SKODA Citigo 2012, Fabia III 2015, Octavia III 2013, Octavia III 2014, Rapid NH 2013 Workshop Manual
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Service
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Workshop Manual
Citigo 2012 ➤ , Fabia III 2015 ➤ ,
Oc
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Superb III 2015 ➤ , Yeti 2010 ➤ ,
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tavia III 2013 ➤ , Octavia III 2014 ➤ ,
Air conditioning system with refrigerant R1234yf
Edition 06.2016
Service Department. Technical Information
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List of Workshop Manual Repair Groups
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R
epa i r G r oup
00 - Technical data
87 - Air conditioning system
Service
Technical information should always be available to the foremen and mechanics, because their
careful
safety. 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 © 2016 ŠKODA AUTO a. s. D4B80655686
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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Contents
00 - Technical data
1 Safety instructions
1.1 Safety precautions when working on air Conditioning systems . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when handling AC service stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when handling pressurised containers . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Regulations and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Filling a refrigerant circuit with other refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Safety at work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Seals for the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Refrigerant and refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Handling pressurised containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Handling refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Information plate for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Filling capacities for refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Filling capacities for refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Technical and physical principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Principles of the air-conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Physical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Product features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4 Function and purpose of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Further sources of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
87 - Air conditioning system
1 Refrigerant circuit
1.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2 General description – components of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Possible complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.4 Identifying leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5 Replace components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.6 Clean the refrigerant circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.7 Checking pressures with the pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Working with the A/C service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Working with the A/C service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2 Connecting the AC service station to the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 79
2.3 Performing gas analysis for the refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.4 Exhaust refrigerant circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.5 Evacuating the refrigerant circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6 Filling the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.7 Operate the air conditioning system after filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.8 Switching off the AC service station and disconnecting it from the refrigerant circuit . . . . 94
2.9 Filling refrigerant into the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.10 Draining the A/C service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.11 Clean the refrigerant circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.12 Filling contaminated refrigerant into a recycling cylinder for analysis, treatment or disposal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Contents i
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2.13 Check pressures
3 Test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.1 Tools and materials available from the importer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.2 Tools and materials, which are commercially available . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.3 Tools that can be made instead of purchasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ii Contents
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00 – Technical data
1 Safety instructions
(SRL000969; Edition 06.2016)
⇒ “1.1 Safety precautions when working on air Conditioning sys‐
tems”, page 1
⇒ “1.2 Safety precautions when handling refrigerants”,
page 2
⇒ “1.3 Safety precautions when working on vehicles with a start/
stop system”, page 2
⇒ “1.4 Safety precautions when handling AC service stations”,
page 2
⇒ “1.5 Safety precautions when handling pressurised containers”,
page 3
1.1 Safety precautions when working on air Conditioning systems
DANGER!
Risk of death and explosion from ignition sources
Risk of death and explosion from ignition sources in proximity
of air conditioning systems and refrigerant containers. Escap‐
ing refrigerant can ignite and cause an explosion. Explosion
can cause death or serious injuries.
♦ Never bring ignition sources into the proximity of air con‐
ditioning systems and refrigerant containers.
♦ Avoid electrostatic discharge, sparks from the impact of
tools, and hot surfaces.
Caution
Risk of damage to the refrigerant lines
The refrigerant lines may be destroyed if the inner lining is torn.
♦ Never bend refrigerant line to a radius less than r =
100 mm.
1. Safety instructions 1
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1.2 Safety precautions when handling re‐
frigerants
DANGER!
Risk of suffocation and poisoning by refrigerant
Refrigerant vapours can cause coughing and nausea, as well
as suffocation and poisoning.
♦ Never inhale refrigerant vapours.
♦ Only work on the refrigerant circuit and store refrigerant
containers in well-ventilated spaces.
♦ Never work in the proximity of basements or above other
low-lying areas.
♦ Switch on the extraction system.
WARNING
Risk of frostbite from refrigerant!
Refrigerant may be ejected under pressure when you are
working on the air conditioning system. This may cause frost‐
bite on the skin and other parts of the body.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Evacuate the refrigerant circuit and immediately open the
refrigerant circuit.
♦ If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure builds up in the refrigerant cir‐
cuit as a result of secondary evaporation.
1.3 Safety
precautions when working on ve‐
hicles with a start/stop system
WARNING
Risk of injury if engine starts unexpectedly!
The engine may start up unexpectedly on vehicles with acti‐
vated start-stop system. To activate/deactivate the start-stop
system, see the ⇒ operating instructions .
♦ Deactivate start/stop system: Switch off ignition.
1.4 Safety precautions when handling AC service stations
• Before connecting the AC service station , make sure that the
applicable shut-off valves are closed.
• Before disconnecting the AC service station from the air con‐
ditioning system, make sure that the filling/extraction process
is complete.
• Once the cleaned refrigerant has been filled into an external
pressurised gas cylinder from the AC service station /extrac‐
2 Rep. gr.00 - Technical data
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tion system, the manual shutoff valves on the cylinder and the
filling system must be closed.
• Do not expose the AC service station /extraction and filling
system to humidity and do not use in a wet environment.
• Before performing maintenance on the AC service station ,
disconnect the power supply to the extraction and filling sys‐
tem.
• To reduce the risk of fire, avoid using an extension cable.
However,
a cross-section of at least 2.5 mm2.
• In case of fire, remove the external cylinder.
• If oil forced out of the air conditioning system by the suction
accumulator of the AC service station is into tapped off into the
supplied beaker, make sure that it is later poured into a seal‐
able container, because the oil contains a small quantity of
refrigerant. Refrigerant must not be allowed to enter the envi‐
ronment.
• Always secure the AC service station against rolling away.
AC service station with refrigerant R1234yf:
• Keep away from heat and direct sunlight and do not store or
use at temperatures above 50 °C.
• Do not store or use in the proximity of basements or other lowlying areas.
• Only store and use in areas with adequate ventilation (all air
replaced at least once per hour in workshops and three times
per hour in low-lying areas).
it an extension cable is necessary, use a cable with
1.5 Safety
precautions when handling pres‐
surised containers
DANGER!
Risk of death and explosion from ignition sources
Risk of death and explosion from ignition sources in proximity
of air conditioning systems and refrigerant containers. Escap‐
ing refrigerant can ignite and cause an explosion. Explosion
can cause death or serious injuries.
♦ Never bring ignition sources into the proximity of air con‐
ditioning systems and refrigerant containers.
♦ Avoid electrostatic discharge, sparks from the impact of
tools, and hot surfaces.
1. Safety instructions 3
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2 Laws and regulations
⇒ “2.1 Regulations and directives”, page 4
⇒ “2.2 Filling a refrigerant circuit with other refrigerants”,
page 5
⇒ “2.3 Safety at work”, page 5
2.1 Regulations and directives
Note
♦
The effects of the climate change can now be observed world‐
wide. The climate protection is therefore one of the most
important tasks of mankind. This task presents huge challeng‐
es for all the parties concerned.
♦
The global climate protection goals are defined, among other
things, in the so-called Kyoto Protocol. In this protocol are in‐
cluded carbon dioxide reduction targets as well as targets for
reducing fluorinated greenhouse gases such as for the refrig‐
erant R134a due to the high greenhouse potential.
A large number of relevant laws have been adopted for the auto‐
motive industry, e.g. at European level:
A number of regulations have been adopted by the European
Community that apply when handling refrigerants, including:
♦ Regulation (EC) No. 1005/2009
♦ Regulation (EC) No. 2037/2000
♦ Regulation (EU) No. 517/2014
♦ Regulation (EC) No. 706/2007
♦ Regulation (EC) No. 307/2008
♦ Directive 2006/40/EC
Note
Other or additional laws and regulations may apply in other coun‐
tries.
Maintenance and repairs to the refrigerant circuit of the air con‐
ditioning system
The refrigerant circuit of the air conditioning system may only be
repaired and serviced by personnel who meet the training re‐
quirements of Regulation (EC) No. 307/2008 (applies to countries
where the regulation is applicable; other laws or regulations may
apply in other countries).
In general the following applies:
Operation, maintenance, taking out of operation, take-back obli‐
gation:
♦ During the operation, when carrying out repair work and when
taking products out of operation that contain refrigerants, con‐
trary to the state of the art, it is prohibited to let those agents
escape into the atmosphere which are contained in these
products.
♦ Therefore it is recommended to keep records on the initial
quantity for the operation and maintenance work so that a
proof of use can be submitted at the request of the responsible
4 Rep. gr.00 - Technical data
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authority, if required. It is currently no longer a requirement to
keep a record sheet in the EC following a 2005 Regulation of
the European Parliament. Other regulations maybe valid in
countries that do not belong to the EC.
♦ Distributors of substances and preparations referred to in the
above regulations are required to take back such substances
and preparations after use or to ensure they are taken back
by a third party designated by them.
♦ Maintenance work on products and those products which are
taken out of operation that contain refrigerants, referred to in
the
above regulations, as well as take-back of the substances
and preparations referred to in these regulations, must only be
carried out by personnel with the required expertise (training
requirements) and technical equipment.
Recycling and Waste Act (Kreislaufwirtschaftsgesetz - KrWG)
and treatment and disposal of contaminated refrigerant and re‐
frigerant oil
The rules and regulations of the applicable country must be com‐
plied with.
2.2 Filling a refrigerant circuit with other re‐
frigerants
Air conditioning systems that have been developed and designed
for refrigerant R1234yf must not be filled with any other refriger‐
ant, e.g. R134a!
Note
Vehicles that are type-tested with refrigerant R1234yf must not
be filled with refrigerant R134a under current law!
2.3 Safety at work
♦ The refrigerant circuit of the air conditioning system may only
be repaired and serviced by personnel who meet the training
requirements of Regulation (EC) No. 307/2008 (applies to
countries
ulations may apply in other countries).
