Volkswagen Amarok 2011 Workshop Manual
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Volkswagen Amarok 2011 Workshop Manual

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Service
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 Department. Technical Information

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Summary of Contents for Volkswagen Amarok 2011

  • Page 1 Service 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 ➤...
  • Page 2 Service 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 ➤...
  • Page 3 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2014 Volkswagen AG, Wolfsburg D4B8027068B...
  • Page 4 Service All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2014 Volkswagen AG, Wolfsburg D4B8027068B...

  • Page 5: Table Of Contents

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Contents 00 - Technical data ........... .
  • Page 6 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Purging (cleaning) refrigerant circuit with refrigerant R134a ......

  • Page 7: Technical Data

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 00 – Technical data General notes on air conditioning systems (VRL007231;...

  • Page 8: Basics Of Air Conditioning

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Basics of air conditioning 1.3.1 Physical basics: The four known physical states of water also apply to air condi‐...

  • Page 9: Vapour Pressure Table For Refrigerant R134A

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vapour pressure curve for water A - Liquid B - Gaseous...

  • Page 10: Refrigerant R134A

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Temperature in °C Pressure in bar (positive pres‐ sure) R134a 2.49...

  • Page 11: Characteristics Of Refrigerant R134A

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Different types of refrigerants must not be mixed with each other.
  • Page 12 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 1.6.4 Physical properties of R134a Because the vapour pressure curves of R134a and other refrig‐...

  • Page 13: Refrigerant Machine Oil

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 1.6.10 Detecting leaks External damage can cause leaks in the refrigerant circuit. Be‐...
  • Page 14 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Do not store refrigerant machine oils open to the atmosphere ♦...

  • Page 15: Comfort

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Comfort A basic requirement for concentrated and safe driving is the feel‐...

  • Page 16: General Safety

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 ditioner compressor on the refrigerant increases its heat content and its temperature. Its temperature is now considerably higher than that of the ambient air.
  • Page 17 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 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.
  • Page 18 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 • Do not throw pressure vessels! When falling, the containers may become severely deformed so that they may be torn open.

  • Page 19: Safety Precautions For When Working On Vehicles With Air Conditioning And When Handling

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 1.11 Safety precautions for when working on vehicles with air conditioning and when...

  • Page 20: Basics For Working On Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Under no circumstances may refrigerant be charged into systems or vessels containing air.
  • Page 21 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If the engine is being started for the first time after the refrig‐...
  • Page 22 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note When purging components with compressed air and nitrogen, ♦...

  • Page 23: General Information On Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 General information on refrigerant circuit Refrigerant circuit components Caution Non-authorised tools or materials (e.g. leak inhibitor additive) may cause damage or adversely influence the system.
  • Page 24 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.2 Air conditioning system compressor with magnetic clutch: The air conditioner compressor is driven by a V-belt from the en‐...
  • Page 25 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.3 Air conditioner compressor without magnetic clutch The air conditioner compressor is driven by a V-belt from the en‐...
  • Page 26 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.4 Air conditioner compressor without magnetic clutch, with elastic drive cou‐...
  • Page 27 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 WARNING The electrical air conditioner compressor requires a different refrigerant oil! For capacities, see workshop manual for specific vehicle.
  • Page 28 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.7 Evaporator The liquid refrigerant evaporates in the tubes of the evaporator.
  • Page 29 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.9 Restrictor The restrictor creates a restriction. This restriction limits the flow, separating the high-pressure and low-pressure sides in the re‐...
  • Page 30 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.11 Expansion valve 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.

  • Page 31: Design Of Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.1.14 High-pressure safety valve The high-pressure safety valve is fitted to the air conditioner com‐...
  • Page 32 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 WARNING Danger of freezing injuries. If refrigerant circuit has not been evacuated, refrigerant will escape.

  • Page 33: Switch And Sender In Refrigerant Circuit And Related Connections

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.3.3 Extraction and charging valve, low-pres‐ sure side Note Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS ♦...
  • Page 34 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.4.2 High-pressure switch for magnetic clutch - F118- Function: In the event of excess pressure in the refrigerant circuit, switches the air conditioner compressor off (at approx.
  • Page 35 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.4.5 Air conditioning system pressure switch - F129- This pressure switch has 3 functions: 1.

