Volkswagen Passat 2012 Workshop Manual

Type
Workshop Manual
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Workshop Manual
Amarok 2011 , Beetle 2012 ,
Bora 1999 , CC 2010 , CC 2012 ,
Caddy 1997 , Caddy 2004 ,
Caddy 2011 ,
Caddy Kasten/Kombi 1996 ,
Caddy Pickup 1997 ,
California 2004 , California 2010 ,
Caravelle 2004 , Caravelle 2010 ,
Crafter 2006 , Eos 2006 ,
Fox 2005 , Golf 1992 , Golf 1998 ,
Golf 2004 , Golf 2009 ,
Golf 2013 , Golf Cabriolet 2012 ,
Golf Plus 2005 , Golf Plus 2009 ,
Golf Sportsvan 2015 ,
Golf Variant 1998 ,
Golf Variant 2007 ,
Golf Variant 2010 ,
Golf Variant 2014 , Jetta 2005 ,
Jetta 2011 , LT 1997 ,
Lupo 1999 , Lupo 3L 1999 ,
Multivan 2004 , Multivan 2010 ,
New Beetle 1999 ,
New Beetle Cabrio 2003 ,
Passat 1994 , Passat 1997 ,
Passat 2006 , Passat 2011 ,
Passat 2015 ,
Passat (NMS - US) 2012 ,
Passat CC 2009 ,
Passat Variant 1997 ,
Passat Variant 2011 ,
Service
Service Department. Technical Information
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Passat Variant 2015 , Phaeton 2003 ,
Polo 1995 , Polo 2002 ,
Polo 2010 , Polo 2014 ,
Polo Classic 1996 ,
Polo KH IN 2010 , Polo KH IN 2015 ,
Polo KH MY 2014 ,
Polo KH MY 2015 ,
Polo Lim IN 2011 ,
Polo Lim MY 2014 ,
Polo Lim RUS 2011 ,
Polo Variant 1998 , Scirocco 2009 ,
Scirocco 2015 , Sharan 1996 ,
Sharan 2011 , Tiguan 2008 ,
Touareg 2003 , Touareg 2010 ,
Touareg 2015 , Touran 2003 ,
Transporter 1996 ,
Transporter 2003 ,
Transporter 2004 ,
Transporter 2010 , XL1 2015 ,
e-Golf 2014 , e-up! 2014 ,
up! 2012
Air conditioning system with refrigerant R134a
Edition 10.2014
Service
Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of
Workshop Manual Repair GroupsList of Workshop
Manual Repair Groups
Repair Group
00 - Technical data
Technical information should always be available to the foremen and mechanics,
because their careful and constant adherence to the instructions is essential to
ensure vehicle road-worthiness and safety. In addition, the normal basic safety
precautions for working on motor vehicles must, as a matter of course, be
observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2014 Volkswagen AG, Wolfsburg D4B8027068B
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Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2014 Volkswagen AG, Wolfsburg D4B8027068B
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Basics of air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Characteristics of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Refrigerant machine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 How air conditioning works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.10 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 Safety precautions for when working on vehicles with air conditioning and when handling
refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.12 Basics for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Refrigerant circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Evacuation and charging valves for quick-release couplings of air conditioner service station
on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Switch and sender in refrigerant circuit and related connections . . . . . . . . . . . . . . . . . . . . 27
2.5 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6 Pressures and temperatures in the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Refrigerant circuit with expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.8 Refrigerant circuit with restrictor and reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Test and measurement work that can be performed using a pressure gauge . . . . . . . . . . 36
2.10 Air conditioner service and recycling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.11 Notes to repairs on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Statutory texts and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Statutes and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Recycling and refuse law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3 Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them
(retrofitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.4 Maintaining records on refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 Important repair notes on air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Retrofitting refrigerant circuit from R12 refrigerant to R134a refrigerant . . . . . . . . . . . . . . 46
5 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Important notes for working with the air conditioner service station . . . . . . . . . . . . . . . . . . 48
5.2 Connecting air conditioner service station for measuring and checking . . . . . . . . . . . . . . 48
5.3 Draining refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . . . . . 49
5.4 Evacuating refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . . . 50
5.5 Charging refrigerant circuit using air conditioner service station . . . . . . . . . . . . . . . . . . . . 51
5.6 Bringing air conditioning system into service after charging . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7 Charging container in air conditioner service station with refrigerant . . . . . . . . . . . . . . . . . . 53
