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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
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