  • Page 36: Electrical Components Not Installed In Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 This refrigerant pressure and temperature sender - G395- is fitted in place of the high-pressure sender - G65- or air conditioning system pressure switch - F129- .
  • Page 37 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 This control unit switches the magnetic clutch and thus the air conditioner compressor on and off.

  • Page 38: Pressures And Temperatures In The Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 2.5.5 Evaporator output temperature sender - G263- or evaporator temperature sen‐...
  • Page 39 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Component Overall state Pressure (in bar) Temperature in degrees of the refriger‐...

  • Page 40: Refrigerant Circuit With Restrictor And Reservoir

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Component Overall state Pressure (in bar) Temperature in degrees of the refriger‐...
  • Page 41 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Component Overall state of Pressure (in bar) Temperature in degrees...

  • Page 42: Test And Measurement Work That Can Be Performed Using A Pressure Gauge

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note In vehicles with air conditioner compressor regulating valve - N280- , the pressure on the low-pressure side is varied by acti‐...

  • Page 43: Air Conditioner Service And Recycling Equipment

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note The dependency between pressure and temperature described on the pressure gauge no longer applies when there is no liquid and the pressure is created by gas alone.

  • Page 44: Notes To Repairs On Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Recommendation: When surplus refrigerant is transferred for one's own require‐...

  • Page 45: Statutory Texts And Instructions

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Statutory texts and instructions Statutes and regulations Note The laws and regulations listed below are valid in the Federal ♦...
  • Page 46 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 frigerant for vehicle air conditioning systems ) so that a proof of use document is available for presentation to the responsi‐...
  • Page 47 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note The Technical Rules for Compressed Gases (TRG), the Tech‐...
  • Page 48 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Supervised work may be done by persons who do not fulfil the requirements according to item 2.1, figures 1 and 2.
  • Page 49 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 ♦ Some regulations of the TRGS 407 do not (fully) apply to con‐...

  • Page 50: Recycling And Refuse Law

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Recycling and refuse law Note The laws and regulations listed below are valid in the Federal ♦...

  • Page 51: Converting R12 Refrigerant Circuits To R134A Refrigerant Circuits And Repairing Them (Retrofitting)

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Reference sources for technical rules and safety at work / acci‐...

  • Page 52: Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Refrigerant circuit Important repair notes on air condition‐ • Air conditioning systems designed for refrigerant R12 must not...

  • Page 53: Working With The Air Conditioner Service Station

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Working with the air conditioner serv‐ ice station Caution ♦ If there is evidence to suggest that chemical substances have been added in the vehicle to seal leaks, do not con‐...

  • Page 54: Important Notes For Working With The Air Conditioner Service Station

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Important notes for working with the air conditioner service station To operate the air conditioner service station - VAS 6007A- , the following must be observed (also applies to other and latest avail‐...

  • Page 55: Draining Refrigerant Circuit Using Air Conditioner Service Station

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Connect air conditioner service station to power supply. – Unscrew the sealing caps from the service connections, or unscrew the connections with the valve (see vehicle-specific refrigerant circuit).

  • Page 56: Evacuating Refrigerant Circuit Using Air Conditioner Service Station

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Connect air conditioner service station to service connections as described in the user's manual for the vehicle ⇒ Rep. gr.

  • Page 57: Charging Refrigerant Circuit Using Air Conditioner Service Station

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Connect the charging hose of the air conditioner service sta‐...

  • Page 58: Bringing Air Conditioning System Into Service After Charging

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Turn handwheel of quick-release coupling adapters outwards (close). – Allow refrigerant to flow into charging hose.

  • Page 59: Charging Container In Air Conditioner Service Station With Refrigerant

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Start with engine with air conditioner compressor switched off (if it is the type with a magnetic clutch).
  • Page 60 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 WARNING ♦ When charging recycling bottles (compressed gas con‐ tainers), observe existing regulations, technical rules and laws.

  • Page 61: Detecting Leaks In Refrigerant Circuit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Detecting leaks in refrigerant circuit Note Different processes are described in this workshop manual for ♦...

  • Page 62: Leak Detection In Refrigerant Circuit Using Compressed Air Or Nitrogen

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Volkswagen rejects the use of chemical substances for pur‐...
  • Page 63 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note A leak in the refrigerant circuit can be detected, for example, ♦...