5.8 Draining air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Detecting leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Leak detection in refrigerant circuit using compressed air or nitrogen . . . . . . . . . . . . . . . . 56
6.2 Searching for leaks in refrigerant circuits using leak detector V.A.G 1796 . . . . . . . . . . . . 58
6.3 Detecting leaks in refrigerant circuit using leak detecting system VAS 6196 or leak detecting
system VAS 6201 or a later model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Clearing refrigerant circuit of contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Blowing through refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . 65
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
Contents i
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7.2 Purging (cleaning) refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . 67
8 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.2 Smells from heater and air conditioner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9 Connecting air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.1 For vehicles that have connections on both low-pressure and high-pressure sides of
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
10 Checking pressures on vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.1 Checking pressures in refrigerant circuit (using air conditioner service station) . . . . . . . . 127
10.2 Checking systems with a restrictor and collector (with internally regulated air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.3 Checking systems with an expansion valve and reservoir (with internally regulated air
conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.4 Checking systems with an expansion valve and reservoir (without regulated air conditioner
compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating
valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . . . . . . . . . 143
10.6 Checking systems with an expansion valve, receiver and air conditioner compressor
regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 148
10.7 With expansion valve, receiver and electrical air conditioner compressor . . . . . . . . . . . . . . 158
11 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
11.1 In the event of leaking or damaged components (apart from the air conditioner compressor,
receiver or reservoir) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
11.2 Renewing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
11.3 Renewing receiver or reservoir, and restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
12 Testing equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
12.1 List of test equipment, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
ii Contents
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00 – Technical data
1 General notes on air conditioning
systems
(VRL007231; Edition 10.2014)
1.1 Introduction
This repair manual is intended to provide technicians and fitters
with the basic knowledge required for performing trained work on
these systems.
Note
Successful completion of a training course such as AB160 or
ST160 Air conditioning systems including "technical informa‐
tion" is required.
This repair manual is a part of the training material.
It should also be available to the responsible supervisory author‐
ities upon request.
Caution
Non-authorised tools or materials (e.g. leak inhibitor additive)
may cause damage or adversely influence the system.
Only tools and materials approved by the manufacturer may
be used.
Use of non-approved tools or materials will render the warranty
void.
1.2 Additional information
Technical Service Handbook with measures for rectifying lat‐
est malfunctions.
Workshop manual for service work specific to model Heat‐
ing, air conditioning; Rep. gr. 87 .
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
Self-study programme No. 208 is no longer up-to-date in some
sections. E.g. the statement “The receiver must be renewed
each time the refrigerant circuit is opened”. The following con‐
ditions apply ⇒ page 159
Video programs for staff training.
Catalogue of special tools / workshop testing.
Service Organisation Volume 1 Additional equipment.
Workshop manual for air conditioning system with R12 refrig‐
erant (for vehicles that were manufactured up to model year
1993). This workshop manual is only available as a hard copy.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 1
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1.3 Basics of air conditioning
1.3.1 Physical basics:
The four known physical states of water also apply to air condi‐
tioning refrigerants.
1 - Gas (invisible)
2 - Vapour
3 - Liquid
4 - Solid
When water is heated in a container (heat absorption), the rising
water vapour is visible. If the vapour is heated by further heat
absorption, the visible vapour becomes invisible gas. This proc‐
ess is reversible. If heat is extracted from gaseous water, it
changes first to vapour, then to water and finally to ice.
