| Vehicles with high-voltage system (hybrid vehicles) |
| Observe the additional warning instructions for working on
vehicles with high-voltage system
→ Electrical system; Rep. gr.93. |
WARNING
| Risk of injury due to unexpected engine start |
| When working on a high-voltage vehicle, switch off
the ignition, and deposit the ignition key somewhere
outside the passenger compartment. |
|
WARNING
| Handling high-voltage cables: |
| l |
Do not support yourself or your tools on
high-voltage cables and their components --> risk of
damage to the insulation. |
| l |
High-voltage cables must not be extensively bent or
kinked --> risk of damage to the insulation. |
| l |
The round high-voltage connectors are colour-coded
with a coloured ring on the outside and mechanically
coded with respective guide lugs. Always observe the
coding when connecting the round high-voltage connectors
in order to prevent any mechanical damage to the
high-voltage connectors.
|
|
DANGER!
| Hazardous voltage resulting from damaged
high-voltage components |
| Observe the following when working in the vicinity
of high-voltage components and cables: |
| Work involving metal-removing, deforming and
sharp-edged tools or heat sources such as welding,
soldering, hot air and thermal bonding is not permitted. |
| Before starting work, carry out a visual check on
the high-voltage components in the area of work. |
| When working in the engine compartment, carry out a
visual check on the power and control electronics for
electric drive -JX1-, the electric drive motor -V141-,
the air conditioner compressor -V470- and the
high-voltage cables.
|
| When working on the underbody, carry out a visual
check on the high-voltage cables and covers. |
| When working on the rear end, carry out a visual
check on the high-voltage cables and the maintenance
connector for high-voltage system - TW -.
|
| Carry out a visual check on all potential
equalisation lines. |
| When carrying out the visual check, observe the
following: |
| The high-voltage components must not reveal any
external damage.
|
| The insulation of the high-voltage cables and the
potential equalisation lines must not be damaged. |
| The high-voltage cables must not show any unusual
deformations.
|
| Each high-voltage component must be clearly
identified with a red warning sticker. |
|
| If repair work in the vicinity of high-voltage components
and cables is necessary, “carry out a visual check for damage on
high-voltage components and cables”, and “observe the general
warning instructions for work on the high-voltage system”
→ Electrical system; Rep. gr.93. |
| If repair work on high-voltage components is necessary, de-energise
the high-voltage system
→ Electrical system; Rep. gr.93, and “observe the
general warning instructions for work on the high-voltage
system”
→ Electrical system; Rep. gr.93. |
Caution
| If there is evidence to suggest that chemical
substances have been added in the vehicle to seal leaks,
do not connect the air conditioner service station 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 conditioning system and cause the
air conditioning system (and your air conditioner
service station) to fail. |
| Make your customer aware of the fact that there are
substances in his/her air conditioning system that do
not have VW approval and therefore the refrigerant
circuit cannot be purged. The refrigerant circuit can
only be repaired by replacing all components that have
come into contact with this substance. . |
|
 Note
| Volkswagen rejects the use of chemical substances for
purposes of sealing leaks in refrigerant circuits. |
| Chemical substances used for sealing leaks in refrigerant
circuits often react with the surrounding air and the humidity
contained within. They cause deposits to build up in the
refrigerant circuit (and your air conditioner service station),
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 purging). The
refrigerant circuit can only be repaired by replacing all
components that have come into contact with this substance. |
| It is often not possible to detect from the outside whether
chemical substances have been used to seal leaks in the
refrigerant circuit. The adhesive label that serves to identify
its use can usually not be found. Therefore, exercise caution on
vehicles for which you have no service or repair record. |
| To work as cleanly as possible and avoid the task becoming
labour intensive when removing contaminants (e.g. friction dust
and particles from defective air conditioner compressor) and old
refrigerant oil, the refrigerant circuit must be purged using
refrigerant R134a. |
| On vehicles with electrical air conditioner compressor,
observe the notes on renewing the electrical air conditioner
compressor -V470-. If the electronics of the air conditioner
compressor are damaged, the refrigerant circuit does not always
need to be cleaned.
