Renewing components of refrigerant system, engine codes ANY and AYZ — VW

Renewing components of refrigerant system, engine codes ANY and AYZ
WARNING
Danger of freezing injuries.
If the refrigerant circuit has not been evacuated, refrigerant will escape.
Extract refrigerant before opening refrigerant circuit. If the refrigerant circuit is not opened within 10 minutes after it has been evacuated, pressure may develop in refrigerant circuit due to re-evaporation. Extract refrigerant again.
Note
The refrigerant must be extracted beforehand, e.g. with
air conditioner service station
VAS 6007A
.
The previously used service stations can still be used ⇒ Volkswagen Workshop Equipment catalogue.
Safety measures when working with an extracted refrigerant circuit
Chapter
. Notes on repair work to vehicles with air conditioning and on handling refrigerant.
To prevent the intrusion of moisture, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.
The colour coding of O-rings for R134a refrigerant circuits has been discontinued. Coloured and black O-rings are used.
Only the components marked with an
“*”
can be renewed without opening and evacuating the refrigerant circuit.
Evaporator
In passenger compartment
Removing: remove heater and air conditioning unit
Chapter
Dismantling and assembling evaporator housing
Chapter
.
O-ring
10.8 mm; 1.82 mm
O-ring
8.2 mm; 1.85 mm
Evacuating and charging valve
High-pressure side
Releasing refrigerant into the environment is a punishable offence.
Removing and installing
Chapter
Capacities
Chapter
.
Refrigerant hose
With damper
Refrigerant hose
O-ring
10.8 mm; 1.82 mm
3/4" thread - 16 UNF
Note
Counterhold threaded connection with suitable tool when loosening and tightening.
30 ± 2 Nm
Condenser
Removing
Chapter
Socket head combi-bolt
12 ± 1 Nm
O-ring
10.8 mm; 1.82 mm
Receiver with dryer
Functions
Chapter
.
Removing
Chapter
Note
Under certain conditions, it is not necessary to renew the receiver with dryer every time that the refrigerant circuit is opened. Information can be found in the workshop information under
“Air conditioning system with refrigerant R134a”
Rep. Gr.
00
“Renewing components”
.
O-ring
10.8 mm; 1.82 mm
Socket head combi-bolt
12 ± 1 Nm
Refrigerant hose
Socket head combi-bolt
12 ± 1 Nm
O-ring
10.8 mm; 1.82 mm
Air conditioning system magnetic clutch
N25
Air conditioner compressor
Manufacturer: Calsonic, designation: CSV613.
Removing and installing
Chapter
Note
If the air conditioner compressor has been exchanged because of internal damage, it is also necessary to purge the refrigerant circuit with refrigerant R134a.
The procedure for purging can be found in the workshop manual
“Air conditioning system with refrigerant R134a VW”
Rep. Gr.
00
, Technical data, Clearing refrigerant circuit of contaminants.
Observe running-in procedures for new air conditioner compressors
Chapter
.
High-pressure safety valve
Checking
Fig.
O-ring
14.3 mm; 2.4 mm
Socket head combi-bolt
22 ± 1 Nm
O-ring
10.8 mm; 1.82 mm
Socket head combi-bolt
22 ± 1 Nm
O-ring
10.8 mm; 1.82 mm
High-pressure sender
G65
*
Check with
vehicle diagnosis, testing and information system
VAS 5051A
in
“guided fault finding”
function.
Removing
Chapter
Refrigerant hose
Bolt
8 ± 1 Nm
O-ring
17 mm; 1.85 mm
Evacuating and charging valve
Low-pressure side
Releasing refrigerant into the environment is a punishable offence.
Removing and installing
Capacities
Chapter
.
Quick release coupling
Removing and installing
Chapter
Expansion valve
In engine compartment on right.
Function and removal
Chapter
.
O-ring
14 mm; 1.82 mm
Threaded plate
Checking excess pressure relief valve on compressor
WARNING
Danger of freezing injuries.
The pressure relief valve releases refrigerant when the engine is running and the pressure in the refrigerant circuit is too high.
Switch off engine.
Task: protects the refrigerant circuit against excessive pressure.
The pressure relief valve has operated when refrigerant oil is found in the immediate vicinity.
In this case, hand over vehicle to a suitable workshop
Chapter
.