A - Heat absorption
B - Heat dissipation
1.3.2 Heat always flows from warmer to colder
material
Every material consists of a mass of moving molecules. The fast
moving molecules of a warmer material loose part of their energy
to slower molecules possessing less heat. This slows down the
molecules of the warmer material and accelerates those with less
heat. This continues until the molecules in both materials are
moving at the same speed. They have the same temperature, and
no further exchange of heat occurs.
1.3.3 Pressure and boiling point
The boiling points given in the table below are always based on
an atmospheric pressure of 1 bar. If the pressure on a liquid is
changed, its boiling point changes also.
It is well known that, for example, the lower the pressure, the lower
the temperature at which water boils.
The vapour pressure curves for water and for refrigerant R134a
show that at constant pressure and falling temperature the vapour
becomes liquid (in the condenser), and that when pressure drops,
the refrigerant changes from liquid into the vapour state (evapo‐
rator).
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
2 Rep. gr.00 - Technical data
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Vapour pressure curve for water
A - Liquid
B - Gaseous
C - Vapour pressure curve for water
1 - Pressure on the liquid in bar (absolute)
2 - Temperature in °C
Vapour pressure curve for refrigerant R134a
A - Liquid
B - Gaseous
D - Vapour pressure curve for refrigerant R134a
1 - Pressure on the liquid in bar (absolute)
2 - Temperature in °C
1.4 Vapour pressure table for refrigerant
R134a
The vapour pressure table for each refrigerant is published in the
literature for refrigeration engineers. This table shows the vapour
pressure exerted on the liquid column in the container for a given
temperature of the container.
Since a characteristic vapour pressure table is known for every
refrigerant, one can determine what refrigerant is present by
measuring pressure and temperature.
Note
Absolute pressure means that 0 bar corresponds to an absolute
vacuum. The normal ambient pressure (positive pressure) corre‐
sponds 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).
Temperature in °C Pressure in bar (positive pres‐
sure) R134a
-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00
-5 1.43
0 1.92
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 3
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Temperature in °C Pressure in bar (positive pres‐
sure) R134a
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6.70
35 7.83
40 9.10
45 10.54
50 12.11
55 13.83
60 15.72
65 17.79
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34
1.5 Refrigerant R134a
Air conditioners in vehicles use the evaporation and condensation
process. The system contains a liquid with a low boiling point,
called the refrigerant.
The refrigerant used is tetrafluoroethane R134a, which boils at
-26.5°C with vapour pressure of 1 bar.
1.5.1 Physical data of refrigerant R134a
Chemical formula CH2F–CF3 or CF3–CH2F
Chemical designation Tetrafluoroethane
Boiling point at 1 bar -26.5℃
Freezing point -101.6℃
Critical temperature 100.6℃
Critical pressure 40.56 bar (technical) pressure
equates to 39.5 bar (standard)
pressure
1.5.2 Critical point
Critical point (critical temperature and critical pressure) means the
point above which there is no longer a surface of separation be‐
tween liquid and gas.
Above its critical point, a substance is always gaseous.
At temperatures below the critical point, all types of refrigerant
contained within a pressure tank exhibit a liquid phase and a gas
phase, so that there is a gas cushion above the liquid.
As long as there is gas in the pressure vessel alongside the liquid,
the pressure depends directly on the ambient temperature
⇒ page 3 .
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
4 Rep. gr.00 - Technical data
Note
Different types of refrigerants must not be mixed with each other.
Only refrigerants specified for the respective air conditioning sys‐
tem may be used.
1.5.3 Environmental aspects of refrigerant
R134a
R134a is a fluorocarbon and contains no chlorine.
R134a has a shorter atmospheric persistence than refrigerant
R12.
R134a does not damage the ozone layer, the potential to re‐
duce the amount of ozone is zero.
The Global Warming Potential (GWP) of R134a lies by ap‐
prox. 1430 (the GWP for carbon dioxide lies by 1).
The contribution of R134a to the greenhouse effect is less by
a factor of 10 than that of refrigerant R12.
1.6 Characteristics of refrigerant R134a
1.6.1 Trade names and designations
Refrigerant R134a is currently available under the following trade
designations:
H-FKW 134a
SUVA 134a
KLEA 134a
Note
Other trade designations may be used in other countries.