→ Chapter |
| The refrigerant circuit must be purged with refrigerant
R134a if: |
| Dirt or other contaminants are in the refrigerant circuit. |
| If during evacuation of a leak-tight refrigerant circuit the
vacuum display is not constant on gauge (moisture in the
refrigerant circuit, which generates vapour pressure). |
| If the refrigerant circuit has been left open for longer
than normally required for repairs (e.g. following an accident). |
| Pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the refrigerant
circuit. |
| There is doubt about the amount of refrigerant oil in the
refrigerant circuit. If the air conditioner compressor is to be
reinstalled, drain refrigerant oil out of air conditioner
compressor via the drain plug. To facilitate this process, turn
the air conditioner compressor over by hand at the poly V-belt
pulley or coupling disc of the magnetic coupling. After purging,
fill refrigerant circuit with total amount of refrigerant oil
(50 g direct into air conditioner compressor) according to
→ vehicle-specific workshop manual. Observe
additional oil requirements for systems with second evaporator. |
| The air conditioner compressor has to be exchanged because
of internal damage (e.g. noisy or no output). |
| the vehicle-specific repair manual deems it necessary after
replacement of certain components. |
| a different air conditioner compressor with other
refrigerant oil is to be fitted. |
| Air conditioner service station with purging device -VAS
6381- or air conditioner service station with purging device
-VAS 6337-. These air conditioner service stations feature an
additional function for “purging the refrigerant circuit with
R134a” and the purging device for refrigerant circuits necessary
for this procedure
→ Workshop equipment and special tools catalogue. |
| Adapter case VW/Audi passenger vehicle set -VAS 6338/1-
→ Chapter and
→ Workshop equipment and special tools catalogue. |
| Adapter case commercial vehicle set -VAS 6338/50-
→ Chapter and
→ Workshop equipment and special tools catalogue. |
Note
| If the above mentioned air conditioner service stations are
not available in the workshop, the rinsing device for
refrigerant circuits -VAS 6336/1- or rinsing device for
refrigerant circuits -VAS 6337/1- can be used to purge the
refrigerant circuit, depending on the type of air conditioner
service station in service (min. 7 kg refrigerant R134a in
refrigerant bottle). The purging process must then be carried
out manually
→ Anchor. |
| On vehicles with threaded connections on the refrigerant
circuit, adapter -V.A.G 1785/1- to adapter -V.A.G 1785/8- from
adapter case VW/Audi passenger vehicle set -VAS 6338/1- or
adapter case commercial vehicle set -VAS 6338/50- can be used.
On vehicles with threaded connections on the air conditioner
compressor and on the reservoir, the adapter -V.A.G 1785/8- is
required two-fold. |
| In the adapter case there is also a charging hose -VAS
6338/31- with 5/8 - 18 UNF connections and large internal
diameter to bridge components (commercially available type). |
| – |
Drain refrigerant circuit
→ Chapter. |
| – |
Remove air conditioner compressor
→ Heating, air conditioning. |
| On vehicles with restrictor and reservoir. |
| – |
Remove restrictor (vehicle-specific) and join the
refrigerant lines together again
→ Heating, air conditioning. |
| – |
Remove reservoir (vehicle-specific)
→ Heating, air conditioning and join refrigerant
pipes together again (to do this, use adapter and charging hose
-VAS 6338/31- from adapter case VW/Audi passenger vehicle set
-VAS 6338/1-)
→ Chapter. |
Note
| The collector could be purged but due to its large inner
volume it would require too much refrigerant. During extraction,
the refrigerant ices up the reservoir heavily and the extraction
procedure takes much longer as a result. |
| On vehicles with expansion valve and receiver. |
| – |
Remove the receiver
→ Heating, air conditioning (vehicle-specific, not
necessary on all vehicles) and join the refrigerant lines
together (use the adapter and the charging hose -VAS 6338/31- to
do this)
→ Chapter. |
| – |
Remove the expansion valve
→ Heating, air conditioning (vehicle-specific) and
insert an adapter in its place
→ Chapter. |
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
removed expansion valve can also be drilled out (the old
expansion valve must be subsequently renewed). |
Caution
| When drilling out, ensure that the sealing surfaces
on the expansion valve are not damaged. |
| Refrigerant would otherwise escape. |
|
Note
|
|
|
Blowing through refrigerant circuit with compressed air and nitrogen
Principle circuit diagrams for various purging circuits