  • Page 64: Searching For Leaks In Refrigerant Circuits Using Leak Detector V.a.g 1796

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Evacuating refrigerant circuit if necessary ⇒ page 49 – Evacuate refrigerant circuit and observe the vacuum gauge over a period of hours.

  • Page 65: Detecting Leaks In Refrigerant Circuit Using Leak Detecting System Vas 6196 Or Leak Detecting

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Detecting leaks in refrigerant circuit us‐ ing leak detecting system - VAS 6196-...
  • Page 66 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Injecting leak detecting additive to an empty refrigerant circuit The cartridge -A- contains 15.4 ml of leak detecting additive (one unit -B- equates to 2.5 ml).
  • Page 67 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 The leak detecting additive can be injected into the empty refrig‐...
  • Page 68 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Injecting leak detecting additive to a charged refrigerant circuit Note Note the following, if a leak detecting additive has been injec‐...
  • Page 69 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Close the service coupling and remove it from the service connection.
  • Page 70 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note The air conditioning system must be operated for at least ♦...

  • Page 71: Clearing Refrigerant Circuit Of Contaminants

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Clearing refrigerant circuit of contam‐ inants Blowing through refrigerant circuit with compressed air and nitrogen •...
  • Page 72 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Always blow through components opposite the direction of re‐...

  • Page 73: Purging (Cleaning) Refrigerant Circuit With Refrigerant R134A

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 7.1.1 Blowing out refrigerant circuit Note On vehicles where no adapters fit the refrigerant pipes, blow ♦...
  • Page 74 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 DANGER! Hazardous voltage resulting from damaged high-voltage com‐ ponents Observe the following when working in the vicinity of high-volt‐...
  • Page 75 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Caution ♦ If there is evidence to suggest that chemical substances have been added in the vehicle to seal leaks, do not con‐...
  • Page 76 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 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.
  • Page 77 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 adapter and charging hose - VAS 6338/31- from adapter case VW/Audi passenger vehicle set - VAS 6338/1- ) ⇒...
  • Page 78 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Before drilling out, some parts have to be removed from the ♦...
  • Page 79 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Two shut-off valves are required for purging the refrigerant ♦...
  • Page 80 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note The components must always be purged against the direction ♦...
  • Page 81 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note The purging process of the refrigerant circuit should be carried ♦...
  • Page 82 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Once the purging cycle is complete, check the sight glass (or sight glasses) for refrigerant circuits.
  • Page 83 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 7.2.1 Principle circuit diagrams for various purging circuits Note The arrows in the following illustrations show the direction of ♦...
  • Page 84 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 1 - Air conditioner service sta‐ tion ❑ With electronics and a purging programme e.g.
  • Page 85 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 10 - Evaporator 11 - Location of restrictor ❑ The restrictor is removed.
  • Page 86 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 1 - Air conditioner service sta‐ tion ❑ With electronics and a purging programme e.g.
  • Page 87 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 ❑ Different versions depending on vehicle ⇒ page 86 ❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .
  • Page 88 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 7.2.2 Purging electrical air conditioner com‐ pressor Vehicles with high-voltage system Observe the additional warning instructions for working on vehi‐...
  • Page 89 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 DANGER! Hazardous voltage resulting from damaged high-voltage com‐ ponents Observe the following when working in the vicinity of high-volt‐...
  • Page 90 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 amount of refrigerant oil from this electrical air conditioner com‐...
  • Page 91 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 1 - Air conditioner service sta‐ tion Note The air conditioner compressor is purged manually.
  • Page 92 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If the adapter - VAS 6338/40- is available, the charging hose can be connected directly to the air condi‐...
  • Page 93 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 ♦ Depending on the type of air conditioner compressor and the period of production, different joining and sealing techniques have been applied in the refrigerant circuit ⇒...
  • Page 94 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Block connections with various types of seals Block connection with radial sealing connection -A- (with guide made from plastic or metal -B-) –...
  • Page 95 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Lupo 1999 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 96 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 up! 2012; e-up! 2014 Vehicle Adapters re‐ Adapters required for Miscella‐...
  • Page 97 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Polo 1995 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 98 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Polo 2002 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 99 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Caddy 1996; Caddy 2004; Caddy 2011 Vehicle Adapters re‐ Adapters required for Miscella‐...
  • Page 100 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Polo 2010; Polo KH IN 2010; Polo KH IN 2015; Polo Lim IN 2011;...
  • Page 101 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Golf 1992; Vento 1992; Passat 1994 Vehicle Adapters re‐ Adapters required for Miscella‐...
  • Page 102 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Touran 2003; Golf 2004; Golf Plus 2005; Golf Plus 2009; Jetta 2005;...
  • Page 103 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Golf 2013; Golf Estate 2014; Golf 2014 (NAR); Golf SV 2015 Vehicle Adapters re‐...
  • Page 104 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Phaeton 2003 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 105 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Passat 1997 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 106 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Passat 2006; Passat CC 2009; CC 2010; Passat 2011; CC FL Vehicle Adapters re‐...
  • Page 107 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 108 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 109 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Sharan 2011 Note On vehicles with a 2nd evaporator (Sharan), the front and rear refrigerant circuit must be rinsed separately.
  • Page 110 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Touareg 2003; Touareg 2010; Touareg 2015; Touareg Hybrid 2010 Note On vehicles with a second evaporator (Touareg), the front and rear refrigerant circuit must be purged separately.
  • Page 111 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 112 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 113 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 114 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 115 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 116 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 117 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 118 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 119 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 120 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 121 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Amarok 2011 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 122 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Golf 2009 blue e-Motion Vehicle Adapters re‐ Adapters required for Miscella‐...
  • Page 123 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 124 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 e-Golf 2014 and e-Golf 2014 with heat pump Vehicle Adapters re‐...
  • Page 125 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Vehicle Adapters re‐ Adapters required for Miscella‐ quired for refrig‐...
  • Page 126 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Golf Hybrid 2014 Vehicle Adapters re‐ Adapters required for Miscella‐...
  • Page 127 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note In the Golf Hybrid 2014, the refrigerant circuit is flushed in 2 cy‐...