Among the large selection of various refrigerants, only this one
may be used for vehicles. The designations Frigen or Freon
are trade names. They apply also to refrigerants which must
not be used in vehicles.
1.6.2 Colour
Like water, the refrigerant is colourless both in the vapour state
and the liquid state. Gases are invisible. Only the boundary layer
between gas and liquid is visible. (Fluid level in indicator tube of
charging cylinder for bubbles in sight glass.) Liquid refrigerant
R134a may appear coloured (milky) in a sight glass. This cloudi‐
ness is caused by partially dissolved refrigerant oil and does not
indicate a fault.
1.6.3 Vapour pressure
In an enclosed container that is not completely full, refrigerant
evaporates as vapour at the surface in a quantity sufficient to form
an equilibrium between vapour and liquid. This equilibrium de‐
velops under pressure and is often called vapour pressure. The
vapour pressure is temperature-dependant ⇒ page 3 .
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 5
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1.6.4 Physical properties of R134a
Because the vapour pressure curves of R134a and other refrig‐
erants are in part very similar, unique identification on the basis
of pressure alone is not possible.
The air conditioner compressor used for R134a is lubricated with
special synthetic refrigerator oils, such as PAG oils (polyalkylene
glycol oils).
1.6.5 Effects on metal
In its pure state, refrigerant R134a is chemically stable and does
not attack iron or aluminium.
However, impurities such as chlorine compounds in the refriger‐
ant do attack certain metals and plastics. This can lead to block‐
ages, leaks and deposits on the air conditioner compressor
piston.
1.6.6 Critical temperature and critical pres‐
sure
Up to a gas pressure of 39.5 bar positive pressure (corresponding
to a temperature of 101°C) the refrigerant R134a remains chem‐
ically stable; however, above this temperature the refrigerant
decomposes (see Combustibility).
1.6.7 Water content
Only very small amounts of water are soluble in liquid refrigerant.
On the other hand, refrigerant vapour and water vapour mix in
any proportion.
Any water present in the refrigerant circuit will be carried along as
droplets. The dryer, dryer bag or dryer cartridge in the receiver or
reservoir are capable of holding approx. 7 grams of water before
they are full and cannot absorb any more water. If there is further
water in the circuit, it will flow to the expansion valve jet or to the
restrictor and becomes ice.
The air conditioning system will stop cooling.
Water destroys the air conditioner because at high pressures and
temperatures it combines with other impurities to form acids.
1.6.8 Combustibility
Refrigerant is non-flammable. On the contrary, it has a fire-inhib‐
iting or fire-extinguishing effect. Refrigerant decomposes when
exposed to flames or incandescent surfaces. UV light can also
decompose refrigerants (UV is emitted by electric arc welding).
Products of this decomposition are poisonous and must not be
inhaled. However, these chemicals irritate the mucous mem‐
branes, giving adequate warning of their presence.
1.6.9 Charge factor
There must be space both for liquid and vapour in a container. As
the temperature rises, the liquid expands. The space occupied by
the vapour becomes smaller. Eventually, there will only be liquid
in the container. After that time, even a small increase in temper‐
ature will result in a very large increase in pressure, since the
liquid is seeking to expand further but there is no space for it to
do so. The resulting forces are sufficient to burst the container.
To prevent containers from being overcharged, regulations gov‐
erning the storage of compressed gases specify how many kilo‐
grams 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 the refrig‐
erants used in cars is 1.15 kg/l.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
6 Rep. gr.00 - Technical data
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1.6.10 Detecting leaks
External damage can cause leaks in the refrigerant circuit. Be‐
cause a small leak will involve only small quantities of refrigerant,
leaks should be checked for using an electronic leak detector or
by introducing a leak detection additive to the refrigerant circuit.