♦ Observe the instructions that apply at the workplace.
where the regulation is applicable; other laws or reg‐
2. Laws and regulations 5
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3 Repair notes
⇒ “3.1 Cleanliness rules”, page 6
⇒ “3.2 Seals for the refrigerant circuit”, page 6
⇒ “3.3 Refrigerant and refrigerant oil”, page 7
⇒ “3.4 Handling pressurised containers”, page 9
⇒ “3.5 Handling refrigerant”, page 10
3.1 Cleanliness rules
Even slight contamination can lead to defects, so that the follow‐
ing rules for cleanliness must be observed when working on the
air conditioning system:
♦ Open the open lines and connections immediately with a clean
plug, e.g. from the screw plug set for engine - VAS 6122- .
♦ Place removed parts on a clean surface and cover, using lint-
free cloths.
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Only unpack replacement parts im‐
mediately
stored unwrapped (e.g. in tool boxes etc.).
♦ When the system is open, do not use compressed air.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
prior to fitting. Do not use any parts which have been
3.2 Seals for the refrigerant circuit
♦ Only use seals that are resistant to refrigerant R1234yf and
applicable refrigerant oils. Seals can no longer be identified by
colour. Black and coloured seals are used, so only use seals
that can be definitely assigned ⇒ Electronic Catalogue of
Original Parts “ETKA”
♦ Seals that have been developed for refrigerant R134a are not
always suitable for refrigerant R1234yf, so only use seals that
can be definitely assigned ⇒ Electronic Catalogue of Original
Parts “ETKA”
♦ Only use seals once.
♦ Replace sealing rings after removal.
♦ Moisten sealing rings with the correct refrigerant oil before in‐
stallation.
♦ Make sure that the sealing rings are correctly seated on the
pipe or in the groove.
♦ Make sure you perform your work cleanly. Even the smallest
foreign object, such as a hair, may cause leaks.
♦ Only install sealing rings that are resistant to refrigerant
R1234yf and the applicable refrigerant oil. These sealing rings
may be marked with colour to avoid confusion ⇒ Electronic
Catalogue of Original Parts “ETKA” .
6 Rep. gr.00 - Technical data
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Dimensions -ais installed ⇒ Electronic Catalogue of Original Parts “ETKA” .
Further information and instructions:
⇒ “1.2.8 Gaskets”, page 36
and -b- vary depending on where the sealing ring
3.3 Refrigerant and refrigerant oil
⇒ “3.3.1 Important instructions for repairs involving refrigerant and
refrigerant oil”, page 7
⇒ “3.3.2 Refrigerant machine oil”, page 8
3.3.1 Important
instructions for repairs involv‐
ing refrigerant and refrigerant oil
• You must not fill refrigerant R1234yf into an air conditioning
system designed for refrigerant R134a.
• The refrigerant oils specifically developed for refrigerant cir‐
cuits
with refrigerants R1234yf or R134a may only be used in
a refrigerant circuit that is filled with the other refrigerant if cor‐
responding approvals have been obtained for this purpose ⇒
Electronic Catalogue of Original Parts “ETKA” and ⇒ Heating,
Air Conditioning; Rep. gr. 00 .
• AC service stations that come into contact with the refrigerant
must only be used for the intended refrigerant.
• An information plate -A- is attached in the engine compartment
at the lock carrier or in the plenum chamber, which indicates
the refrigerant that is used.
• Never mix different refrigerants.
• Depending on design and date of manufacture, this may also
indicate the GWP value of the refrigerant that is used.
• To ensure that only refrigerant R1234yf with a specific purity
is drawn into the R1234yf AC service station , a gas analysis
must be performed before the refrigerant circuit is emptied
⇒ “2.3 Performing gas analysis for the refrigerant”,
page 82 .
Note
If the gas analysis shows that the refrigerant R1234yf is conta‐
minated by another gas, it must be extracted from the refrigerant
circuit and analysed, treated or disposed of as a gas of unknown
composition in accordance with statutory provisions
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82 .
3. Repair notes 7
Page 12
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3.3.2 Refrigerant machine oil
WARNING
There is a risk of acid burns from atomised refrigerant oil. This
may injure the eyes or other parts of the body.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Never inhale atomised refrigerant oil.
♦ Refrigerant oil mixes (about 10-40 %, depending on the com‐
pressor
stantly circulates in the circuit and lubricates the moving parts.
♦ In combination with R1234yf air conditioning systems, special
synthetic refrigerant oils such as poly-alkyl-glycol (PAG) oil are
used with additives specifically selected for the refrigerant.
This is necessary because, for example, mineral oil does not
mix with R1234yf and undesirable reactions may occur with
the refrigerant circuit or the parts of the refrigerant circuit is
these additives are not added. In addition, the parts of the
R1234yf air conditioning system may be attacked if the mixture
flows through the refrigerant circuit under pressure and at high
temperatures or the lubricating film in the AC compressor
tears. The use of non-approved oils may cause the air condi‐
tioning system to fail, so only refrigerant oils approved for
refrigerant R1234yf may be filled ⇒ Electronic Catalogue of
Original Parts “ETKA” .
♦ Types of oil for refrigerant R1234yf in motor vehicles: PAG oil
with specific additives for refrigerant R1234yf (poly-alkyl-gly‐
col with specific additives)
♦ The main properties are a high dissolving power with refriger‐
ant, good lubricating properties, acid-free and very low water
content. For this reason, only very specific oils may be used;
for a list of approved refrigerant oils and filling capacities, see
⇒ Electronic Catalogue of Original Parts “ETKA” and ⇒ Heat‐
ing, Air Conditioning; Rep. gr. 00 (vehicle-specific workshop
manual).
♦ The PAG oils which are suitable for refrigerant R1234yf are
strongly hygroscopic and cannot be always be mixed with oth‐
er oils. Therefore, only use approved refrigerant oils.
♦ Refrigerant oil ages when exposed to humidity and acids; it
becomes dark, viscous and corrodes metals. Therefore, keep
containers of refrigerant oil closed to protect against penetrat‐
ing humidity; re-close opened containers immediately.
♦ Because of its chemical properties, refrigerator oil must not be
disposed of with engine oil or gearbox oil. Used refrigerant oil
of unknown origin must be disposed of (following local regu‐
lations) ⇒ Škoda-ServiceNet .
♦ For refrigerant circuits with refrigerant R1234yf, only oil ap‐
proved for the refrigerant and the installed air conditioning
compressor may be used ⇒ Electronic Catalogue of Original
Parts “ETKA” and ⇒ Heating, Air Conditioning; Rep. gr. 00 .
♦ Refrigerant oil developed for refrigerant R134a is not suitable
for refrigerant circuits with refrigerant R1234yf (lacks specific
additives).
♦ Refrigerant oil developed for refrigerant R1234yf may suitable
for refrigerant circuits with refrigerant R134a - see ⇒ Elec‐
type and refrigerant volume) with the refrigerant, con‐
8 Rep. gr.00 - Technical data
Page 13
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tronic Catalogue of Original Parts “ETKA” and ⇒ Heating, Air
Conditioning; Rep. gr. 00 .
Note
♦
Usage instructions for the refrigerant oil can be found on the
supply cylinder.
♦
The date can be ignored if the supply cylinder is sealed leaktight.
♦
Refrigerant oil from a sealed leak-tight supply cylinder can also
be used after the date specified on the supply cylinder.
Note
Keeps containers with refrigerant oil and the refrigerant circuit it‐
self closed at all times.
3.4 Handling pressurised containers
Keep containers tightly closed in a well-ventilated and cool loca‐
tion!
The refrigerant is heavier than air and therefore disperses along
the floor in particular when gas escapes.
Keep away from heat and direct sunlight and do not store at tem‐
peratures above 50 °C.
Do not store in the proximity of basements or other low-lying
areas.
Only store in areas with adequate ventilation.
Keep container away from sources of ignition!
Do not smoke where refrigerant R1234yf is present. Also take
precautionary measures to prevent static discharge.
Secure container against falling over!
Secure upright cylinders against falling and cylinders that are ly‐
ing down against rolling away!
Do not throw the reservoir!
When the reservoirs fall, they can become severely deformed
causing them to tear open. The refrigerant evaporates abruptly,
thus releasing considerable forces. Bottle parts which go flying
can cause serious injuries.
To protect the bottle valves, the bottles may only be transported
with the protective cap screwed on.
If improperly transported, the bottle valve can break off.
Do not place near radiators!
Increased temperatures can occur next to the radiators. Higher
temperatures also mean higher pressures, whereby the permis‐
sible pressure for the reservoir can be exceeded.
Do not heat above 50 °C.
To prevent hazard, the German Pressure Container Regulations
stipulate that containers with refrigerant must not be heated
above 50 °C.
3. Repair notes 9
Page 14
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Do not heat in an uncontrolled manner.
Under no circumstances heat on an open flame. Local overheat‐
ing
may cause structural changes in the material of the container,
which reduces the pressure of the container. Moreover, there is
the danger of refrigerant decomposition by local overheating.
Close and seal empty containers.
In any case, empty refrigerant reservoirs must be sealed to pre‐
vent any humidity from penetrating. Humidity leads to corrosion
of reservoirs made of steel. This weakens the wall of the reservoir.
In addition, rust particles that get into the refrigerant circuit from
the containers cause malfunctions in the circuit.
3.5 Handling refrigerant
Note
♦
The refrigerant has an almost imperceptible distinctive odour
and therefore you normally are not aware of it.
♦
The refrigerant gas is heavier than air, collect in low-lying
areas such as inspection pits, basement rooms and depres‐
sions, where it displaces the ambient air and therefore oxygen
as well. Storing the refrigerant in low-oxygen environments
can be life-threatening.
♦
If liquid refrigerant escapes e.g. because of a leak, it vaporises
at an ambient pressure of approx. 1 bar at around -29.4 °C. If
the refrigerant condenses on the skin, it causes cold burns or
frostbite. Sensitive parts of the body, such as the cornea of the
eyes and the mucous membranes are particularly at risk; se‐
rious cold burns can be life-threatening.
♦
Refrigerant gas is flammable; electrostatic discharge, sparks
from the impact of tools, hot surfaces and open flames can
ignite a mixture of the refrigerant R1234yf and the ambient air.
However, the refrigerant only burns in the present of a sup‐
porting flame or in the region of a hot surfaces; the refrigerant
flame extinguishes if, for example, the supporting flame is no
longer present.
