed
is regulated at approx. 4000 to 5000 rpm. This value is vehicle-
specific and is displayed as a measured value by the respec‐
tive control unit ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
♦ Absolute pressure means that 0 bar corresponds to an abso‐
lute vacuum. The normal ambient pressure corresponds to 1
bar absolute. On most pressure gauges, a reading of 0 bar
corresponds to an absolute pressure of 1 bar (which can be
identified by -1 bar under the 0 scale marking).
♦ If on a vehicle with 2 evaporators (one in the heating and air
conditioning unit and one for cooling the high-voltage compo‐
nents, e.g. the heat exchanger for the high-voltage battery)
and 2 condensers (one on the front end for the air conditioning
system and one as a heat exchanger for the heat pump func‐
tion), the specifications for the measured temperatures or
pressures are met on one component but not on another (de‐
pending on the selected function), check actuation of the
electrically actuated valves installed in the refrigerant circuit.
When doing this, observe the pressure distribution in the re‐
frigerant circuit depending on the
swa
geninstalled
AG. Volkswnon-return
agen AG
doesvalves
⇒ Vehicle diagnostic tester y Volkin “Guided Fault Finding” mode
not
gu
and ⇒ Heating, air rconditioning;
ise
d b
Rep. gr. 87 ; Refrigerant cir‐ara
nte
cuit (vehicle-specific
ut
ho workshop manual). eo
r
sa ac
♦ For the air conditioning
s
system to function correctly, it is also ce
le
important - depending on the selected function - for sufficient
un
pt
an
d
heat to be supplied to the respective heat exchangers and
itte
y li
subsequently dissipated. Also note, therefore, the inclusion of
rm
ab
pe
ility
the heat exchangers in the respective coolant circuit of the
ot
engine and the high-voltage system and the function of the
wit
, is n
h re
pumps and valves installed therein ⇒ Vehicle diagnostic tester
hole
in “Guided Fault Finding” mode and ⇒ Heating, air condition‐
spec
ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop
es, in part or in w
t to the co
manual).
♦ Since the output of the evaporator for cooling on the high-volt‐
age components (in the battery cooling module and in the heat
rrectness of i
exchanger for high-voltage battery) is lower than the output of
l purpos
the evaporator in the heating and air conditioning unit, the
requisite specified temperature in the evaporator for cooling of
the high-voltage components may still be reached if there is
nform
ercia
insufficient refrigerant in the circuit but the specified tempera‐
ture in the evaporator of the heating and air conditioning unit
m
a
com
is no longer reached (even though the air conditioner com‐
ion in
pressor is actuated at a higher speed).
r
te o
thi
s
iva
do
r
rp
Possible deviations from specification,
um
fo
cause and rectification
en
ng
t.
yi Co
op py
• High pressure remains constant or in‐ ⇒ page 234 t. C rig
gh ht
creases only slightly (above the pressure yri
p by
o Vo
measured when the engine is stopped).
c by lksw
cted agen
Prote AG.
• High pressure drops quickly to the spec‐
ification or lower.
• The requisite cooling output in the evap‐
orator of the heating and air conditioning
unit and in the evaporator for cooling the
high-voltage components is not reached.
• High pressure normal ⇒ page 237
• Low pressure equates to specification
• The required cooling output is not
reached.
232 Rep. gr.87 - Air conditioning system
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Arteon 2018 ➤uth, Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤
o e o, Crafter 201 ...
ra
a
Air conditioning systemss with refrigerant R1234yf - General information - Edition
s c 01.2018
ce
le
un
pt
an
d
Possible deviations from specification,
itte
y li
cause and rectification
rm
ab
pe
ility
• High pressure normal ⇒ page 238
ot
wit
, is n
h re
• Low pressure normal or too low (lower
hole
spec
than specification)
es, in part or in w
t to the co
• The requisite cooling output is then not
reached at the evaporator in the heater
and air conditioning unit (the cooling out‐
rrectness of i
put at the evaporator to cool the high-
voltage components is OK).
l purpos
• High pressure normal ⇒ page 239
nform
ercia
• Low pressure normal or too low (lower
m
than specification)
a
com
tion in
• The requisite cooling output is then not
r
te o
thi
reached at the evaporator to cool the
s
iva
do
high-voltage components (the cooling
r
rp
cum
output at the evaporator in the heating
fo
en
g
and air conditioning unit is OK).
n
t.
yi Co
Cop py
ht. rig
• High pressure does not increase or only ⇒ page 240 rig ht
py by
marginally above the pressure with the
co Vo
by lksw
cted
engine stationary.
agen
Prote AG.
• The low pressure does not drop or only
marginally.
• The requisite cooling output in the evap‐
orator of the heating and air conditioning
unit and in the evaporator for cooling the
high-voltage components is not reached.
• High pressure increases above specifi‐ ⇒ page 241
cation
• Low pressure drops quickly to the spec‐
ification
• The requisite cooling output in the evap‐
orator of the front heating and air condi‐
tioning unit (and/or in the evaporator
used to cool the high-voltage compo‐
nents) is not reached.
• The high pressure and low pressure are ⇒ page 243
normal to start with but after a while the
high pressure rises above the specifica‐
tion and the low pressure drops to the
specification or lower.
• The requisite cooling output in the evap‐
orator of the heating and air conditioning
unit (and/or in the evaporator used to
cool the high-voltage components) is not
reached or no longer reached.
• High pressure and low pressure are nor‐ ⇒ page 244
mal at first but after a longer drive the low
pressure falls to below the specification
(evaporator in heater and air condition‐
ing unit iced up).
2. Working with air conditioner service station 233
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviations from specification,
cause and rectification
• High pressure normal ⇒ page 246
• Low pressure too low
• The requisite cooling output in the evap‐
orator of the heating and air conditioning
unit (and/or in the evaporator used to
cool the high-voltage components) is not
reached.
• High pressure normal or too high ⇒ page 247
• Low pressure too high
• The air conditioner compressor is noisy
(especially immediately after being
switched on)
• The requisite cooling output in the evap‐
orator of the front heating and air condi‐
tioning unit (and/or in the evaporator
used to cool the high-voltage compo‐
nents) is not reached.