Electronic leak detectors can detect leakage rates of less than 5
grams loss of refrigerant per year. The leak detector should be
specific to the composition of the particular refrigerant in use. For
example, a leak detector for R12 refrigerant is not appropriate for
R134a refrigerant because R134a refrigerant has no chlorine
atoms to which the lead detector responds.)
1.7 Refrigerant machine oil
Refrigerant machine oil is miscible (approx. 20%–40% depending
on the type of air conditioner compressor and the quantity of re‐
frigerant) in the refrigerant. It circulates continuously in the circuit
and lubricates the moving parts.
Special synthetic refrigerant machine oils such as polyalkylene
glycol (PAG) oil are used in conjunction with R134a air condition‐
ing systems. This is necessary because ordinary mineral oils are
immiscible in R134a. In addition the materials of the R134a air
conditioning system could be attacked if the mixture circulated
within the refrigerant circuit under pressure and at high tempera‐
tures, or the lubricant film in the air conditioner compressor broke
down. The use of unapproved oils can lead to the failure of the air
conditioning system, so only approved oils must be used.
⇒ Parts catalogue
Type of oil for R134a in cars: PAG
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 7
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Note
Do not store refrigerant machine oils open to the atmosphere
since they are very hygroscopic (they readily absorb water).
Always keep oil containers tightly sealed.
Do not reuse used refrigerant machine oil.
Disposing of used oil: Volkswagen InfoNet; Operation; Man‐
uals and dealership documentation; Service handbook;
15. Environmental Protection; Follow link “Environmental pro‐
tection in the dealership and in the workshop” in "General
notes"; 4. Waste disposal; 6. Disposal channels; g. Disposal
of used oil; Refrigerant oils
Used refrigerant machine oils from systems with halogenated
hydrocarbons (at least one hydrogen atom has been replaced
by e.g the halogens fluorine, chlorine, bromine or iodine) must
be disposed of as waste requiring particular care. It is imper‐
missible to mix such oils with other oils or materials. Proper
storage and disposal must be performed according to guide‐
lines in the country where the work is being performed. Ob‐
serve, for example in the Federal Republic of Germany, the
climate protective regulation concerning chemicals; closed
substance cycle waste management and ensuring environ‐
mentally compatible waste disposal (in other countries other
statutes and regulations may apply)
Reference sources for technical rules and safety at work / ac‐
cident prevention for the Federal Republic of Germany
Sources in other countries may be obtained from the respon‐
sible authorities
Ester-based oils are suitable only for larger systems (not for
air conditioning systems in cars).
1.7.1 Properties of refrigerant oils
The most important properties are high solubility in refrigerants,
good lubrication characteristics, freedom from acid and very low
water content. For this reason, only certain oils may be used. A
list of approved refrigerant oils and quantities can be found in the
vehicle-specific workshop manuals in ⇒ Rep. gr. 00 or ⇒ Rep.
gr. 87 .
The PAG oils suitable for refrigerant R134a are strongly hygro‐
scopic and are immiscible with other oils. Therefore, opened
containers should be closed again immediately to protect them
from moisture. Refrigerant oils age under the influence of mois‐
ture and acids; they become dark, viscous and aggressive to‐
wards metals.
Note
For refrigerant circuits with refrigerant R134a, use only the oil
approved for the air conditioner compressor. See ⇒ Rep. gr.
00 or ⇒ Rep. gr. 87 in the repair manual for the specific ve‐
hicle.
Disposing of used oil: Volkswagen InfoNet; Operation; Man‐
uals and dealership documentation; Service handbook;
15. Environmental Protection; Follow link “Environmental pro‐
tection in the dealership and in the workshop” in "General
notes"; 4. Waste disposal; 6. Disposal channels; g. Disposal
of used oil; Refrigerant oils
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
8 Rep. gr.00 - Technical data
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1.8 Comfort
A basic requirement for concentrated and safe driving is the feel‐
ing of comfort in the passenger compartment. Especially when it
is hot and humid, comfort can be attained only through the use of
air conditioning. Of course, open windows, an open sunroof or
increased air ventilation can contribute to comfort, but they all
have certain disadvantages within the vehicle interior, such as
additional noise, draughts, exhaust gases, unfiltered entry of pol‐
len (unpleasant for allergy sufferers).