♦
The refrigerant decomposes at a flame or in contact with a hot
surface. There is risk of poisoning if the poisonous products of
decomposition are inhaled. If the odour is pungent, then the
products of decomposition have already formed. It must be
avoided by all means to breathe in these substances, other‐
wise damage to the respiratory tract, lungs and other organs,
could be the consequence.
• Do not weld, braze or soft-solder any parts of the charged air
conditioning system. This rule holds for welding and soldering
work where there is the risk that parts of the Air Conditioning
may heat up. During paint repairs, the temperature of the ob‐
jects placed in the drying oven or in its pre-heating zone must
not exceed 80 °C.
Reason
Heat leads to high pressure in the system, which can cause the
system's pressure relief valve to open.
Precautions during repair work:
– Empty the refrigerant circuit with the AC service station
⇒ “2 Working with the A/C service station”, page 77 .
10 Rep. gr.00 - Technical data
Page 15
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Note
Damaged or leaky components of the air conditioning system
must not be repaired by welding or soldering, but must be re‐
placed.
Containers (e.g. filling cylinders for the AC service station ) with
refrigerant must never be overfilled, heated excessively or ex‐
posed to direct sunlight.
Reason
Refrigerant expands when heated.
Precautions:
– When filling and storing pressurised gas cylinders (reusable
and recycling cylinders etc.), the applicable regulations, tech‐
nical rules and laws must be observed.
– Never fill the containers completely with liquid refrigerant. With
sufficient expansion space (gas blanket) the container will
burst as the temperature rises with catastrophic consequen‐
ces
⇒ “6.2 Physical properties”, page 18 .
Under no circumstances should refrigerant be filled into systems
and containers that contain air.
Precautions:
– Evacuate
systems and containers before filling with refrigerant
⇒ “2 Working with the A/C service station”, page 77 .
3. Repair notes 11
Page 16
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4 Identification
⇒ “4.1 Information plate for refrigerant circuit”, page 12
4.1 Information plate for refrigerant circuit
♦ The information plate -A- provides information about the type
of refrigerator that is used, the volume of refrigerant filled in
production and the refrigerant oil that is filled.
♦ Symbols on the information plate -A- indicates the hazards
that may occur when handling the refrigerant and working on
the refrigerant circuit.
♦ It may also note the test and other standards. SAE J639 de‐
scribes the safety standards for automotive air conditioning
systems. SAE J842 describes that only components and ma‐
terials
approved for refrigerant R1234yf may be used and SAE
J2845 states that only trained and certified personnel may
perform repair or service operations on the refrigerant circuit
of the air conditioning system.
♦ Depending on design and date of manufacture, this may also
indicate the GWP value of the refrigerant that is used.
♦ The filling capacities specified on the information plate -A- and
the type of the refrigerant oil indicate the status at the date of
vehicle manufacture. The current values must always be taken
from the vehicle-specific workshop manuals ⇒ Heating, Air
Conditioning; Rep. gr. 00 (vehicle-specific workshop manual).
Note
Regardless of the information on the information plate -A-, coun‐
try-specific laws, regulations and standard must always be com‐
plied with. In the European Union, for example, this means the
applicable EC regulations.
12 Rep. gr.00 - Technical data
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5 Technical data
⇒ “5.1 Filling capacities for refrigerant”, page 13
⇒ “5.2 Filling capacities for refrigerant oil”, page 13
5.1 Filling capacities for refrigerant
The filling capacities for refrigerant R1234yf are provided in the
vehicle-specific workshop manual ⇒ Heating, Air Conditioning;
Rep. gr. 00 .
5.2 Filling capacities for refrigerant oil
The filling capacities for refrigerant oils are provided in the vehi‐
cle-specific workshop manual ⇒ Heating, Air Conditioning; Rep.
gr. 00 .
5. Technical data 13
Page 18
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6 Technical and physical principles
⇒ “6.1 Principles of the air-conditioning technology”, page 14
⇒ “6.2 Physical properties”, page 18
⇒ “6.3 Product features”, page 24
⇒ “6.4 Function and purpose of the air conditioning system”, page
24
⇒ “6.5 Further sources of information”, page 26
6.1 Principles of the air-conditioning tech‐
nology
⇒ “6.1.1 Physical principles of the air conditioning system”, page
14
⇒ “6.1.2 Pressure and boiling point of the refrigerant”, page 15
⇒ “6.1.3 Vapour pressure table for the refrigerant”, page 16
⇒ “6.2 Physical properties”, page 18
6.1.1 Physical principles of the air condition‐
ing system
The four known aggregate phases of water also exist for the re‐
frigerants of the air conditioning system.
1 - gaseous (not visible)
2 - vaporous
3 - liquid
4 - solid
14 Rep. gr.00 - Technical data
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If water is heated in a container (heat absorption) rising water
vapour
absorption, the visible vapour becomes invisible gas. The proce‐
dure is reversible. If the heat content is extracted from the gas‐
eous water -A-, this first creates vapour -B-, after which the vapour
turns into water and then into ice.
A - Heat absorption
B - Heat dissipation
Heat always flows from a warmer substance to a colder substance
Each substance consists of a mass of moving molecules. The fast
moving molecules of a warmer substance give up a part of their
energy to the molecules which are slower and have less heat.
This slows down the molecular movement of the warmer sub‐
stance and the molecular movement of the colder substance is
accelerated. This happens until the molecules of both substances
move with the same speed. They then have the same tempera‐
ture and no further heat exchange takes place.
is visible. If the vapour is heated even more through heat
6.1.2 Pressure and boiling point of the refrig‐
erant
The boiling point of a liquid as specified in the tables always refers
to the atmospheric pressure (1 bar absolute pressure). If the
pressure of a liquid changes, so does its boiling point.
Note
The pressure is stated in different units; 1 MPa (mega Pascal)
equals 10 bar overpressure or 145 psi; 1 bar absolute pressure
approximately equals the ambient pressure (atmospheric pres‐
sure) at 0 bar overpressure.
It is known, for example, that water boils at lower temperatures if
the pressure is lower.
Based on the vapour pressure curves for water and refrigerant
R1234yf, we can see, for example, that while maintaining pres‐
sure, by lowering the temperature, the vapour turns to liquid (in
the condenser), or that, for example, by reducing the pressure,
the refrigerant turns from the liquid state into the vapour state
(evaporator).
Vapour pressure curve of water
A - liquid
B - gaseous
C - Vapour pressure curve of water
1 - Pressure of the liquid in bar (absolutely)
2 - Temperature in °C
6. Technical and physical principles 15
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Vapour pressure curve of refrigerant R1234yf
A - liquid
B - gaseous
D - Vapour pressure curve of refrigerant R1234yf
1 - Pressure of the liquid in bar (absolutely)
2 - Temperature in °C
Note
The vapour pressure curves of the two refrigerants R1234yf and
R134a are very similar over a wide range of temperatures. The
different in pressure between the two refrigerants in the temper‐
ature range from 0 °C to +50 °C is just approx. 0.2 bar, for
example. It is therefore not possible to differentiate between the
two refrigerants on this basis
⇒ “6.1.3 Vapour pressure table for the refrigerant”, page 16 and
⇒ Air conditioning system with refrigerant R134a; Rep. gr. 00 .
It is only possible to differentiate by using appropriate sensors that
can analyse the chemical structure of the refrigerant
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23 .
6.1.3 Vapour
The vapour pressure table is decisive for each refrigerant used in
the literature for refrigeration technicians. From this table can be
read
which vapour pressure above the liquid column in the vessel
pushes when the temperature of the reservoir is known.
As for there is a known, characteristic vapour pressure table for
each refrigerant, it is possible to identify the refrigerants that have
different vapour pressure over a specific temperature range (not
applicable if differentiating R1234yf and R134a, which have very
similar vapour pressures
⇒ “6.1.2 Pressure and boiling point of the refrigerant”, page 15 )
by measuring the pressure and temperature.
pressure table for the refrigerant
16 Rep. gr.00 - Technical data
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Note
♦
This method of differentiation only applies to pure refrigerants
that have sufficiently different vapour pressures. If different
refrigerants are mixed to form a new refrigerant (e.g. 3 different
refrigerant to form refrigerant R407C), the vapour pressure is
calculated from the vapour pressures of the individual refrig‐
erants and their proportion in the mixture.
♦
At absolute pressure, “0 bar” corresponds to an absolute vac‐
uum. The normal ambient pressure (overpressure) corre‐
sponds to “1 bar” absolute pressure. On the scales of most
pressure gauges, “0 bar” corresponds to an absolute pressure
of one bar (recognizable by the indication “-1 bar” below “0”).
♦
The pressure is stated in different units; 1 MPa (mega Pascal)
equals 10 bar overpressure or 145 psi; 1 bar absolute pressure
approximately equals the ambient pressure (atmospheric
pressure) at 0 bar overpressure.
♦
The vapour pressures of the two refrigerants R1234yf and
R134a are very similar over a wide range of temperatures. It
is therefore not possible to differentiate the two refrigerants by
vapour pressure ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 . It is only possible to differentiate by using
appropriate sensors that can analyse the chemical structure
of the refrigerant
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23 .
Temperature in °C
-40 -0,40
-30 -0,01
-25 0,12
-20 0,50
-15 0,83
-10 1,21
-5 1,65
0 2,15
5 2,72
10 3,36
15 4,09
20 4,90
25 5,81
30 6,82
35 7,93
40 9,17
45 10,52
50 12,01
55 13,64
60 15,41
65 17,35
70 19,46
75 21,75
80 24,24
85 26,94
Pressure in bar (overpressure)
R1234yf
6. Technical and physical principles 17
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Temperature in °C Pressure in bar (overpressure)
R1234yf
90 29,09
6.2 Physical properties
⇒ “6.2.1 Refrigerant R1234yf”, page 18
⇒ “6.2.2 Potential hazards of refrigerant R1234yf”, page 18
⇒ “6.2.3 Physical and chemical properties of refrigerant R1234yf”,
page 19
⇒ “6.2.4 Critical point”, page 19
⇒ “6.2.5 Environmental aspects of refrigerant R1234yf”,
page 20
⇒ “6.2.6 Trade names and designations of refrigerant R1234yf”,
page 20
⇒ “6.2.7 Colour and odour of refrigerant R1234yf”, page 20
⇒ “6.2.8 Vapour pressure of refrigerant R1234yf”, page 20
⇒ “6.2.9 Physical properties of refrigerant R1234yf”, page 21
⇒ “6.2.10 Behaviour of refrigerant R1234yf in contact with metals
and plastics”, page 21
⇒ “6.2.11 Critical temperature/critical pressure of refrigerant
R1234yf”, page 21
⇒ “6.2.12 Water content of refrigerant R1234yf”, page 21
⇒ “6.2.13 Flammability/decomposition of refrigerant R1234yf”,
page 22
⇒ “6.2.14 Filling factor of refrigerant R1234yf”, page 22
⇒ “6.2.15 Evidence of leaks in a refrigerant circuit with refrigerant
R1234yf”, page 23
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23
6.2.1 Refrigerant R1234yf
♦ The evaporation and condensation process is the procedure
used for all air conditioning systems in vehicles. In this proc‐
ess, a substance (the refrigerant) is conveyed in a circuit in a
closed system.