• High pressure and low pressure normal ⇒ page 249
• The requisite cooling output in the evap‐
orator of the heating and air conditioning
unit and in the evaporator for cooling the
high-voltage components is not reached.
or
• High pressure and low pressure normal
• The air conditioner compressor is noisy
(especially immediately after being
switched on)
• The requisite cooling output in the evap‐ AG. Volkswagen AG d
orator of the heating and air conditioning lksw
agen oes
not
unit (and/or in the evaporator used to d byV
o gu
ara
cool the high-voltage components) is not orise nte
eo
reached. aut
h
ra
ss c
ce
le
• High pressure and low pressure normal ⇒ page 250
un
pt
an
d
itte
y li
• The requisite cooling output in the evap‐
rm
ab
orator of the front heating and air condi‐
pe
ility
tioning unit (and in the evaporator for
ot
wit
, is n
cooling the high-voltage components) is
h re
not reached.
hole
spec
es, in part or in w
• The requisite cooling output is not
t to the co
reached in the heat exchanger for heat
pump operation.
rrectness of i
l purpos
Possible deviation from specification during pressure test
nform
ercia
• High pressure remains constant or increases only slightly (above the pressure measured when the engine
is stopped).
m
a
com
tio
• High pressure drops quickly to the specification or lower.
n in
r
te o
thi
• The requisite cooling output in the evaporator of the heating and air conditioning unit and in the evaporator
s
iva
do
for cooling the high-voltage components is not reached.
r
rp
cum
fo
en
ng
t.
Possible causes for deviation from specification and rectification
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
234
by lksw
cted agen
Rep. gr.87 - Air conditioning system Prote AG.
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Too little refrigerant in circuit.
♦ Actuation of the air conditioner compressor or one of the valves installed in the refrigerant circuit faulty.
– Check the measured values of the various pressure/temperature senders and temperature sensors during
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air nconditioning;
AG. VolkswagenRep.
AG do gr. 87 ; Overview of
fitting locations - air conditioning system . If no fault canVbe
lkswage extract the refrigerant.
found, es n
o ot gu
by ara
ed
– Extract refrigerant from the refrigerant circuit ⇒ “2.4
tho
ris Emptying refrigerant circuit”, page 132 .ntee
o u ra
sa c
– If the extracted refrigerant volume is considerably
s less than the specified fill volume (more than 100 g less)
ce
e
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
nl
pt
du
an
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68 itte
y li
erm
ab
ility
– The extracted refrigerant volume approximately equates to the prescribed fill volume, check actuation of
ot p
the air conditioner compressor and the installed shut-off valves. If no fault is found, renew the expansion
wit
, is n
h re
valve for the evaporator in the heater and air conditioning unit ⇒ Heating, air conditioning; Rep. gr. 87 ;
hole
Refrigerant circuit (vehicle-specific workshop manual)
spec
es, in part or in w
t to the co
– Depending on the result, repair the actuation or renew the defective component (air conditioner compres‐
sor, shut-off valve, expansion valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
rrectness of i
Final measures
l purpos
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
nf
ercia
o
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
rm
m
tioning compressor”, page 200
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. Working with air conditioner service station 235
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ To localise the potential cause of the malfunction, various rou‐
G. Volkswage
tines have been stored in the basic settings of thelksrespective
wage
nA n AG d
oes
control unit (e.g. in the thermal management control unit ) with
o not
y V gu
db ara
which the “air conditioning cooling”, “heatorpump”
ise and “cooling nte
components of the high-voltage system” ut functions can be ac‐
h eo
ra
tuated ⇒ Vehicle diagnostic tester in s“Guided
sa Fault Finding” c
mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
ce
le
un
pt
erant circuit (vehicle-specific workshop manual).
an
d
itte
y li
erm
♦ If no fault is found with this complaint, first check actuation of
ab
ility
the electrically actuated valves installed in the refrigerant cir‐
ot p
wit
cuit. If no fault can be found here, remove and check the non-
is n
h re
return valves installed in the refrigerant circuit. If no fault can
ole,
spec
be found here either, clean the refrigerant circuit (flush with
urposes, in part or in wh
R1234yf refrigerant). A bottle-neck or a blockage in the refrig‐
t to the co
erant circuit can also result in one of these complaints ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual) and
rrectne
⇒ “1.6 Cleaning refrigerant circuit”, page 92
♦ On vehicles with “heat pump” function and/or “high-voltage
ss
battery cooling” function, high pressure is not always at the
o
cial p
f
service connection on the high pressure side in all operating
inform
conditions of the air conditioning system. On these vehicles,
mer
depending on the operating status of the air conditioning sys‐
atio
m
tem, pressure in the refrigerant circuit on the high pressure
o
n
c
i
side can only be measured via the pressure/temperature
or
n thi
e
sender installed in the refrigerant circuit ⇒ Heating, air condi‐
t
sd
iva
o
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific work‐
pr
cum
r
fo
shop manual) and ⇒ Vehicle diagnostic tester “Guided Fault
en
ng
t.
Finding” mode.
yi Co
Cop py
t. rig
♦ Before commencing the repair work, check the measured val‐
gh ht
yri by
ues of the various pressure/temperature senders installed in cop Vo
by lksw
the refrigerant circuit. If there is a fault in the measured value
cted agen
Prote AG.
of a pressure/temperature sender, problems in the cooling
output may also be experienced or the evaporator in the front
heating and air conditioning unit could ice up ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
workshop manual), ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode and ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
♦ When checking the various functions (heat pump or cooling of
the high-voltage battery) take note also of the actuation and
function of the components of the coolant circuit that are rela‐
ted to these functions ⇒ Heating, air conditioning; Rep. gr.
87 ; Coolant circuit (vehicle-specific workshop manual).
♦ If, after repeating the test when the expansion valve has been
renewed, the air conditioning system is not operating correctly,
clean the refrigerant circuit (flush with R134a refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 . Then renew air
conditioner compressor and receiver/desiccant cartridge.
♦ In the event of a fault in a temperature sensor, the evaporator
may ice up even though the correct quantity of refrigerant is
present in the circuit.