A well regulated air conditioning system in conjunction with a well
thought-out heating and ventilation system can create a feeling
of well-being and comfort by regulating the interior temperature,
humidity and rate of air change, regardless of the external con‐
ditions. This must be available whether the vehicle is moving or
not.
Other important advantages of air conditioning are
The cleansing of the air directed into the passenger compart‐
ment. (Dust and pollen, for example, are washed out by the
moist fins of the evaporator and carried off with the conden‐
sation water.)
Temperatures in a mid-range car (for example, after a short
period of driving, ambient temperature 30°C in the shade and
the vehicle in direct sunlight).
With air conditioning
system
Without air condi‐
tioning system
Head region 23℃ 42℃
Chest region 24℃ 40℃
Footwell 30℃ 35℃
1.8.1 Environmental aspects
Since about 1992, the air conditioning systems of newly manu‐
factured cars have been successively changed to refrigerant
R134a. This refrigerant contains no chlorine and thus does not
damage the ozone layer.
Up until about 1992, air conditioning systems were charged with
refrigerant R12. Due to its chlorine atoms, this CFC has a high
potential for destroying ozone and, in addition, a potential for in‐
creasing the greenhouse effect.
There are programs for exchanging old air conditioning systems
containing the ozone-damaging refrigerant R12.
⇒ Repair manual for air conditioning systems with refrigerant
R12 . This workshop manual is only available as a hard copy.
To protect the environment, no refrigerant should be released into
the atmosphere ⇒ page 39 (statutory texts and instructions).
1.9 How air conditioning works
The temperature in the passenger compartment depends on the
amount of heat radiated through the windows and conducted by
the metal parts of the body. In order to maintain comfortable tem‐
peratures for the occupants on very warm days, part of the
available heat must be pumped away.
Since heat spreads towards cooler bodies, a unit that can create
low temperatures is fitted in the vehicle interior. Refrigerant is
constantly being evaporated in it. The latent heat of evaporation
is taken from the air passing 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 con‐
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 9
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ditioner compressor on the refrigerant increases its heat content
and its temperature. Its temperature is now considerably higher
than that of the ambient air.
The hot refrigerant flows with its heat content to the condenser.
There the refrigerant looses its heat through the condenser to the
surrounding air due to the temperature gradient between the re‐
frigerant and the surrounding air.
Thus, the refrigerant is a means of heat transport. Because it will
be needed again, it returns to the evaporator.
All air conditioning systems basically depend on the circulation of
refrigerant. However, there are differences in the construction of
the system.
1.10 General safety
In accordance with VBG 20, the Federation of Employers Li‐
ability Insurance Associations.
Observe instructions specific to the workplace; Volkswagen
ServiceNet; Handbooks; Service handbook; Environmental
protection . Refrigerant from air conditioning systems / refrig‐
erant oils - to be displayed at refrigerant designated working
area.
1.10.1 Product characteristics
Refrigerants used in car air conditioning systems belong to the
new generation of refrigerants, the chlorine-free, partially-fluori‐
dated hydrocarbons (H-CFC, R134a).
In regard to their physical behaviour, they are refrigerants which
can be liquefied under pressure. They are subject to Regulations
for Pressure Tanks and may be charged only into approved and
identified pressurised gas containers.
Specific conditions which apply for safe and proper use must be
maintained.
1.10.2 Handling refrigerants
WARNING
Danger of freezing injuries.
The refrigerant can emerge as liquid or as vapour.
Do not open containers in which this refrigerant is present.
If refrigerant containers are opened, the contents may escape in
liquid or vapour form. The higher the pressure in the container,
the more energetic the emergence will be.
How high the pressure is depends on two factors:
What type of refrigerant is in the container. “This is because
the lower the boiling point, the higher the pressure.”
How high the temperature is. “This is because the higher the
temperature, the higher the pressure.”