♦ The process uses a substance with a low boiling point, which
is described as a refrigerant – in this case, R1234yf.
♦ The refrigerant R1234yf is known by various trade names (e.g.
HFO 1234yf, Opteon 1234yf etc.).
♦ Only approved refrigerant at the required purity may be used
for the air conditioning system
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23 .
♦ Refrigerant R1234yf is a halogenated hydrocarbon compound
with the chemical designation “2,3,3,3-Tetrafluoroprop-1ene”,
which boils at -29.4 °C and a vapour pressure of “1 bar”.
6.2.2 Potential
♦ The refrigerant is flammable at certain mixing ratios with am‐
bient air
⇒ “6.2.3 Physical and chemical properties of refrigerant
R1234yf”, page 19 and
⇒ “6.2.13 Flammability/decomposition of refrigerant R1234yf”,
page 22 .
hazards of refrigerant R1234yf
18 Rep. gr.00 - Technical data
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♦ Rapid evaporation of the liquid can cause frostbite.
♦ High concentrations of vapour can cause headaches, dizzi‐
ness, drowsiness, sleepiness and nausea and even loss of
consciousness.
6.2.3 Physical and chemical properties of re‐
frigerant R1234yf
The most important properties and safety instructions for refrig‐
erant
R1234yf are provided below. Comprehensive information is
provided on the applicable safety datasheets.
Chemical formula
Chemical designation 2,3,3,3-Tetrafluoroprop-1-en,
Boiling point at 1 bar -29.4 ℃
Solidification point -152.2 ℃
Critical temperature 94.7 ℃
Critical pressure 32.82 bar (overpressure)
Self-ignition temperature 405 °C at 1.02 bar (absolute
Flammability Flammable gas
Form Compressed, liquefied gas
Colour Colourless
Odour Weak distinctive odour
CF3CF=CH2
HFO-1234yf
33.82 bar (absolute pressure)
pressure)
♦ Lower explosion limit 6.2%
(volume)
♦ Upper explosion limit 12.3%
(volume)
6.2.4 Critical point
The critical point (critical temperature and critical pressure)
means that there is no divide over the same interface between
the surface of the liquid and the gas.
A substance is always gaseous when it is above its critical point.
At temperatures below the critical point, all types of refrigerants
in pressurised containers have a liquid and a gas phase, which
means that there is a gas blanket above the liquid.
As long as gas is still present in the tank aside from liquid, the
pressure depends upon the ambient temperature
⇒ “6.1.3 Vapour pressure table for the refrigerant”, page 16 .
Note
♦
The refrigerants used in motor vehicles must not be substitu‐
ted for each other. Only the refrigerant specified for the specific
air conditioning system may be used.
♦
The vapour pressures of the two refrigerants R1234yf and
R134a are very similar over a wide range of temperatures, so
that the vapour pressure cannot be used to differentiate be‐
tween the two refrigerants and ⇒ Air conditioning system with
refrigerant R134a, General description of the air conditioning
system . It is only possible to differentiate by using appropriate
sensors that can analyse the chemical structure of the refrig‐
erant ⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23 .
6. Technical and physical principles 19
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6.2.5 Environmental aspects of refrigerant R1234yf
♦ R1234yf is a fluorinated hydrocarbon (PFC) and does not con‐
tain chlorine.
♦ R1234yf has a shorted atmospheric life than refrigerant R134a
and therefore causes less of a greenhouse effect (has lower
global warming potential (GWP)).
♦ R1234yf does not attack the ozone layer – its ozone depletion
potential (ODP) is zero (as for R134a).
♦ The global warming potential (GWP) of R1234yf is 4 (the GWP
of carbon dioxide is 1).
♦ The contribution of R1234yf to the greenhouse effect is less
than
the contribution of refrigerant R134a by a factor of approx.
“350” (GWP of R134a is approx. 1400).
Note
The greenhouse effect of substances is calculated in relation to
the effect over a period of 100 years using various methods, which
produce different results (e.g. a GWP between 1300 and 1450 for
R134a).
6.2.6 Trade names and designations of refrig‐
erant R1234yf
Refrigerant R1234yf is currently available under the following
trade names:
♦ H-FKW 1234yf
♦ HFO 1234yf
♦ “Opteon yf” or “Solstice yf” (examples of company names)
Note
♦
In other countries, other trade names may also be common.
♦
Among the wide range of different refrigerants, only this re‐
frigerant should be used for automobiles. The designations
Frigen or Freon are trade names. They also apply to refriger‐
ants that are not intended to be used for motor vehicles.
6.2.7 Colour and odour of refrigerant R1234yf
♦ As vapour and liquid, the refrigerant is as colourless as water.
As
gas it is invisible. Only the boundary layer between the gas
and liquid is visible. (Fluid level in the standpipe of the filling
cylinder or bubbles in an inspection glass). In an inspection
glass, the liquid refrigerant R1234yf may appear coloured (mil‐
ky). This opacity arises from partially dissolved refrigerant oil
and does not indicate an error.
♦ The refrigerant is almost odourless. If refrigerant R1234yf es‐
capes, you may notice a slight ether-like odour, depending on
ambient conditions.
6.2.8 Vapour pressure of refrigerant R1234yf
In a partially filled and closed container, the refrigerant vaporises
on the surface to the same extent that it liquefies again when the
vapour particles concentrate. This balanced status is created un‐
der pressure and is frequently called vapour pressure. The vapour
20 Rep. gr.00 - Technical data
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pressure is temperature dependent
⇒ “6.1.3 Vapour pressure table for the refrigerant”, page 16 .
6.2.9 Physical properties of refrigerant R1234yf
♦ The vapour pressure curves of the two refrigerants R1234yf
and
R134a are very similar over a wide range of temperatures,
so that the vapour pressure cannot be used to differentiate
between the two refrigerants
⇒ “6.1.3 Vapour pressure table for the refrigerant”, page 16
and
⇒ Air conditioning system with refrigerant R134a, General
description of the air conditioning system . It is only possible
to differentiate by using appropriate sensors that can analyse
the chemical structure of the refrigerant
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23 .
♦ The air conditioning compressor with R1234yf is lubricated
with special synthetic refrigerant oils, such as PAG oils (polyalkyl-glycol
the air conditioning compressor and the operating conditions.
oils) with specific additives for refrigerant R1234yf,
6.2.10 Behaviour
of refrigerant R1234yf in con‐
tact with metals and plastics
♦ In pure form, refrigerant R1234yf is chemically stable and does
not attack e.g. iron and aluminium or suitable plastics devel‐
oped for use with the refrigerant.
♦ However, contamination of the refrigerant can cause the com‐
ponents
♦ Unsuitable materials (e.g. seals and hoses that have not been
developed for refrigerant R1234yf and the refrigerant oil that
is used) may also be attached and damaged by pure refriger‐
ant R1234yf or refrigerant oil.
♦ However, if there is contamination of the refrigerant, e.g. with
chlorine compounds or from UV light, metals and the plastics
developed and tested for this refrigerant and the applicable
refrigerant oil are attached. This may lead to choking, leaks or
other deposits on the AC compressor piston.
♦ Specific metals may be attached by refrigerant R1234yf (e.g.
finely dispersed aluminium, zinc and magnesium).
of the refrigerant circuit to be attacked and destroyed.
6.2.11 Critical temperature/critical pressure of refrigerant R1234yf
Up to a gas pressure of 32.82 bar overpressure (equivalent to a
temperature of 94.7 °C), the refrigerant remains chemically stable
and becomes liquid again when the vapour particles concentrate.
Above this temperature/pressure, there is no longer a separating
layer between liquid and gas.
6.2.12 Water content of refrigerant R1234yf
♦ Water is only soluble in very small quantities in the liquid re‐
frigerant. In contract, refrigerant vapour and water vapour mix
in any proportion.
♦ Any water that is present in the system is conveyed through
the refrigerant circuit as droplets, once the desiccator in the
fluid reservoir or AC reservoir has become saturated (has al‐
ready absorbed approx. 7 grams of water). This water flows to
the nozzle of the expansion valve or restrictor where it turns
to ice, and the air conditioning system ceases to provide cool‐
ing.
♦ If the water present at the control valve of the air conditioning
compressor turns to ice, a range of different problems may be
6. Technical and physical principles 21
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reported, depending on the design of the air conditioning com‐
pressor
air conditioning system cools so much that the evaporator ices
up).
♦ Water destroys the air conditioning system, as acids are pro‐
duced under high pressures and temperatures in combination
with other contamination.
(either the air conditioning system stops cooling or the
6.2.13 Flammability/decomposition of refriger‐
ant R1234yf
♦ Refrigerant R1234yf is flammable within certain concentra‐
tions in ambient air.
♦ Refrigerant R1234yf decomposes when brought into contact
with flames or scorching and red-hot surfaces. Refrigerant al‐
so decomposes when exposed to UV light (UV light is a part
of normal sunlight, but is also formed e.g. during electrical
welding), which produces poisonous products that must not
be inhaled. However, irritation of the mucous membranes is
sufficient warning in time.
♦ On decomposition, certain hazardous products, such as car‐
bon monoxide, hydrogen fluoride and/or hydrogen halide are
formed.