236 Rep. gr.87 - Air conditioning system
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Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
♦ If the expansion valve on the evaporator in the heater and air
conditioning unit is defective (always closed or does not open
sufficiently), the air conditioner compressor is actuated at the
maximum output and low pressure drops to the diagram value
or lower (the air conditioner compressor draws in refrigerant
from the low pressure side). Sinceagrefrigerant
en AG. V
olkswcannot
agen AG flow via
does
the expansion valve, however, yV
olkthe
sw cooling output is not not
gu
reached and the high pressureised b may also not increase or only ara
nte
increase slightly due to horthe absence of energy exchange ⇒ Ve‐ eo
ut
hicle diagnostic tester
s a in “Guided Fault Finding” mode - air ra
c
conditioning system s
and battery regulation ⇒ Heating, air con‐
ce
e
nl
ditioning; Rep. gr. 00 ; Repair information; Checking cooling
pt
du
an
output (vehicle-specific workshop manual).
itte
y li
erm
ab
♦ The evaporator in the heater and air conditioning unit has a
ility
ot p
higher output than the evaporator in the battery cooling mod‐
wit
, is n
ule. The expansion valve in front of this evaporator (the heat
h re
hole
exchanger for cooling the components of the high-voltage sys‐
spec
tem) is currently actuated, depending on the version, only from
es, in part or in w
t to the co
or up to a certain battery temperature to cool the drive battery /
hybrid battery unit (hybrid battery) by the respective control
unit so that the energy exchange through this evaporator is not
rrectness of i
increased or only marginally ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode and ⇒ Heating, air conditioning;
l purpos
Rep. gr. 00 ; Repair instructions; Checking cooling output
(vehicle-specific workshop manual).
nf
ercia
♦ If there is too much refrigerant in the refrigerant circuit, the air
orm
conditioner compressor must also be emptied (flushed) and
m
atio
m
the receiver/desiccant cartridge renewed. After cleaning the
o
n in
c
refrigerant circuit (flushing with R134a refrigerant)
or
thi
⇒ “1.6 Cleaning refrigerant circuit”, page 92 , pour in the cor‐
te
sd
a
rect amount of refrigerant oil in the circuit (in the air conditioner
iv
o
r
rp
cu
compressor) ⇒ Heating, air conditioning; Rep. gr. 00 ; Tech‐
o
m
f
en
ng
nical data (vehicle-specific workshop manual).
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Possible deviation from specification during pressure test
• High pressure normal
• Low pressure equates to specification
• The required cooling output is not reached.
Possible causes for deviation from specification and rectification
2. Working with air conditioner service station 237
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Too little refrigerant in circuit.
♦ Shut-off valve before the expansion valve for the evaporator in the front heating and air conditioning unit
defective.
♦ One of the other valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ Expansion valve for the evaporator in the front heating and air conditioning unit defective.
– Check the measured values of the various pressure/temperature senders and temperature sensors during
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system . If no fault can be found, extract the refrigerant.
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
– The extracted refrigerant volume approximately equates to the prescribed fill volume, check actuation of
the air conditioner compressor and the installed shut-off valves if no fault is found ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual)
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
AG. Volkswagen A
n G do
wage es n
olks ot g
– Repeat test by
V ua
⇒ “2.14.5 Checking pressures with ed r n
oris air conditioning system switched on - avehicles
tee with electrical air condi‐
tioning compressor”, page 200au
th or
ac
ss
ce
e
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
nl
pt
du
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
an
itte
y li
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
erm
ab
ility
ot p
– Depending on the result, repair the actuation or renew the defective component (shut-off valve/expansion
wit
, is n
valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
h re
hole
spec
Final measures
es, in part or in w
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
t to the co
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
rrectness of i
tioning compressor”, page 200
l purpos
Note
nform
mercia
at
Observe the information relating to this ⇒ page 236 .
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
Possible deviation from specification during pressure test C py
ht. rig
rig ht
• High pressure normal py by
co Vo
by lksw
cted agen
• Low pressure normal or too low (lower than specification) Prote AG.
• The requisite cooling output is then not reached at the evaporator in the heater and air conditioning unit
(the cooling output at the evaporator to cool the high-voltage components is OK).
Possible causes for deviation from specification and rectification
238 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Too little refrigerant in circuit.
♦ Actuation of air conditioner compressor is defective.
♦ Expansion valve for the evaporator in the front heating and air conditioning unit defective.
♦ Shut-off valve before the expansion valve for the evaporator in the front heating and air conditioning unit
defective.
♦ One of the other valves installed in the refrigerant circuit is defective or does not work properly.
– Check the measured values of the various pressure/temperature senders and temperature sensors during
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system . If no fault can
lksw
be found, extract the refrigerant.
. Vo agen AG
gen AG does
swa
– Extract refrigerant from the refrigerant
by
Vocircuit
lk ⇒ “2.4 Emptying refrigerant
not
gu circuit”, page 132 .
ara
ed nte
ris
– If the extracted refrigerant volume
ut
ho is considerably less than the specified fill volume
eo
ra (more than 100 g less)
⇒ Heating, air conditioning;ss aRep. gr. 00 ; Technical data (vehicle-specific workshop
c manual), search for
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
ce
le
un
pt
an
d
itte
– The extracted refrigerant volume approximately equates to the prescribed fill volume, check actuation of
y li
erm
ab
the air conditioner compressor and the installed shut-off valves if no fault is found ⇒ Heating, air condi‐
ility
ot p
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual)
wit
is n
h re
ole,
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
spec
urposes, in part or in wh
– Repeat test
t to the co
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
rrectne
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
s
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
s o
cial p
f in
– Depending on the result, repair the actuation or renew the defective component (shut-off valve/expansion
form
mer
valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
atio
m
Final measures
o
n
c
i
or
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
thi
te
sd
iva
o
pr
– Repeat test
um
r
fo
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
en
ng
t.
yi Co
tioning compressor”, page 200 t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
Observe the information relating to this ⇒ page 236 .
Possible deviation from specification during pressure test
• High pressure normal
• Low pressure normal or too low (lower than specification)
• The requisite cooling output is then not reached at the evaporator to cool the high-voltage components (the
cooling output at the evaporator in the heating and air conditioning unit is OK).