  • Page 128: Complaints

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Complaints Possible complaints about refrigerant circuit Note The air conditioning system is operating correctly if the air ♦...

  • Page 129: Smells From Heater And Air Conditioner Unit

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Noises (refrigerant hammering) occur immediately after the air conditioning is switched on and/or in a curve or when the brakes are applied: –...
  • Page 130 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Clean plenum chamber. – Use water so that it cannot flow out of plenum chamber.
  • Page 131 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 8.2.3 Spraying the evaporator with the suction feed spray-gun - V.A.G 1538- and spray...

  • Page 132: Connecting Air Conditioner Service Station

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Connecting air conditioner service station For vehicles that have connections on...

  • Page 133: Checking Pressures On Vehicles

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Checking pressures on vehicles 10.1 Checking pressures in refrigerant circuit...
  • Page 134 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 • With engine running and air conditioning set for maximum cooling output: ⇒...
  • Page 135 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note The temperature of the components of the refrigerant circuit ♦...

  • Page 136: Checking Systems With A Restrictor And Collector

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If the low-pressure switch had been removed in order to connect the air conditioner service station, bridge the electrical connec‐...
  • Page 137 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Switch pressures for switches in refrigerant circuit are vehicle- ♦...

  • Page 138: Compressor

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specification Possible cause of fault Rectifying fault •...
  • Page 139 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specification Possible cause of fault Rectifying fault •...
  • Page 140 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation Possible cause of fault Rectifying from specification fault •...

  • Page 141: Checking Systems With An Expansion Valve And Reservoir (With Internally Regulated Air Conditioner Compressor)

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Overfilling with refrigerant oil can occur if the refrigerant oil ♦...
  • Page 142 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Low-pressure side: Falling from starting pressure (when pressure gauge is connec‐...
  • Page 143 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation Possible cause of fault Rectifying from specification fault •...
  • Page 144 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If no fault can be determined and the function of the air condi‐...
  • Page 145 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If the air conditioning system is still not operating correctly after the refrigerant circuit has been purged with compressed air and nitrogen, the expansion valve must be renewed.
  • Page 146 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specification Possible cause of fault Rectifying fault •...