6.2.14 Filling factor of refrigerant R1234yf
♦ When filling pressurised gas cylinders (reusable and recycling
cylinders etc.), the applicable regulations, technical rules and
laws must be observed.
♦ You must always avoid overfilling the pressurised gas cylin‐
ders (reusable and recycling cylinders etc.). Overfilled pres‐
surised gas cylinders have too little a gas blanket to be able
to absorb the liquid expansion caused by the effect of the heat.
There is a risk of bursting.
♦ For your own safety, only use pressurised gas cylinder with a
safety valve fitted.
♦ Reusable and recycling cylinders must be weighed on a cali‐
brated scale when filling or, if filling by volume, you must make
sure that the permitted weight for filling that is specified on the
cylinder is not exceeded. The maximum permitted filling ca‐
pacity is 80% of the maximum refrigerant filling capacity of the
filling weight specified on the reusable or recyling cylinder or
70% of the maximum filling volume (filling factor; the lower
value always applies). Reasons: It is always possible that re‐
frigerant oil is also filled into the reusable or recycling cylinder,
as well as the refrigerant.
♦ The container must also include vapour space in addition to
the fluid space. As the temperature rises the fluid expands
(volume increases). The space filled with vapour becomes
smaller. At a given moment there will only be fluid left in the
reservoir. After this, only a minor temperature increase is re‐
quired to generate very high pressures in the reservoir as the
fluid can no longer expand because there is no more space.
The resulting forces are great enough to burst the reservoir.
In order to ensure a reservoir is not over-filled, the pressure
gas regulations stipulate how many kilos of refrigerant may be
filled per litre of inside volume of the reservoir. This filling factor
multiplied by the insides volume gives the permitted filling ca‐
pacity. It is 1.15 kg/litre for the refrigerant used in motor
vehicles.
♦ As contaminated refrigerant may have a different density than
pure refrigerant R1234yf, the maximum permitted filling factor
must always be observed.
22 Rep. gr.00 - Technical data
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6.2.15 Evidence of leaks in a refrigerant circuit with refrigerant R1234yf
♦ The refrigerant circuit may start leaking because of external
damage,
tested materials.
♦ Because of the small amount of leaked refrigerant, evidence
of minor leaks can be detected for example with an electronic
leak detector or leak detection additive which is filled into the
refrigerant circuit. Leaks with less than 5 grams of refrigerant
loss per year can be detected with the electronic leak detector.
For the different refrigerants, leak detectors are used which are
designed for the composition of the relevant refrigerant. For ex‐
ample, leak detectors for refrigerant R134a are not suitable for
R1234yf, which is why these leak detectors do not always re‐
spond. Refrigerant R1234yf has a different chemical structure to
R134a, so that the leak detectors do not respond or only respond
at higher concentrations of the refrigerant in air (see ⇒ Catalogue
of factory equipment ).
use of unsuitable or contaminated refrigerants or un‐
Note
6.2.16 Analysis of refrigerant R1234yf
The refrigerant that is used must have a certain purity to run the
air conditioning system.
Note
♦
The gas analysis may be incorrect if there is air in the refrig‐
erant hoses or the gas analysis procedure in the operating
instructions is not observed.
♦
Always carefully follow the operating instructions for the gas
analyser/ AC service station .
♦
Evacuate the refrigerant hoses of the AC service station be‐
fore connecting the service couplers to the refrigerant circuit/
a gas cylinder with refrigerant R1234yf (see operating instruc‐
tions for the gas analyser/ AC service station )
⇒ “2.3 Performing gas analysis for the refrigerant”,
page 82 .
Contamination with other refrigerants or gases can cause dam‐
age and therefore failure of the air conditioning system and the
AC service station .
Contaminated refrigerant must be analysed and then treated (or
disposed of) as a gas of unknown composition in accordance with
statutory provisions
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82 .
Note
Return contaminated refrigerant R1234yf to your refrigerant sup‐
plier for analysis.
For gas analysis, the following limits apply to clean refrigerant
R1234yf:
♦ The extracted refrigerant gas consists of at least 95% refrig‐
erant R1234yf.
6. Technical and physical principles 23
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♦ The proportion of other gases (oxygen, nitrogen, water vapour
and other refrigerants) is less than 5%.
Note
To make sure that liquid components (e.g. droplets of refrigerant
oil) in the extracted refrigerant gas does not cause the gas anal‐
ysis result to be false, filters are installed in the gas analyser to
filter out the droplets of liquid. Replace the filters as specified in
the operating instructions for the gas analyser or AC service sta‐
tion ⇒ Gas analyser operating instructions or ⇒ AC service
station operating instructions .
6.3 Product features
The refrigerant R1234yf which is used in the air conditioning sys‐
tems for motor vehicles is one of the new generation of refriger‐
ants based on chlorine-free hydrofluorocarbons.
In regards to their physical behavior, this relates to under pres‐
sure liquefied refrigerant. They are subject to the German Pres‐
sure
Container Regulations and must only be filled into approved
and marked pressurised gas cylinders.
6.4 Function and purpose of the air condi‐
tioning system
⇒ “6.4.1 Operating principle”, page 24
⇒ “6.4.2 Comfort”, page 24
⇒ “6.4.3 Environmental aspects”, page 25
6.4.1 Operating principle
♦ The temperature in the passenger compartment is influenced
by radiant heat through the window and by the contact heat
emitted by metallic parts. To provide agreeable temperatures
the passengers on very hot days, some of the ambient heat
for
must be pumped out.
♦ As heat dissipates towards colder temperatures, an unit that
generates low temperatures is installed in the passenger com‐
partment. Refrigerant is continuously evaporated in this evap‐
orator. The heat required for this operation is drawn from the
air flowing through the evaporator.
♦ The refrigerant with the absorbed heat is pumped out of the
evaporator by the AC compressor. Compression by the AC
compressor increases the heat content and the temperature
of the refrigerant. The temperature is now considerably higher
than the ambient air temperature.
♦ The high-temperature refrigerant and its heat content flow to
the condenser. As a result of the temperature difference be‐
tween the refrigerant and the ambient air, the refrigerant re‐
leases heat into the ambient air via the condenser.
♦ The refrigerant is also a heat conveyor. As it is still needed, it
is pumped back to the evaporator.
♦ For this reason, the basic principle of all air conditioning sys‐
tems is a circuit for refrigerants. Differences arise in the com‐
position of the units
⇒ “1.1 System overview - refrigerant circuit”, page 27 .
6.4.2 Comfort
♦ One of the basic requirements for a concentrated and safe
driving is the feeling of comfort in the vehicle interior. This
24 Rep. gr.00 - Technical data
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comfort is only possible through the use of an air conditioning
system,
especially in warm temperatures and at high humidity.
Open windows, an open sliding sunroof or a higher air flow
rate certainly contribute to the comfort, but there are disad‐
vantages for the vehicle interior, such as: additional noise,
draught, exhaust, unhindered infiltration of pollen and dust
(unpleasant for allergy sufferers).
♦ Through a controlled air conditioning system, in combination
with a well-designed heating and ventilation system, the feel‐
ing of well-being and comfort can be achieved by controlling
the indoor temperature, humidity and air movement, according
to the external conditions. This is possible when the vehicle is
stationary as well as when driving.
Further important advantages of the air conditioning system are:
♦ Air is dried in the passenger compartment (the ambient hu‐
midity condenses on the cold evaporator and is drained as
condensation water; the air is heated again to a preset tem‐
perature at the heat exchanger for heating, which reduces the
amount of water in the air and the absolute and relative hu‐
midity falls).
♦ Additional cleaning of the air drawn into the interior (the wet
fins of the evaporator, for example, wash out any dust or pollen
that has passed through the dust and pollen filter and extracts
the pollen with the condensation water).
♦ Temperatures in a midsize car (example: after a short period
driving, an outdoor temperature of 30 °C in the shade and the
vehicle under direct sunlight).
Head room 23 ℃ 42 ℃
with air conditioning
system
without air condi‐
tioning system
Chest 24 ℃ 40 ℃
Footwell 30 ℃ 35 ℃
6.4.3 Environmental aspects
♦ Refrigerant R134a does not contain chlorine and is therefore
ozone-friendly. Because of the high global warming potential
(GWP) of approx. 1400, however, it must no longer be used
in new type-tested vehicles from 2011. Vehicles type-tested
before 2011 may still be brought into circulation for the first
time with refrigerant R134a until 31/12/2016 (this applies to
countries
outside the EU).
♦ After 01/01/2011, only vehicles with a refrigerant with a GWP
below 150 in the refrigerant circuit of the air conditioning sys‐
tem shall be granted new type approval. Refrigerant R1234yf
has a GWP of approx. 4 and therefore is significantly below
the required value.
♦ From 2011, the air conditioning systems of newly manufac‐
tured motor vehicles have been gradually switched from re‐
frigerant R134a to refrigerant R1234yf. This refrigerant has a
global warming potential (GWP) of approx. 4. The GWP of
carbon dioxide is 1, so this refrigerant has a significantly lower
impact on the earth's atmosphere than refrigerant R134a.
♦ Vehicles that have been type-tested with refrigerant R134a
may still be filled with refrigerant R134a under current law until
such vehicles are taken out of service. There are therefore
currently no plans to switch air conditioning systems from re‐
frigerant R134a to refrigerant R1234yf.
in the EU – other regulations may apply in countries
6. Technical and physical principles 25
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♦ Refrigerant must not be released into the atmosphere, as it
damages the environment.
♦ Refrigerant R1234yf is chemically stable in a closed system.
However, in the earth's atmosphere is rapidly decomposes
under the influence of UV lights (within approx. 14 days) into
compounds
fore, GWP of 4).
that are not hazardous to the atmosphere (there‐
6.5 Further sources of information
♦ Workshop manual for type related repair work ⇒ Heating, Air
Conditioning; Rep. gr. 87 (vehicle-specific workshop manual)
and ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ Technical Service Handbook with instructions to correct cur‐
rent issues.
♦ Self-study and video programmes for occupational training.
♦ List of specific special tools and workshop equipment to repair
air conditioning systems ⇒ Electronic Catalogue of Original
Parts “ETKA” (tools; workshop equipment/tools; air condition‐
ing/heating).