Possible causes for deviation from specification and rectification
2. Working with air conditioner service station 239
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ One of the pumps or one of the valves in the coolant circuit of the high-voltage battery is defective or does
not work properly ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit (vehicle-specific workshop
manual).
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Bottle-neck or blockage in the refrigerant line to or from the expansion valve on the evaporator used to cool
the high-voltage components
– Check the measured values of the various pressure/temperature senders and temperature sensors during
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system .
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– Check the function and actuation of the components used to cool the high-voltage components ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode - air conditioning system, air conditioner compressor and
battery regulation
– Depending on the result, repair the actuation or renew the defective component (shut-off valve, expansion
valve, coolant pump, coolant shut-off valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific workshop manual) and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific workshop manual).
– Check the lines of the refrigerant circuit. If a hose or pipe is kinked or crushed, renew this component.
– If no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ).
Final measures AG. Volkswagen AG d
agen oes
– Recharge the refrigerant circuit
yV
olks⇒w “2.6 Charging refrigerant nocircuit”,
tg page 141
b ua
ed ran
– Repeat test oris tee
h
ut o
⇒ “2.14.5 Checking
ss
apressures
with air conditioning system switched on
r a - vehicles with electrical air condi‐
c
tioning compressor”, page 200
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Observe the information relating to this ⇒ page 236 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Possible deviation from specification during pressure test
l purpos
• High pressure does not increase or only marginally above the pressure with the engine stationary.
• The low pressure does not drop or only marginally.
nf
ercia
• The requisite cooling output in the evaporator of the heating and air conditioning unit and in the evaporator
rm
m
atio
for cooling the high-voltage components is not reached.
om
n in
or c
Possible causes for deviation from specification and rectification
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.
240 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ No actuation of the air conditioner compressor. The air conditioner compressor is not driven.
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ Bottle-neck or blockage in refrigerant circuit (e.g. in refrigerant line between service connection on “low
pressure side” and air conditioner compressor).
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
olkswagen AG
in “Guided FaultsFinding”
wage mode
n AG. V does
k not
Vol gu
by
– Check theris function and actuation of the various valves
ed
ara
nte installed in the refrigerant circuit by means of the
pressure
tho distribution in the refrigerant circuit ⇒ Vehicle
e o diagnostic tester in “Guided Fault Finding” mode
and au ra
ss ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant c circuit (vehicle-specific workshop manual).
ce
le
un
pt
– Depending on the result, repair the actuation or renew the defective component (air conditioner compres‐
an
d
itte
sor, shut-off valve, expansion valve) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
y li
erm
ab
specific workshop manual).
ility
ot p
wit
is n
– Check the lines of the refrigerant circuit. If a hose or pipe is kinked or crushed, renew this component ⇒
h re
ole,
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
spec
urposes, in part or in wh
– Touch the refrigerant circuit by hand during operation to feel for temperature drops (bottle-neck or block‐
t to the co
age). If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
rrectne
– If no fault can be found in the air conditioner compressor, renew the air conditioner compressor
⇒ “1.5 Renewing components”, page 79
ss o
– If no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant
cial p
f in
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ).
form
mer
Final measures
atio
om
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
c
i
or
n thi
te
sd
a
– Repeat test
iv
o
pr
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
um
r
fo
tioning compressor”, page 200
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
o Vo
by c lksw
cted agen
Prote AG.
Observe the information relating to this ⇒ page 236 .
Possible deviation from specification during pressure test
• High pressure increases above specification
• Low pressure drops quickly to the specification
• The requisite cooling output in the evaporator of the front heating and air conditioning unit (and/or in the
evaporator used to cool the high-voltage components) is not reached.
Possible causes for deviation from specification and rectification
2. Working with air conditioner service station 241
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ Actuation or function of air conditioner compressor defective.
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ Constriction or obstruction in refrigerant circuit
♦ Expansion valve defective
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– Check the lines of the refrigerant circuit. If a hose or pipe is kinked or crushed, renew this component ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– Touch the refrigerant circuit by hand during operation to feel for temperature drops (bottle-neck or block‐
age). If there is a blockage, clean the refrigerant circuit (flush with R1234yf refrigerant)
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .
Final measures
– Recharge the refrigerant circuit
agen ⇒ “2.6 Charging
AG. Volkswagen AG d refrigerant circuit”, page 141
o
w es n
olks ot g
yV
– Repeat test ed
b ua
ran
⇒ “2.14.5 Checkingris pressures with air conditioning system teeswitched on - vehicles with electrical air condi‐
tho or
tioning compressor”,
ss au page 200 ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
242 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ In this case, the evaporator may ice up even though the correct
volume of refrigerant is present in the refrigerant circuit.
♦ If the expansion valve on the evaporator in the heater and air
conditioning unit or the previously installed shut-off valve is
defective (always closed or does not open sufficiently), the air
conditioner compressor is actuated at the maximum output
and low pressure drops to the specification or lower (the air
conditioner compressor draws in refrigerantgfrom AG.the
Volklow
swagpres‐
en AG
a en
sure side). Since no (or too little) refrigerant
olksw can flow via the
does
not
expansion valve, however, the cooling ed by V
output is not reached gu
ara
and the high pressure may also horisnot increase or only increase nte
eo
slightly due to the absences aof energy exchange ⇒ Vehicle di‐
ut ra
c
agnostic tester in “Guided sFault Finding” mode - air condition‐
ce
le
ing system and battery regulation ⇒ Heating, air conditioning;
un
pt
an
d
Rep. gr. 00 ; Repair information; Checking cooling output (ve‐
itte
y li
hicle-specific workshop manual).