  • Page 147: Checking Systems With An Expansion Valve And Reservoir

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note ♦ If repeated check results in air conditioning system still not operating correctly, purge (clean) the refrigerant circuit ⇒...
  • Page 148 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 With the engine running and the air conditioning system set to full power, check the following points: •...

  • Page 149: Checking Systems With A Restrictor And Reservoir And Air Conditioner Compressor Regulating Valve N280 (With Externally Regulated Air Conditioner Compressor)

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 10.4.3 Specifications High-pressure side: Increasing from the pressure when the engine is stopped to a maximum of 20 bar positive pressure.
  • Page 150 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Low-pressure side: Falling from starting pressure (when pressure gauge is connec‐...
  • Page 151 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation Possible cause of fault Rectifying fault from specification •...
  • Page 152 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specifica‐ Possible cause of fault Rectifying fault tion •...
  • Page 153 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specifica‐ Possible cause of fault Rectifying fault tion •...

  • Page 154: Checking Systems With An Expansion Valve, Receiver And Air Conditioner Compressor

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specifi‐ Possible cause of fault Rectifying fault cation •...
  • Page 155 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Low-pressure side: Falling from starting pressure (when pressure gauge is connec‐...
  • Page 156 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation Possible cause of fault Rectifying fault from specification •...
  • Page 157 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation Possible cause of fault Rectifying fault from specification •...
  • Page 158 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specifica‐ Possible cause of fault Rectifying fault tion ♦...
  • Page 159 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note In this case, the evaporator may ice up although the correct ♦...
  • Page 160 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If this complaint occurs after a longer period of operation or ♦...
  • Page 161 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If the fault is “high pressure normal, low pressure too low ” note ♦...
  • Page 162 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Possible deviation from specifi‐ Possible cause of fault Rectifying fault cation ♦...
  • Page 163 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note If the defect is in the air conditioner compressor regulating ♦...

  • Page 164: With Expansion Valve, Receiver And Electrical Air Conditioner Compressor

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Note Overfilling with refrigerant oil can occur if the refrigerant oil ♦...

  • Page 165: Renewing Components

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Renewing components • All components of the refrigerant circuit submitted for quality monitoring must always be sealed (use the original sealing caps from the genuine part).

  • Page 166: In The Event Of Leaking Or Damaged Components (Apart From The Air Conditioner Compressor, Receiver Or Reservoir)

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 • The reservoir or receiver is damaged (e.g. in an accident).

  • Page 167: Renewing Air Conditioner Compressor

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Remove defective part, purge with compressed air and collect escaping refrigerant oil.
  • Page 168 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Then, remove as much refrigerant oil from the new air conditioner compressor as is necessary to ensure that only the same amount of refrigerant oil which has been purged from the old air condi‐...

  • Page 169: Renewing Receiver Or Reservoir, And Restrictor

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 11.2.2 Leaks or internal damage (e.g. noises or lack of power) –...
  • Page 170 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 – Rectify cause of fault. – Examine the expansion valve for dirt or corrosion; renew if necessary.

  • Page 171: Testing Equipment And Tools

    Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Testing equipment and tools 12.1 List of test equipment, tools and materi‐...
  • Page 172 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Overview page Purging device for refrigerant circuits - VAS ⇒ page 169 6336/1- , (other available refrigerant circuit purging devices ⇒...
  • Page 173 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Overview page Combination fine filter unit for compressed not illustrated air systems;...
  • Page 174 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 12.1.3 Tools to be made locally Overview page Charging hose with connector to the work‐...
  • Page 175 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Purging device for refrigerant circuits - VAS 6337/1- from “Behr”...
  • Page 176 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Leak detecting system VAS 6201 or later model Release tool - VAS 6127- case comprising release tool - VAS...
  • Page 177 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Counterhold - V.A.G 1616- for clutch pulley (for “Sanden” air con‐...
  • Page 178 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 ♦ M 18x1.5 V.A.G 1785/5 ♦ M 20x1.5 V.A.G 1785/6 ♦...
  • Page 179 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Charging hoses 5/8"-18 UNF valve Note Various colours of charging hose can be used, 1,800 mm long.
  • Page 180 Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ... Air conditioning system with refrigerant R134a - Edition 10.2014 Quick-release coupling adapter for service connection ♦ High-pressure side with nominal diameter of 16 mm ♦...

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