♦ Instructions for disposing of refrigerant oil and contaminated
refrigerant are provided on ⇒ Škoda-ServiceNet .
26 Rep. gr.00 - Technical data
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87 – Air conditioning system
1 Refrigerant circuit
⇒ “1.1 System overview - refrigerant circuit”, page 27
⇒ “1.2 General description – components of the refrigerant cir‐
cuit”, page 29
⇒ “1.3 Possible complaints”, page 42
⇒ “1.4 Identifying leaks”, page 45
⇒ “1.5 Replace components”, page 55
⇒ “1.6 Clean the refrigerant circuit.”, page 61
⇒ “1.7 Checking pressures with the pressure gauge”, page 74
1.1 System overview - refrigerant circuit
Note
♦
The arrows point in the direction of flow of the refrigerant.
♦
The following illustration shows a refrigerant circuit with 2
evaporators and one internal heat exchanger as an example.
♦
The layout of the refrigerant circuit is vehicle-specific ⇒ Heat‐
ing, Air Conditioning; Rep. gr. 87 (vehicle-specific workshop
manual).
HP = High-pressure side
LP = Low-pressure side
1. Refrigerant circuit 27
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1 - Regulating valve for com‐
pressor
tem - N280-
2 - AC compressor
3 - Belt pulley
4 - Pressure relief valve
5 - Refrigerant pressure send‐
er
6 - Condenser (with fluid res‐
ervoir)
7 - Fluid reservoir
8 - Service connector on highpressure side
9 - Refrigerant pipe with inter‐
nal heat exchanger
10 - Expansion valve
11 - Evaporator
12 - Service connector on low-pressure side
of air conditioning sys‐
❑ Vehicle-specific designs
⇒ Heating, Air Condi‐
tioning; Rep. gr. 87
❑ Install on or in the con‐
denser ⇒ Heating, Air
Conditioning; Rep. gr.
87 (vehicle-specific
workshop manual)
❑ with desiccator car‐
tridge
❑ with end cap
❑ Evaporator at the front
of the heating and air
conditioning unit (instal‐
led under the dash‐
board)
❑ with end cap
28 Rep. gr.87 - Air conditioning system
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1.2 General description – components of the refrigerant circuit
⇒ “1.2.1 Arrangement and function of the refrigerant circuit”, page
29
⇒ “1.2.2 AC compressor”, page 29
⇒ “1.2.3 Condenser”, page 32
⇒ “1.2.4 Evaporator”, page 32
⇒ “1.2.5 Fluid reservoir”, page 34
⇒ “1.2.6 Expansion valve”, page 35
⇒ “1.2.7 Refrigerant pipe with internal heat exchanger”,
page 35
⇒ “1.2.8 Gaskets”, page 36
⇒ “1.2.9 Pipes and hoses of the refrigerant circuit”, page 36
⇒ “1.2.10 Pressure relief valve”, page 36
⇒ “1.2.11 Connections for quick couplers on refrigerant circuit”,
page 38
⇒ “1.2.12 Connections with valve for switches on refrigerant cir‐
cuit ”, page 40
⇒ “1.2.13 High-pressure sender G65 ”, page 40
⇒ “1.2.14 Pressure sender and switch on refrigerant circuit”, page
41
⇒ “1.2.15 Regulating valve for compressor of air conditioning
system N280 ”, page 41
1.2.1 Arrangement and function of the refrig‐
erant circuit
♦ The condenser and fluid reservoir are on the high-pressure
side, as well as the restrictor or expansion valve separating
the high-pressure side (HP liquid side) and the low-pressure
side (LP liquid side).
♦ The high pressure arises from the fact that the restrictor or
expansion
which leads to an increase in pressure and temperature.
♦ Too much high pressure arises if too much refrigerant or re‐
frigerant oil is added, the condenser is contaminated, the
radiator fan is defective, a blockage is present in the system
or if there is moisture in the refrigerant circuit (icing of the re‐
strictor or expansion valve).
♦ The evaporator and evaporator temperature sensor are on the
low-pressure side, as well as the AC compressor separating
the low-pressure side (LP gas side) from the high-pressure
side (HP gas side).
♦ A pressure drop in the system may occur as a result of loss of
refrigerant, if the restrictor or expansion valve (restrictions) is
defective or blocked, if the AC compressor is defective or the
evaporator is iced up.
valve creates a restriction and the refrigerant dams,
1.2.2 AC compressor
The AC compressor sucks refrigerant gas from the evaporator,
compresses it and transfers it to the condenser.
1. Refrigerant circuit 29
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Note
♦
The AC compressor contains refrigerant oil, which can mix
with refrigerant R1234yf at all temperatures.
♦
The identification plate indicates which refrigerant is suitable
for the AC compressor. A control valve controls the pressure
on the low-pressure side within the specified target range
(control characteristic) ⇒ Heating, Air Conditioning; Rep. gr.
87 .
♦
Depending on the design of the AC compressor, the AC com‐
pressor is filled with different refrigerant oils. Refrigerant oils
that have been developed exclusively for refrigerant R134a
must not be used for refrigerant R1234yf ⇒ Heating, Air Con‐
ditioning; Rep. gr. 00 .
♦
AC compressors with or without AC magnetic clutch - N25- are
currently actuated externally via an AC compressor regulating
valve - N280- -C- ⇒ Heating, Air Conditioning; Rep. gr. 87 .
♦
The name plate indicates which refrigerant is suitable for the
AC compressor.
♦
An AC compressor regulating valve - N280- controls the pres‐
sure on the low-pressure side within the specified target range
(control characteristic) ⇒ Heating, Air Conditioning; Rep. gr.
87 .
♦
On a vehicle with an AC compressor without AC magnetic
clutch - N25- , the engine must not be started if there is a vac‐
uum in the refrigerant circuit (e.g. when evacuating)
⇒ “2 Working with the A/C service station”, page 77 .
♦
On a vehicle with an AC compressor without AC magnetic
clutch - N25- , the engine may only be started if the refrigerant
circuit has been fully assembled.
♦
To prevent damage to the AC compressor when the refrigerant
circuit is empty, the AC compressor control valve, air condi‐
tioning system - N280- is not longer activated (the AC com‐
pressor runs at idling speed with the engine) if the pressure in
the refrigerant circuit is too low (less than approx. 2 bar).
♦
An AC compressor with AC compressor control valve, air con‐
ditioning system - N280- is switched to internal lubrication via
a valve if the refrigerant circuit is empty.
♦
Depending on the design of the AC compressor, a valve may
be installed on the high-pressure side of the AC compressor,
which prevents liquid refrigerant flowing back into the AC com‐
pressor after the air conditioning system has been switched
off. If an AC compressor with such a valve is installed in a
vehicle with a refrigerant circuit with expansion valve, it may
take a relatively long time until the pressure on the high-pres‐
sure side falls (the expansion valve is cold and the pressure
on the low-pressure side increases rapidly after switching off,
the expansion valve closes and the refrigerant circuit can only
flow slowly to the low-pressure side). If the AC compressor is
switched on, the pressure on the low-pressure side falls, the
expansion valve opens and the refrigerant can flow to the lowpressure side.
♦
For an AC compressor with electro-magnetic clutch -A- and a
control valve -C-, the electromagnetic clutch -A- is normally
only activated if the control valve -C- is activated ⇒ Heating,
Air Conditioning; Rep. gr. 87 .
30 Rep. gr.87 - Air conditioning system
Page 35
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AC compressor with AC magnetic clutch - N25- :
♦ When the air conditioning system is switched on, an electro‐
magnetic
clutch -A- mounted on the AC compressor generates
the traction between the belt pulley -B- and the compressor
crankshaft.
Note
To prevent damage to the AC compressor when the refrigerant
circuit is empty, the AC magnetic clutch - N25- is switched off and
the AC compressor regulating valve - N280- -C- is no longer ac‐
tuated.
AC compressor without magnetic coupling:
♦ Overload protection installed on the belt pulley or in the drive
unit of the AC compressor is triggered if the AC compressor is
difficult to move and thereby protects the belt drive against
overload.
♦ Externally controlled A/C compressors with variable displace‐
ment of piston. The displacement of the AC compressor is
controlled via an externally driven regulating valve with PWM
signal on the suction side in accordance with the required
cooling output.
♦ The AC compressor continues operating with a minimum pow‐
er supply requirement even when the air conditioning system
is off.
Belt protection for blocked A/C compressor (AC compressors
without magnetic coupling)
The AC compressor operates continuously via a driver clutch
-1- and -2- in the belt drive, whether or not the air conditioning
system is switched on.
If the AC compressor blocks, the rubber elements -2- will shear
off or the driver disc -1- will become deformed depending on the
compressor temperature (it depends on the temperature).
In any case the belt pulley of the AC compressor can rotate while
the driver disc/A/C compressor shaft is at a standstill.
Replace the AC compressor.
Note
The design of the driver clutch may differ depending on the com‐
pressor.
1. Refrigerant circuit 31
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1.2.3 Condenser
♦ The condenser -A- dissipates heat from the compressed re‐
frigerant gas to the ambient air.
♦ During this process the refrigerant gas condenses and lique‐
fies.
Note
♦
Depending on the design of the refrigerant circuit, the fluid
reservoir may be mounted on the condenser or installed (in‐
tegrated) in the condenser ⇒ Heating, Air Conditioning; Rep.
gr. 87 (vehicle-specific workshop manual) ⇒ Electronic Cata‐
logue of Original Parts “ETKA” .
♦
There are various different types of condenser that can be
identified externally from the part number. In type -1-, the con‐
denser is split into 2 sections “2-pass condenser”. In type -2-,
the condenser is split into 4 sections “4-pass condenser”.
♦
This illustration shows a condenser with attached fluid reser‐
voir -C-.
♦
The gaseous refrigerant enters the condenser at the connec‐
tion -A-, then the refrigerant is cooled in the condenser and
becomes liquid.
♦
The liquid refrigerant collects in the fluid reservoir -C- (with
desiccator) and flows to connection -B- over the cool section
beneath.