1.10.3 Wear protective glasses
Put on protective glasses. This will prevent the refrigerant enter‐
ing the eyes, which in certain circumstances can cause severe
injury due to frostbite.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
10 Rep. gr.00 - Technical data
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1.10.4 Wear protective gloves and apron
Refrigerants dissolve fats and oils very well. Therefore, when they
come in contact with the skin, they take away the protective layer
of fat. Skin from which the natural oil and fat have been removed
is vulnerable to cold and germs.
1.10.5 Do not allow liquid refrigerant to come in
contact with the skin
The refrigerant will draw its latent heat of evaporation from its
surroundings. That can be your skin. This can result in very low
temperatures. The result is local frostbite (boiling point of R134a
is -26.5°C at normal atmospheric pressure).
1.10.6 Do not breath in refrigerant vapour
Note
In high concentrations, emerging refrigerant vapours can mix with
the air and displace the oxygen necessary for breathing.
1.10.7 Absolutely NO SMOKING
Refrigerant can decompose in a burning cigarette. The resulting
substances are poisonous and must not be breathed in.
1.10.8 Welding and soldering on refrigeration
systems
Before welding and brazing on vehicles (in the vicinity of the air
conditioning system components), extract the refrigerant and
then purge the system by blowing through with compressed air
and using nitrogen.
The products of decomposition of refrigerants under heat are not
only poisonous but are strongly corrosive, so that pipework and
system parts could be attacked. This refers primarily to hydrogen
fluoride.
1.10.9 Pungent smell
A pungent odour indicates that the products of decomposition
mentioned above are already present. Breathing in these sub‐
stances must be avoided under all circumstances, or the bron‐
chial tubes, lungs and other organs could be injured.
1.10.10 First aid
In the event of contact with the eyes or mucous membranes,
wash immediately with copious running water and summon an
eye specialist.
In the event of contact with the skin, remove wetted clothing
and wash the affected skin with copious water.
If refrigerant vapours are breathed in high concentrations, take
the patient immediately into the fresh air. Summon a doctor. If
the patient has trouble breathing, administer oxygen. If the
patient's breathing is restricted or stops, bend the head at the
neck and commence resuscitation.
1.10.11 Handling pressure tanks
Secure vessels against falling over!
Secure standing cylinders against falling over and lying cylinders
from rolling away.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 11
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Do not throw pressure vessels!
When falling, the containers may become severely deformed so
that they may be torn open. The refrigerant evaporates immedi‐
ately, releasing violent forces. Flying fragments of cylinders can
cause severe injuries.
Bottle valves can brake during improper transport. To protect cyl‐
inder valves, bottles may be transported only with protective
covers screwed on.
Do not place near radiators!
High temperatures can occur near radiators. Higher temperatures
however also mean higher pressures, which may exceed the rat‐
ed pressure of the vessel.
1.10.12 Do not heat above 50°C
To prevent danger, the Regulations for Pressure Tanks provide
that tanks shall not be heated to more than 50°C.
1.10.13 Do not apply uncontrolled heat
Do not heat with an open flame under any circumstance. The local
overheating that will result can change the structure of the con‐
tainer's materials, thereby reducing the safe maximum pressure
limit of the container. In addition, the danger arises that the re‐
frigerant decomposes due to localised overheating.
1.10.14 Seal empty containers
Empty refrigerant containers must in all cases be sealed so as to
prevent intrusion of moisture. Moisture causes steel containers to
rust. This weakens the walls of the containers. In addition, rust
particles which enter the refrigerant system from the container
cause malfunctions.
1.10.15 Safety instructions for using extraction
and charging equipment
Before connecting the charging system to the air conditioning
system, make sure that all existing shut-off valves are closed.
Before the charging equipment is decoupled from the air con‐
ditioning system, ensure that the process has finished. The
reason for this is to ensure that no refrigerant oil escapes into
the atmosphere.
After the cleaned refrigerant from the charging system has
been charged into an external pressurised gas cylinder, close
the hand shut-off valves on the bottle and the charging system.