rm
ab
pe
ility
♦ If the expansion valve in front of the evaporator used to cool
ot
wit
, is n
the high-voltage components is defective (or function and ac‐
h re
tuation are faulty), permanently closed or does not open far
hole
spec
enough, the air conditioner compressor is likewise actuated
es, in part or in w
with maximum output (the requisite temperatures in the heat
t to the co
exchanger are not reached). The pressure on the low pressure
side then only drops to the specification or lower if, at the same
time, no cooling output is required in the heating and air con‐
rrectness of i
ditioning unit. The air conditioner compressor extracts refrig‐
l purpos
erant on the low pressure from both evaporators. Since no
refrigerant can flow through the expansion valve in the front
heating and air conditioning unit, however, and the cooling
nform
ercia
output in the evaporator used to cool the high-voltage compo‐
nents is not reached (there is a fault in the area of the evapo‐
m
a
com
t
rator used to cool the high-voltage components), the electrical
ion in
air conditioning compressor is actuated with a higher speed.
r
te o
thi
However, no refrigerant can flow, which causes pressure on
s
iva
do
the low pressure side to drop below the specification. High
r
rp
cum
pressure may not rise or only marginally as no energy ex‐
fo
en
g
change takes place. The same applies if a valve in the refrig‐
n
t.
yi Co
op
erant circuit is not OK, if there is a fault with integration of the C py
t. rig
evaporator for cooling of the high-voltage components in the gh ht
yri by
refrigerant circuit of the high-voltage system or a pump or cop Vo
by lksw
valve installed there is not OK. Here, the heat exchanger for
cted agen
Prote AG.
high-voltage battery does actually cool down but the cooled
coolant does not reach the high-voltage components that need
to be cooled down ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode and ⇒ Heating, air conditioning system; Rep.
gr. 87 ; Coolant circuit (vehicle-specific workshop manual).
♦ Further notes regarding this ⇒ page 236 .
Possible deviation from specification during pressure test
• The high pressure and low pressure are normal to start with but after a while the high pressure rises above
the specification and the low pressure drops to the specification or lower.
• The requisite cooling output in the evaporator of the heating and air conditioning unit (and/or in the evap‐
orator used to cool the high-voltage components) is not reached or no longer reached.
Possible causes for deviation from specification and rectification
2. Working with air conditioner service station 243
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Actuation and function of air conditioner compressor faulty ⇒ Vehicleendiagnostic
AG. Volkswagtester
en AG in “Guided Fault
Finding” mode. olks
wag does
not
V gu
by a
♦ One of the valves installed in the refrigerant circuit is defective
ris
ed or is not working properly ⇒ Heating,
ran
tee air
tho
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual). or
au a c
ss
♦ Moisture in refrigerant circuit
ce
le
un
pt
an
d
– Check the measured values of the various pressure/temperature senders and temperature sensors during
itte
y li
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
rm
ab
pe
ility
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system . ot
wit
, is n
h re
hole
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
spec
in “Guided Fault Finding” mode
es, in part or in w
t to the co
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
rrectness of i
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
l purpos
– If no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ).
nform
ercia
Final measures
m
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
a
com
tion in
r
– Repeat test
te o
thi
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
s
iva
do
tioning compressor”, page 200
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
Observe the information relating to this ⇒ page 236 .
cted agen
Prote AG.
Possible deviation from specification during pressure test
• High pressure and low pressure are normal at first but after a longer drive the low pressure falls to below
the specification (evaporator in heater and air conditioning unit iced up).
Possible causes for deviation from specification and rectification
244 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Actuation and function of air conditioner compressor faulty ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Moisture in refrigerant circuit
– Check the measured values of the various pressure/temperature senders and temperature sensors during
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system .
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If no fault can be found, renew the desiccant bag/desiccant cartridge (or reservoir/receiver) and evacuate
the refrigerant circuit for at least 3 hours.
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
♦ With this complaint, there isrisnoe need to clean the refrigerant
d
nte
circuit (flush with R1334yf ut refrigerant
ho eo
ra
⇒ “1.6 Cleaning refrigerant
ss a
circuit”, page 92 ) as there is usu‐ c
ally only a small amount of moisture in the system, which can
ce
le
un
pt
be removed by a longer evacuation period.
an
d
itte
y li
rm
♦ If this complaint occurs after a longer period of operation or
ab
pe
ility
only occasionally due to moisture in the refrigerant circuit (low
ot
wit
pressure falls below the specification and the evaporator ices
, is n
h re
up), renewing the dryer (fitted within the receiver) is sufficient.
hole
spec
Refrigerant circuit is then to be evacuated for at least 3 hours.
es, in part or in w
t to the co
♦ In this case, the evaporator may ice up even though the correct
volume of refrigerant is present in the refrigerant circuit.
♦ A fault in the evaporator output temperature sender - G263-
rrectness of i
and / or a pressure/temperature sender could also cause the
l purpos
refrigerant circuit to ice up. With this complaint, therefore, also
take note of the measured values of the various pressure/
temperature senders in the refrigerant circuit ⇒ Vehicle diag‐
nform
ercia
nostic tester in “Guided Fault Finding” mode and ⇒ Heating,
air conditioning; Rep. gr. 00 ; Repair information; Checking
m
a
com
cooling output (vehicle-specific workshop manual).
ion in
r
te o
♦ Further notes regarding this ⇒ page 236 .
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
245
cop Vo
by lksw
Prote
cted AG. 2. Working with air conditioner service station
agen
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
• High pressure normal
• Low pressure too low
• The requisite cooling output in the evaporator of the heating and air conditioning unit (and/or in the evap‐
orator used to cool the high-voltage components) is not reached.
Possible causes for deviation from specification and rectification
♦ Too little refrigerant in circuit.
♦ Actuation or function of the air conditioner compressor defective ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
. Volkswagen AG
gen AG d
♦ One of the valves installed in the refrigerant
Vol
ksw circuit is defective oresisnonot
a o
t gu working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant
ed b circuit (vehicle-specific workshop
y aramanual).
is nte
or e
♦ One of the pressure/temperatureau
th senders or temperature sensors on or in theor refrigerant circuit supplies
a
incorrect values ⇒ Vehicle diagnostic
ss tester in “Guided Fault Finding” mode and ⇒c Heating, air conditioning;
ce
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
le
un
pt
an
d
itte
– Check the measured values of the various pressure/temperature senders and temperature sensors during
y li
erm
ab
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
ility
ot p
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
wit
is n
fitting locations - air conditioning system . If no fault can be found, extract the refrigerant.
h re
ole,
spec
– Extract refrigerant from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
urposes, in part or in wh
t to the co
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
rrectne
– The extracted refrigerant volume approximately equates to the prescribed fill volume, check actuation of
s
the air conditioner compressor and the installed shut-off valves if no fault is found ⇒ Heating, air condi‐
s o
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual)
cial p
f inform
mer
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
atio
om
– Repeat test
c
i
or
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
thi
te
sd
a
tioning compressor”, page 200
iv
o
pr
cum
r
fo
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
en
ng
t.
yi Co
in “Guided Fault Finding” mode t. Cop py
rig
gh ht
yri
– Check the function and actuation of the various valves installed in the refrigerant circuit by means of the
p by
co Vo
by lksw
pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode Prote
cted AG.
agen
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– Depending on the result, repair the actuation or renew the defective component (air conditioner compres‐
sor, shut-off valve, expansion valve, pressure/temperature sender) ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific workshop manual).