♦
Depending on the condenser design (inner volume, flow etc.),
the filling capacity for the refrigerant circuit in a refrigerant cir‐
cuit may vary. You should therefore always check that the type
and arrangement of the condenser is correct ⇒ Heating, Air
Conditioning; Rep. gr. 00 (vehicle-specific workshop manual
and ⇒ Electronic Catalogue of Original Parts “ETKA” ).
1.2.4 Evaporator
There are different types of evaporator. Depending on the design
and function, the heat required to evaporate the refrigerant (e.g.
the evaporator in the heating and air conditioning unit or in the
in
battery cooling module) is drawn from the air flowing through ⇒
Heating, Air Conditioning; Rep. gr. 87 (vehicle-specific workshop
manual).
Note
2 types of evaporator are described below.
32 Rep. gr.87 - Air conditioning system
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Evaporator in the heating and air conditioning unit
♦ The liquid refrigerant evaporates in the pipes of the evaporator
-A-. The heat required for this operation is drawn from the air
flowing through the evaporator fins
-B-. The refrigerant evap‐
orates and is sucked in with the absorbed heat as gas by the
AC compressor.
♦ An expansion valve (restrictor) supplies the evaporator with a
defined volume of refrigerant. In systems with expansion
valve, the flow rate is controlled so that refrigerant only comes
out of the evaporator's outlet in gas form.
♦ Following the introduction of refrigerant R1234yf, the evapo‐
rators have been adapted to the refrigerant, so make sure that
you select the correct type ⇒ Electronic Catalogue of Original
Parts “ETKA” .
1. Refrigerant circuit 33
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1.2.5 Fluid reservoir
♦ The fluid reservoir -B- collects the liquid drops and conveys
them to the expansion valve in a constant flow. Humidity that
has penetrated into the refrigerant circuit during assembly is
collected by a desiccator
♦ Depending on the design of the refrigerant circuit and type of
condenser -A-, the fluid reservoir -B- may be mounted on the
condenser -A- or installed (integrated) in the condenser ⇒
Heating, Air Conditioning; Rep. gr. 87 (vehicle-specific work‐
shop manual) ⇒ Electronic Catalogue of Original Parts “ET‐
KA” .
♦ The fluid reservoir -B- contains a desiccator (e.g. a desiccator
bag -D-) and a strainer -F- (which collects smaller contami‐
nants).
Note
♦
There are different types of fluid reservoir -B- with different
designs ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehiclespecific workshop manual and ⇒ Electronic Catalogue of
Original Parts “ETKA” ).
♦
Replace the fluid reservoir -B- or the plastic screw (with seals)
-C-, the desiccator cartridge -D-, the filter holder -E- and the
strainer -F- if the refrigerant circuit has been open for a longer
period of time and humidity has penetrated or if necessary be‐
cause of a specific issue
⇒ “1.5 Replace components”, page 55 .
♦
Remove the plugs on a fluid reservoir only just before instal‐
lation, because the desiccator bag in an open fluid reservoir is
saturated with humidity and becomes unusable after a short
time.
♦
Keep the air-sealed delivery bag with the desiccator cartridge
closed for as long as possible. Only open the delivery bag just
before you install the desiccator cartridge -D- in the fluid res‐
ervoir -B- of the condenser. After the delivery bag is opened,
the desiccator cartridge is saturated by the humidity in the
ambient air after a short time and is then unusable.
♦
If necessary, observe the arrow for the direction of flow when
installing.
♦
The procedure in the event of a complaint varies depending
on the type of fluid reservoir/desiccator cartridge. If the fluid
reservoir is e.g. mounted on the condenser, it can be replaced
completely together with the desiccator cartridge. If the fluid
reservoir is e.g. integrated onto the condenser, the fluid res‐
ervoir and any other additional filter element can be replaced
separately for most types of dessicator cartridge. If the fluid
reservoir is integrated in the condenser and it is not possible
to replace the fluid reservoir or desiccator cartridge separately,
the entire condenser must be replaced ⇒ Heating, Air Condi‐
tioning; Rep. gr. 87 (vehicle-specific workshop manual) and
⇒ Electronic Catalogue of Original Parts “ETKA” .
♦
Depending on the design of the refrigerant circuit, the fluid
reservoir (with desiccator bag or desiccator cartridge) may al‐
so be integrated in the refrigerant circuit (it does not always
have to be installed on or in the condenser) ⇒ Heating, Air
Conditioning; Rep. gr. 87 (vehicle-specific workshop manual)
and ⇒ Electronic Catalogue of Original Parts “ETKA” .
-D- in the fluid reservoir -B-.
34 Rep. gr.87 - Air conditioning system
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1.2.6 Expansion valve
The expansion valve -A- atomises incoming refrigerant and reg‐
ulates the flow so that, depending on the heat conveyed, the
vapour does not become a gas until it reaches the outlet of the
evaporator.
Note
♦
Following the introduction of refrigerant R1234yf, the expan‐
sion valves have been adapted to the refrigerant (different
characteristics), so make sure that you select the correct type
⇒ Electronic Catalogue of Original Parts “ETKA” .
♦
There are different types of expansion valve because of the
different characteristics that are adapted to the specific refrig‐
erant circuit ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehiclespecific workshop manual) and ⇒ Electronic Catalogue of
Original Parts “ETKA” .
♦
When replacing the expansion valve, make sure that the part
number is correct ⇒ Electronic Catalogue of Original Parts
“ETKA” .
♦
Depending on the design of the AC compressor, a valve may
be installed on the high-pressure side of the AC compressor,
which prevents liquid refrigerant flowing back into the AC com‐
pressor after the air conditioning system has been switched
off. If an AC compressor with such a valve is installed in a
vehicle with a refrigerant circuit with expansion valve, it may
take a relatively long time until the pressure on the high-pres‐
sure side falls (the expansion valve is cold and the pressure
on the low-pressure side increases rapidly after switching off,
the expansion valve closes and the refrigerant circuit can only
flow slowly to the low-pressure side). If the AC compressor is
switched on, the pressure on the low-pressure side falls, the
expansion valve opens and the refrigerant can flow to the lowpressure side.
1.2.7 Refrigerant pipe with internal heat ex‐
changer
♦ In this refrigerant line, the liquid warm refrigerant flowing on
the high-pressure side loses energy to the cold gaseous re‐
frigerant or refrigerant vapour flowing on the low-pressure
which increases the efficiency of the air conditioning sys‐
side,
tem.
A - Refrigerant pipe with internal heat exchanger
B - Channels in the refrigerant circuit, in which the warm liquid
refrigerant flows to the evaporator (high-pressure side of the re‐
frigerant circuit).
C - Channel in the refrigerant line, in which the cold gaseous re‐
frigerant or refrigerant vapour flows to the AC compressor (lowpressure side of the refrigerant circuit)
1. Refrigerant circuit 35
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1.2.8 Gaskets
♦ These seals seal off the connection points between the indi‐
vidual components of the refrigerant circuit
⇒ “3.2 Seals for the refrigerant circuit”, page 6 .
1.2.9 Pipes
♦ In pure form, refrigerant R1234yf is chemically stable and does
not attack e.g. iron and aluminium or suitable plastics devel‐
oped
for use with the refrigerant. The mixture of refrigerant oil
and refrigerant R1234yf can attack certain metals (e.g. alloys
of copper) and attack/release certain hose materials and plas‐
tics. Therefore, only use original spare parts ⇒ Electronic
Catalogue of Original Parts “ETKA” .
♦ Only use components that are resistant to refrigerant R1234yf
and applicable refrigerant oils. Do not use components (such
as seals and hoses that are made of plastic) that cannot be
definitely assigned ⇒ Electronic Catalogue of Original Parts
“ETKA” .
♦ The pipes and hoses are held together by bolted or other types
of connection ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehi‐
cle-specific workshop manual).
♦ Replace the sealing elements (e.g. seals) between the com‐
ponents ⇒ Electronic Catalogue of Original Parts “ETKA” .
♦ For bolted connections, note the specific torques; for plug
connections, use the correct release tools ⇒ Heating, Air Con‐
ditioning; Rep. gr. 87 (vehicle-specific workshop manual).
and hoses of the refrigerant circuit
1.2.10 Pressure relief valve
The pressure relief valve is attached to the AC compressor or fluid
reservoir.
At a pressure of approx. 38 bar (excess pressure), the valve
opens, then closes again when the pressure has dropped (at ap‐
prox. 35 bar).
The refrigerant does not flow out completely.
36 Rep. gr.87 - Air conditioning system
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Note
♦
Depending on the design, there may be a transparent plastic
washer -B- on the pressure relief valve -A-, which pops out as
soon as the valve is triggered.
♦
Depending on the design of the pressure relief valve -A-, there
may also be a cover -C-, which is slid onto the pressure relief
valve -A-. If the pressure in the refrigerant circuit in fact rises
above the opening pressure of the pressure relief valve -Aand the pressure relief valve opens, the refrigerant does not
escape in one direction, but is divided between the openings
-D- under the cover -C- as it escapes.
1. Refrigerant circuit 37
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1.2.11 Connections for quick couplers on re‐
frigerant circuit
Service connectors with Schrader valve (needle or push pin)
♦ Only use valves and connections that are resistant to refrig‐
erant R1234yf and applicable refrigerant oils.
♦ The service connectors -C- and -F- on a R1234yf refrigerant
circuit are designed so that service couplers designed for the
service connectors of a R134a refrigerant circuit cannot be
connected.
♦ There are different connections (outside diameter) for the
high-pressure and low-pressure side (
♦ Before removing the valve or valve cores -B- and -E-, empty
the refrigerant circuit.
♦ Screw on end caps -A- and -D- with seal -G- completely.
Arrangement in the vehicle ⇒ Heating, Air Conditioning; Rep. gr.
87 (vehicle-specific workshop manual).
– Extract refrigerant before unscrewing and removing the
valves.
♦ Service connector on low-pressure side -F♦ Service connector on high-pressure side -C♦ Valve core (The designation: Schrader or needle valve)
♦ End cap for service connector on low-pressure side with seal
-A-
♦ End cap for service connector on high-pressure side with seal
-D-
-C- and -F-).