Do not expose charging system to moisture or use it in a wet
environment.
Before performing service work and the charging system, dis‐
connect the current supply.
To reduce danger of fire, avoid using extension cords. If nev‐
ertheless it is necessary to use an extension cable, use an
extension cable with a cross-section of at least 2.5 mm
2
.
In case of fire, remove external cylinder.
If entrained oil from the air conditioning system suction accu‐
mulator is trapped in the measuring beaker supplied, be sure
subsequently to pour the oil into a container that can be
sealed, since the oil contains a small amount of refrigerant.
Refrigerants must not be released into the environment.
When the air conditioner service station is switched off, it must
be secured against rolling away.
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
12 Rep. gr.00 - Technical data
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1.11 Safety precautions for when working on
vehicles with air conditioning and when
handling refrigerant R134a
Air conditioning service station - VAS 6007A- (and further service
stations currently available)
⇒ Workshop equipment
WARNING
It is recommended that a bottle containing water be kept
at hand for purging out the eyes.
Should liquid refrigerant get into the eyes, thoroughly
purge the eyes with water for about 15 minutes. Then ad‐
minister eye drops and visit a doctor immediately even if
the eyes do not hurt.
The doctor must be informed that the frostbite has been
caused by refrigerant R134a. If, in spite of these safety
measures, refrigerant comes into contact with other body
parts, these areas must also be immediately purge with
cold water for at least 15 minutes.
Work on the air conditioning system refrigerant circuit in
well ventilated rooms only. Switch on exhaust gas fume
extractor (if there is one).
Refrigerant must not be stored in low-lying rooms (e.g.
cellars) or their stairways or window shafts.
Do not weld, braze or soft-solder any parts of the charged air
conditioning system. This also applies to welding and solder‐
ing work on the vehicle when the danger exists that parts of
the air conditioning system may heat up. During painting op‐
erations, temperatures of objects in the drying oven or in its
pre-heating zone must not exceed 80°C.
Reason:
Heating causes great excess pressure to develop in the system,
which can cause the pressure release valve of the system to
open.
Precautions:
Use the air conditioner service station to evacuate the refrig‐
erant circuit.
Note
Damaged or leaking components of the air conditioning system
must not be repaired by welding or soldering. They must always
be renewed.
Refrigerant containers (e.g. charging cylinders of air conditioner
service station) must never be subjected to excessive heat or ex‐
posed to direct sunlight.
Precautions:
Never charge a container completely with liquid refrigerant.
Without sufficient expansion space (gas cushion), the con‐
tainer will burst should the temperature rise, with devastating
consequences ⇒ page 5 .
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
1. General notes on air conditioning systems 13
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Under no circumstances may refrigerant be charged into systems
or vessels containing air.
Precautions:
Evacuate systems and containers before charging with refrig‐
erant.
1.12 Basics for working on refrigerant circuit
Observe instructions specific to the workplace; Volkswagen
ServiceNet; Handbooks; Service handbook; Environmental
protection . Refrigerant from air conditioning systems / refrig‐
erant oils - to be displayed at refrigerant designated working
area.
Observe the utmost cleanliness when working.
When handling refrigerants and nitrogen, wear protective
clothing, protective glasses and protective gloves.
Switch on exhaust gas fume extractor (if there is one).
Extract the refrigerant circuit using only the air conditioner
service station, and only then loosen the threaded joints and
renew the defective components.
Protect units and hoses against moisture and dirt using sealing
caps.
Use only tools and materials that are intended for use with
refrigerant R134a.
Protect refrigerant oil by sealing container to prevent ingress
of moisture.
Blow through refrigerant circuit with compressed air and nitro‐
gen ⇒ page 65 :
Purge refrigerant circuit with refrigerant R134a. ⇒ page 67
In vehicles that have an air conditioner compressor without a
magnetic clutch:
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...
Air conditioning system with refrigerant R134a - Edition 10.2014
14 Rep. gr.00 - Technical data
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Volkswagen Passat 2012 Workshop Manual

Type
Workshop Manual

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