– If no fault can be found, clean the refrigerant circuit (flush with R1234yf refrigerant
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ).
Final measures
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
246 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
. Volkswagen AG
gen AG does
swa
Note byV
olk not
gu
d ara
ise nte
or
♦ In the event of the following fault “Highaupressure
th normal, low eo
ra
pressure too low”, please note the following:
ss With this fault, c
there is a chance that the evaporator in the heating and air
ce
le
un
pt
conditioning unit could ice up even though the refrigerant vol‐
an
d
itte
y li
ume in the circuit is OK.
erm
ab
ility
ot p
♦ If the problem is with the air conditioner compressor (the air
wit
is n
conditioner compressor is actuated at excessively high speed
h re
by the control unit for air conditioning compressor ), the refrig‐ ole,
spec
erant circuit does not have to be cleaned (by flushing with
urposes, in part or in wh
R1234yf refrigerant
t to the co
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ). With this fault,
it is sufficient to renew the air conditioner compressor (take
note of refrigerant oil in air conditioner compressor and re‐
rrectne
plenish as necessary).
♦ If the expansion valve in front of the evaporator used to cool
ss
the high-voltage components is defective (or function and ac‐
o
cial p
f i
tuation are faulty), permanently closed or does not open far
nform
enough, the air conditioner compressor is likewise actuated
mer
with maximum output (the requisite temperatures in the heat
atio
m
exchanger are not reached). The pressure on the low pressure
o
n
c
i
or
n
side then only drops to the specification or lower if, at the same
thi
te
time, no cooling output is required in the heating and air con‐
sd
iva
o
ditioning unit. The air conditioner compressor extracts refrig‐
pr
cum
r
fo
erant on the low pressure from both evaporators. Since no
en
ng
t.
refrigerant can flow through the expansion valve in the front
yi Co
op py
heating and air conditioning unit, however, and the cooling
. C rig
ht ht
output in the evaporator used to cool the high-voltage compo‐
rig by
opy Vo
nents is not reached (there is a fault in the area of the evapo‐
by c lksw
cted agen
rator used to cool the high-voltage components), the electrical
Prote AG.
air conditioning compressor is actuated with a higher speed.
However, no refrigerant can flow, which causes pressure on
the low pressure side to drop below the specification. High
pressure may not rise or only marginally as no energy ex‐
change takes place. The same applies if a valve in the refrig‐
erant circuit is not OK, if there is a fault with integration of the
evaporator for cooling of the high-voltage components in the
refrigerant circuit of the high-voltage system or a pump or
valve installed there is not OK. Here, the heat exchanger for
high-voltage battery does actually cool down but the cooled
coolant does not reach the high-voltage components that need
to be cooled down ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode and ⇒ Heating, air conditioning system; Rep.
gr. 87 ; Coolant circuit (vehicle-specific workshop manual).
♦ A fault in the evaporator output temperature sender - G263-
and / or a pressure/temperature sender could also cause this
problem. Therefore, also take note of the measured values of
the various pressure/temperature senders in the refrigerant
circuit ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
information; Checking cooling output (vehicle-specific work‐
shop manual).
♦ Further notes regarding this ⇒ page 236 .
2. Working with air conditioner service station 247
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
• High pressure normal or too high
• Low pressure too high
• The air conditioner compressor is noisy (especially immediately after being switched on)
• The requisite cooling output in the evaporator of the front heating and air conditioning unit (and/or in the
evaporator used to cool the high-voltage components) is not reached.
Possible causes for deviation from specification and rectification
♦ Actuation and function of air conditioner compressor faulty ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ Too much refrigerant in circuit.
♦ Too much refrigerant oil in circuit.
– Check the measured values of the various pressure/temperature senders and temperature sensors during
AG. Volkswagen AG d
operation of the air conditioning system, renew components lkswwith
agen false measured values
oes
n
⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating,
byV
o air conditioning; Rep. gr. ot87
gu ; Overview of
ara
fitting locations - air conditioning system . or
ise
d
nte
th eo
au ra
– Check the actuation and function of the air conditioner
ss compressor and repair ⇒ Vehicle diagnostic
c tester
in “Guided Fault Finding” mode
ce
e
nl
pt
du
an
itte
y li
– Check the function and actuation of the various valves and pressure/temperature senders installed in the
erm
ab
refrigerant circuit by means of the pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester
ility
ot p
in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
wit
, is n
specific workshop manual).
h re
hole
spec
– If no fault can be found, extract the refrigerant from the refrigerant circuit.
es, in part or in w
t to the co
• The quantity of refrigerant extracted is significantly greater than the prescribed charge quantity:
– Recharge the refrigerant circuit and repeat the test.
rrectness of i
• The quantity of refrigerant extracted is about equal to the prescribed charge quantity:
l purpos
– Check the actuation and function of the air conditioner compressor and the valves installed in the refrigerant
circuit (shut-off valves and expansion valves) ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
nf
ercia
orm
m
– Depending on the result, repair the actuation or renew the defective component (shut-off valve, expansion
atio
m
valve or air conditioner compressor as well as receiver/dryer) ⇒ Heating, air conditioning; Rep. gr. 87 ;
o
n in
or c
Refrigerant circuit (vehicle-specific workshop manual).
thi
te
sd
iva
– If no fault can be found there may be too much refrigerant oil in the circuit. Clean the refrigerant circuit
r
rp
cu
o
(flush with R1234yf refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 ).
f
en
ng
t.
yi Co
Final measures t. Cop py
rig
gh
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
ht
pyri by
Vo
co lksw
by
cted agen
– Repeat test Prote AG.
