Repairing refrigerant circuit components — VW

Repairing refrigerant circuit components
Note
The refrigerant must be extracted beforehand, e.g. with
air conditioning service station
VAS 6007A
.
The previously used service stations can still be used ⇒ Volkswagen Workshop Equipment catalogue.
Safety measures when working on an evacuated refrigerant circuit
Chapter
.
Only the components marked with an
“*”
can be replaced without opening and evacuating.
All of the refrigerant circuit's components that have been opened must be sealed with suitable plugs to prevent the ingress of moisture.
The colour coding of O-rings for R134a refrigerant circuits has been discontinued. Coloured and black O-rings are used.
Moisten threaded connections of refrigerant circuit with polyethylene glycol (PEG) VW part number 294440 before installation.
Under certain conditions, it is no longer necessary to renew the receiver each time the refrigerant circuit is opened
Rep. Gr.
00
Technical information
“Air conditioning systems - with refrigerant R134a VW”
Renewing parts.
Bolt
15 Nm.
O-ring
10.8 mm; 1.8 mm.
Receiver with dryer bag
Functions
Chapter
.
O-ring
10.8 mm; 1.8 mm.
Refrigerant line
From receiver with dryer bag to expansion valve.
Bolt
15 Nm.
Air conditioning system pressure switch
F129
* or
high pressure sender
G65
*
Removing and installing:
Torque setting 8 Nm
Renew O-ring (note part number).
Air conditioning system pressure switch
F129
and
high pressure sender
G65
can be removed without having to evacuate refrigerant from refrigerant circuit.
The
high pressure sensor
G65
cannot be checked via the Climatronic self-diagnosis, but only via the engine control unit.
Checking:
vehicle diagnosis, testing and information system
VAS 5051B
in guided fault finding.
The
high pressure sensor
G65
supplies information to
radiator fan control unit
J293
and engine control unit.
Check
air conditioning system pressure switch
F129
Chapter
.
Check
high pressure sender
G65
Chapter
.
Function:
Switches
radiator fan
V7
to next higher speed when pressure increases in refrigerant circuit.
Switches off the air conditioner when the pressure is high (for example, insufficient engine cooling).
Switches off the air conditioner when the pressure is too low (for example, loss of refrigerant).
O-ring
10.8 mm; 1.8 mm.
Schrader valve
Threaded plate
O-ring
10.8 mm; 1.8 mm.
Expansion valve
In engine compartment on right.
Aperture must be sealed against splashed water.
Removing
Chapter
.
Function
The expansion valve atomises incoming refrigerant and regulates the flow so that, depending on the heat transport, the vapour does not become a gas until it reaches the outlet of the evaporator.
The expansion valves for R134a refrigerant circuits are marked with a green sticker.
Bolts
8 Nm.
O-ring
14 mm; 1.8 mm.
Damper
In refrigerant hose from expansion valve to air conditioner compressor.
For vehicles with the engine code BDE near the expansion valve.
Extraction and charging valve
Low pressure side.
Releasing refrigerant into the environment is a punishable offence.
Removing and installing
Chapter
.
Capacities
Chapter
.
Refrigerant hose
From expansion valve to air conditioner compressor.
With damper.
Extraction and charging valve
High pressure side.
Releasing refrigerant into the environment is a punishable offence.
Removing and installing
Chapter
.
Capacities
Chapter
.
O-ring
10.8 mm; 1.8 mm.
Evaporator
In passenger compartment.
Removal
Chapter
, Dismantling and assembling evaporator housing.
O-ring
16.7 mm; 1.8 mm.
Heat insulation*
O-ring
7.6 mm; 1.8 mm.
Bolt
8 Nm.
Refrigerant hose
From air conditioner compressor to condenser.
Bolt
15 Nm.
O-ring
10.8 mm; 1.8 mm.
Condenser
Removing
Chapter
.
Air conditioner compressor
With
air conditioning system magnetic coupling
N25
.
Repairing
air conditioning system magnetic coupling
N25
Chapter
.
An air conditioner compressor with no
air conditioning system magnetic coupling
N25
is installed in vehicles with engine code BAD. Notes
Chapter
.
O-ring
14.3 mm; 2.4 mm.
Bolts
20 Nm.
O-ring
10.8 mm; 1.8 mm.
High-pressure safety valve
Checking
Chapter
.
Air conditioning system magnetic coupling
N25
Manufacturer Sanden:
Repairing
air conditioning system magnetic coupling
N25
Chapter
.
Manufacturer Zexel:
Repairing
air conditioning system magnetic coupling
N25
Chapter
.