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
248 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note
♦ The cause of this fault could also be too much refrigerant oil
in the circuit. Overfilling with refrigerant oil can occur if the re‐
frigerant oil level was not checked after the air conditioner
compressor was renewed.
♦ Further notes regarding this ⇒ page 236 .
Possible deviation from specification during pressure test n AG. Volkswagen AG do
swage es n
• High pressure and low pressure normal byV
olk ot g
ua
d ran
ir se
• The requisite cooling output in the evaporator ofththe
o heating and air conditioning unit and in the tee evaporator
or
for cooling the high-voltage components is not au reached. ac
ss
ce
e
or
nl
pt
du
• High pressure and low pressure normal
an
itte
y li
erm
ab
• The air conditioner compressor is noisy (especially immediately after being switched on)
ility
ot p
wit
• The requisite cooling output in the evaporator of the heating and air conditioning unit (and/or in the evap‐
, is n
h re
orator used to cool the high-voltage components) is not reached.
hole
spec
es, in part or in w
Possible causes for deviation from specification and rectification
t to the co
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
rrectness of i
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
l purpos
♦ Actuation and function of air conditioner compressor faulty ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
nform
ercia
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
m
at
om
io
♦ Too much refrigerant in circuit.
n
c
in t
or
his
e
♦ Expansion valve for the evaporator in the front heating and air conditioning unit defective.
at
do
priv
c
♦ Too much refrigerant oil in circuit.
um
for
en
ng
t.
yi
– Check the measured values of the various pressure/temperature senders and temperature sensors during
Co
op py
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐ t. C rig
gh ht
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of yri
p by
co Vo
fitting locations - air conditioning system .
by lksw
cted agen
Prote AG.
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode
– Check the function and actuation of the various valves and pressure/temperature senders installed in the
refrigerant circuit by means of the pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
– If no fault can be found, extract the refrigerant from the refrigerant circuit.
• The quantity of refrigerant extracted is significantly greater than the prescribed charge quantity:
– Recharge the refrigerant circuit and repeat the test.
• The quantity of refrigerant extracted is about equal to the prescribed charge quantity:
– Clean the refrigerant circuit (flush with R1234yf refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 ).
– Pour in the correct amount of refrigerant oil in the circuit (see note).
Final measures
2. Working with air conditioner service station 249
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
tioning compressor”, page 200
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ Overfilling with refrigerant oil can occur if the refrigerantby V oil
o gu
ara
level was not checked after the air conditioner compressor
d
rise nte
o
was renewed. auth eo
ra
ss c
♦ If e.g. the expansion valve for the evaporator in the heating
ce
e
nl
pt
and air conditioning unit or for the evaporator used to cool the
du
an
itte
high-voltage components is defective (always open), the
y li
erm
ab
evaporator temperature (in the front heating and air condition‐
ility
ot p
ing unit) is no longer regulated in such a way that only gaseous
wit
, is n
refrigerant exits the evaporator. It is then possible that under
h re
certain operating conditions, drops of liquid will be drawn into
hole
spec
the air conditioner compressor, which will hen cause noise
es, in part or in w
(because liquid is incompressible).
t to the co
♦ If there is too much refrigerant in the refrigerant circuit, the air
conditioner compressor must be emptied and the receiver re‐
rrectness of i
newed. After cleaning the refrigerant circuit (flushing with
R1234yf refrigerant)
l purpos
⇒ “1.6 Cleaning refrigerant circuit”, page 92 , pour the correct
amount of refrigerant oil in the circuit ⇒ Heating, air condi‐
tioning; Rep. gr. 00 ; Technical data (vehicle-specific work‐
nform
ercia
shop manual).
m
at
om
i
♦ Further notes regarding this ⇒ page 236 .
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
Possible deviation from specification during pressure test t. C rig
gh ht
pyri by
• High pressure and low pressure normal
co Vo
by lksw
cted agen
Prote AG.
• The requisite cooling output in the evaporator of the front heating and air conditioning unit (and in the
evaporator for cooling the high-voltage components) is not reached.
• The requisite cooling output is not reached in the heat exchanger for heat pump operation.
Possible causes for deviation from specification and rectification
250 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Possible deviation from specification during pressure test
♦ One of the pressure/temperature senders or temperature sensors on or in the refrigerant circuit supplies
incorrect values ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Overview of fitting locations - air conditioning system
♦ One of the pumps or one of the valves in the coolant circuit of the high-voltage battery or the engine is
defective or does not work properly ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit (vehicle-
specific workshop manual).
♦ Actuation and function of air conditioner compressor faulty ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
♦ One of the valves installed in the refrigerant circuit is defective or is not working properly ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).
– Check the measured values of the various pressure/temperature senders and temperature sensors during
operation of the air conditioning system, renew components with false measured values ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - air conditioning system .
– Check how the heat exchanger is included in the coolant circuit of the engine and also check the function
and actuation of the various pumps and valves ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit
(vehicle-specific workshop manual).
– Check the actuation and function of the air conditioner compressor and repair ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode
– Check the function and actuation of the various valves and pressure/temperature senders installed in the
refrigerant circuit by means of the pressure distribution in the refrigerant circuit ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific workshop manual).
– Check the function and actuation of the components used to cool the high-voltage components ⇒ Vehicle
diagnostic tester in “Guided Fault Finding”
n AG. Volksmode - Gair
wagen A
doconditioning system, air conditioner compressor and
battery regulation lkswage es n
Vo ot g
y ua
db ran
se
– If no fault can be found,
tho
ri extract the refrigerant from the refrigerant
tee circuit.
o
u ra
sa c
– Extract refrigerant
s
from the refrigerant circuit ⇒ “2.4 Emptying refrigerant circuit”, page 132 .
ce
le
un
pt
an
d
– If the extracted refrigerant volume is considerably less than the specified fill volume (more than 100 g less)
itte
y li
rm
⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-specific workshop manual), search for
ab
pe
ility
the leak and rectify the cause ⇒ “1.4 Investigating leaks”, page 68
ot
wit
, is n
h re
– The extracted refrigerant volume approximately equates to the prescribed fill volume, check actuation of
hole
spec
the air conditioner compressor and the installed shut-off valves if no fault is found ⇒ Heating, air condi‐
es, in part or in w
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual)
t to the co
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
rrectness of i
– Repeat test
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
l purpos
tioning compressor”, page 200
Final measures
nform
ercia
– Recharge the refrigerant circuit ⇒ “2.6 Charging refrigerant circuit”, page 141
m
a
com
tio
– Repeat test
n in
r
⇒ “2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air condi‐
te o
thi
tioning compressor”, page 200
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Working with air conditioner service station 251
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
♦ If the requisite cooling risoutput at the evaporator in the front
ed
nte
heating and air conditioning
ut
ho
unit (and at the evaporator used eo
ra
to cool the high-voltage components) is OK and there is a
s a c
s
problem owing to lack of heating output in the heat exchanger
ce
le
un
pt
for heat pump operation. The cause could be in the coolant
an
d
itte
circuit of the high-voltage system or in the coolant circuit of the
y li
erm
ab
engine. If the pumps and valves in the coolant circuit of the
ility
ot p
high-voltage system are not actuated correctly or their function
wit
is n
is not OK, not enough heat energy can be drawn from the
h re
ole,
coolant via the evaporator (heat exchanger) used to cool the
spec
high-voltage components. If the pumps and valves in the cool‐
urposes, in part or in wh
ant circuit of the engine are not actuated correctly or their
t to the co
function is not OK, the heat energy cannot be dissipated via
the heat exchanger for heat pump function to the coolant that
flows to the heat exchanger in the heating and air conditioning
rrectne
unit ⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit
s
(vehicle-specific workshop manual).
s o
cial p
f in
♦ Further notes regarding this ⇒ page 236 .
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
252 Rep. gr.87 - Air conditioning system
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
3 Testing equipment and tools
⇒ “3.1 Tools and materials available from distribution centre or
importer”, page 253
⇒ “3.2 Tools and materials available commercially”, page 253
⇒ “3.3 Tools that can be locally manufactured”, page 254
3.1 Tools and materials available from dis‐
tribution centre or importer
Tools and materials are available from the “Electronic parts cata‐
logue (ETKA)” ⇒ Electronic parts catalogue .
Overview
Air conditioner service station with flushing device
– With integrated program for flushing the refrigerant circuit with R1234yf refrigerant and the associated
flushing device
– With integrated analysis unit for finding contamination in the R1234yf refrigerant
R1234yf refrigerant ⇒ Electronic parts catalogue
Extraction device (for R1234yf refrigerant) dry ice box
Adapter case, VW/Audi passenger vehicle set
– Used to connect the air conditioner service station to the refrigerant circuit for flushing and for bridging
removed components when flushing
– Used to connect certain components to the pressure hose to blow through with compressed air or nitrogen
Leak detector for R1234yf/R134A AG. Volkswagen AG d
agen oes
ksw
Combination fine filter unit forbcompressed
yV
ol
air system not
gu
ara
ed
Seals (different versions,thopay attention to correct allocation) ⇒ Electronic
ris nte
e o parts catalogue
u ra
Refrigerant oil (different
s versions, pay attention to correct allocation) ⇒ Electronic
s a c parts catalogue
ce
le
Leak detection system with following contents:
un
pt
an
d
♦ Cleaning agent
itte
y li
erm
ab
♦ UV leak detector lamp
ility
ot p
wit
is n
♦ Replacement bulb for leak detector lamp
h re
ole,
♦ Safety glasses
spec
urposes, in part or in wh
t to the co
♦ Sticker
♦ Protective gloves
rrectne
♦ System case
s
Tracer replenishment cartridge
s o
cial p
Release tools for refrigerant line with quick-release couplings
inform
mer
Removal tool for quick-release couplings of refrigerant lines
atio
m
Tool attachments for removing and installing valves
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
3.2 Tools and materials available commer‐
fo
en
ng
t.
yi
cially
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Note
agen
Prote AG.
This list is an overview of the test equipment, tools and materials
necessary for professional repairs to the refrigerant circuit.
3. Testing equipment and tools 253
Arteon 2018 ➤ , Atlas 2017 ➤ , CC 2012 ➤ , Caddy 2016 ➤ , Crafter 201 ...
Air conditioning systems with refrigerant R1234yf - General information - Edition 01.2018
Overview
Fin comb
Charge hoses 5/8"-18 UNF
Connector piece for pressure cylinders for refrigerant and sealing ring with quick-release connector or threaded
connector
Valve cap 5/8" -18 UNF
Pressure gauge set with pressure reducer for nitrogen
Quick release coupling adapter for service connections (qty. 2 included with air conditioner service station ).
Flared ring spanners of widths matching those of the threaded connections on the refrigerant lines.
Valve opener for charge hoses
Connection nipple for conical surface seal 5/8"-18 UNF
Compressed air gun with rubber tip
Manual stop valve 5/8" -18 UNF
Recycling cylinder for contaminated R1234yf refrigerant
Digital thermometer
Protective gloves
Safety glasses
Dry ice pellets
3.3 Tools that can be locally manufacturedolkswagen AG.
Volkswagen AG
does
not
yV gu
db ara
rise nte
tho eo
Note s au ra
c
s
ce
le
This list is an overview of the test equipment, tools and materials
un
pt
an
d
necessary for professional repairs to the refrigerant circuit.
itte
y li
erm
ab
ility
ot p
Overview Page
wit
is n
h re
ole,
Charging hose with connection to workshop compressed air system Not illustrated
spec
urposes, in part or in wh
t to the co
Charging hose with connection to workshop compressed air sys‐
tem
rrectne
A - Charging hose 5/8" - 18 UNF** (version with large internal
diameter)
ss o
cial p
B - Connector for workshop compressed air system** (for use only
inform
with filter)
mer
atio
** Tools and materials available commercially
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.
254 Rep. gr.87 - Air conditioning system
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