38 Rep. gr.87 - Air conditioning system
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Note
♦
Carefully screw in the handwheel of the service coupler after
connecting and only into the quick coupler adapter until the
valve in the service connector is definitely open (watch the
pressure gauge, do not apply excess pressure to the valve).
♦
The service connectors on a R1234yf refrigerant circuit are
designed so that the service couplers designed for the service
connectors of a R134a refrigerant circuit cannot be connected.
♦
The service connectors, for example, are soldered into the re‐
frigerant line and therefore cannot be replaced individually.
♦
Use e.g. an adapter from the socket insert - T10364- to remove
and install the valve core on an empty refrigerant circuit.
♦
Only tighten the valve core slightly, as the required tightening
torque is low.
♦
These valves come in different designs and therefore have
different tightening torques. A valve core -C- with a VG5 thread
(5.2 x 0.7 mm, tyre valve) has a tightening torque of 0.4±0.1
Nm; a valve core with an M6 x 0.75 mm thread has a tightening
torque of 0.9±0.1 Nm and a valve core with an M8 x 1.0 mm
thread has a tightening torque of 2.0±0.2 Nm.
♦
These valve caps come in different designs and therefore
have different tightening torques. A valve cap with an M8 x 1
mm or M10 x 1 mm thread has a tightening torque of 0.4 Nm
± 0.1 Nm.
♦
These valves, valve cores and applicable end caps comes in
different designs. Make sure you are using the correct type of
valve core and that the screw cap is correct ⇒ Electronic
Catalogue of Original Parts “ETKA” .
Dimensions of the service connectors
♦ Valve core -A- (different designs)
♦ Service connector -B- (different designs for high- and low-
pressure sides, depending on refrigerant)
Dimensions of the
service connectors
-B-
Outer diameter -D1-
Outer diameter -D2- 14.0 mm 11.0
Shoulder -L1- 4.6 mm 5 mm 9.0 mm 4.75 mm
Shoulder -L2- 8.16 mm 9.16
Installation position of
valve (unactuated)
-C-
Service connector
for refrigerant
R134a
Highpressure
side
16.0 mm 13.0
-7.1 mm -7.1 mm 8.3...9.3mm8.3...9.3
Lowpres‐
sure
side
mm
mm
mm
Service connector
for refrigerant
R1234yf
Highpressure
side
17.0 mm 14.0 mm
13.0 mm 12.0 mm
12.5 mm 7.2 mm
Lowpressure
side
mm
1. Refrigerant circuit 39
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1.2.12 Connections with valve for switches on
refrigerant circuit
Note
For switching pressures, removing and installing switches, as well
as switch arrangement and design, see the vehicle-specific re‐
frigerant circuit ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehiclespecific workshop manual).
• There are different threads for switches on high- and low-
pressure sides.
• Only use valves and seals that are resistant to refrigerant
R1234yf and applicable refrigerant oils ⇒ Electronic Cata‐
logue of Original Parts “ETKA” .
A - Connection (soldered)
B - Gasket
C - Valve (with seal)
Note
♦
Use e.g. an adapter from the socket insert - T10364- to remove
and install the valve core -C- on an empty refrigerant circuit
⇒ “1.2.11 Connections for quick couplers on refrigerant cir‐
cuit”, page 38 .
♦
These valves come in different designs and therefore have
different tightening torques. A valve core -C- with a VG5 thread
(5.2 x 0.7 mm, tyre valve) has a tightening torque of 0.4±0.1
Nm; a valve core with an M6 x 0.75 mm thread has a tightening
torque of 0.9±0.1 Nm and a valve core with an M8 x 1.0 mm
thread has a tightening torque of 2.0±0.2 Nm.
1.2.13 High-pressure sender - G65-
Note
The high pressure sender - G65- (specifically designed for vehi‐
cles) can be installed instead of the pressure switch for the air
conditioning system - F129.- .
The high-pressure sender - G65- determines the pressure in the
refrigerant circuit and transmits the values to the Air conditioning
system control unit - J301- or to the Climatronic control unit J255- .
The following are shifted via these control units:
♦ The radiator fan - V7- switches to the next speed in the event
of a pressure rise in the refrigerant circuit
♦ Reduction of the A/C compressor output if the pressure is too
high, 3.2 MPa (32 bar), e.g. too little engine cooling
♦ Reduction of the AC compressor output if the pressure is too
low, 0.2 MPa (2 bar), e.g. after loss of refrigerant
40 Rep. gr.87 - Air conditioning system
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1.2.14 Pressure sender and switch on refriger‐
ant circuit
Note
♦
There are different types of pressure sender and switch with
different functions and different names ⇒ Heating, Air Condi‐
tioning; Rep. gr. 87 (vehicle-specific workshop manual).
♦
For switching pressures, removing and installing switches, as
well as switch arrangement and design, see ⇒ Heating, Air
Conditioning; Rep. gr. 87 (vehicle-specific workshop manual).
♦ One of the types of pressure sender generates a square wave
signal when a voltage is applied; the signal changes with the
pressure in the system. The other type of pressure sender ex‐
changes information with the applicable control unit over the
databus when a voltage is applied (e.g. over the “LIN bus”)
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations and ⇒ Vehicle diagnostic tester in the “Targeted faultfinding” function for the air conditioning system. Therefore,
always make sure you use the right type of pressure sender.
♦ There are different types of pressure sender that currently can
only be distinguished on the outside by part number, so make
sure you are using the correct type (part number ⇒ Electronic
Catalogue of Original Parts “ETKA” ). Reasons: These sensor
transmit different signals and the applicable control units can
only assess the signal they are designed for ⇒ Vehicle diag‐
nostic tester in “Targeted fault-finding” for the air conditioning
system and ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehiclespecific workshop manual).
♦ One of the types of pressure sender only transfers the meas‐
ured value for the pressure in the refrigerant circuit to the
connected control unit. The other type transfers the measured
value for the pressure in the refrigerant circuit and the meas‐
ured temperature to the connected control unit, so make sure
you use the correct type ⇒ Electronic Catalogue of Original
Parts “ETKA” .
♦ The downstream control units use this signal to calculate the
pressure in the refrigerant circuit and then actuate the radiator
fans, the engine and the AC magnetic clutch - N25- accord‐
ingly or change the level of actuation of the AC compressor
control valve - N280- ⇒ Vehicle diagnostic tester in the “Tar‐
geted fault-finding” function for the air conditioning system and
⇒ Heating, Air Conditioning; Rep. gr. 87 (vehicle-specific
workshop manual).
1.2.15 Regulating valve for compressor of air conditioning system - N280-
Note
For switching pressures, removing and installing switches, as well
as switch arrangement and design, see the vehicle-specific re‐
frigerant circuit ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehiclespecific workshop manual).
1. Refrigerant circuit 41
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♦ The regulating valve is installed in the AC compressor. It is
actuated,
control and display unit - E87- or the Climatronic control unit J255- (depending on vehicle, this may be via the databus and
an additional control unit) ⇒ Vehicle diagnostic tester in the
“Targeted fault-finding” function for the air conditioning system
and ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehicle-specific
workshop manual).
♦ The pressure on the low-pressure side is influenced by the
regulating valve and thus the temperature in the evaporator is
regulated.
for example, by the AC control unit - J301- , the AC
Note
The AC compressor regulating valve - N280- is a part of the AC
compressor and cannot be replaced separately in all AC com‐
pressors ⇒ Electronic Catalogue of Original Parts “ETKA” .
1.3 Possible complaints
⇒ “1.3.1 Requirements for investigating a complaint”, page 42
⇒ “1.3.2 Possible complaints”, page 42
⇒ “1.3.3 Odour from the heating and air conditioning unit”,
page 43
1.3.1 Requirements for investigating a com‐
plaint
• Fault finding has not identified a fault in the electrical system,
the vacuum system and the air guides ⇒ Vehicle diagnostic
tester in the “Targeted fault-finding” function of the air condi‐
tioning system (and the battery control) ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations and ⇒
Heating, Air Conditioning; Rep. gr. 00 .
• Self-diagnosis in the “Targeted fault-finding” function of the air
conditioning system, e.g. with the ⇒ Vehicle diagnostic tester
in the “Targeted fault-finding” function of the air conditioning
system) does not detect any events for a complaint.
• No switch-off condition for the AC compressor is displayed in
measured values from the AC control unit ⇒ Vehicle diag‐
the
nostic tester in the “Targeted fault-finding” function for the air
conditioning system.
1.3.2 Possible complaints
Note
For all complaints marked with an *
⇒ “2.13 Check pressures”, page 106 .
♦ The radiator has failed completely.*
♦ Insufficient cooling capacity for all vehicle speeds or engine
speeds.*
♦ No cooling or insufficient cooling after a few kilometres of driv‐
ing.*
♦ No cooling or insufficient cooling at the evaporator.
♦ Actuation of the AC compressor (via the AC magnetic clutch -
N25- or the AC compressor regulating valve - N280- ) is
switched off by the applicable control unit (e.g. the AC control
42 Rep. gr.87 - Air conditioning system
Page 47
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and display unit - E87- , the AC control unit - J301- or the Cli‐
matronic
pressure in the refrigerant circuit * ⇒ Vehicle diagnostic tester
in the “Targeted fault-finding” function for the air conditioning
system.
♦ There is no fresh air supply or there is a strong decrease of
fresh air supply after a few kilometres of driving (evaporator
ices up) * ⇒ Vehicle diagnostic tester in the “Targeted fault-
finding” function for the air conditioning system.
In addition, the following complaints may still arise:
The AC compressor makes noises.
– Tighten the securing bolts for the AC compressor and the AC
compressor bracket with a torque wrench ⇒ Heating, Air Con‐
ditioning; Rep. gr. 87 .
– Check the routing of the refrigerant lines, which must not be
in contact with other components and must be installed free of
tension (align if necessary) ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
Immediately after switching on the air conditioning system and/or
when cornering or braking, noises occur (refrigerant hammering):
– Drain, evacuate and fill refrigerant circuit again (too much re‐
frigerant or refrigerant oil in the circuit)
⇒ “2 Working with the A/C service station”, page 77 and
⇒ “2.13 Check pressures”, page 106 .
control unit - J255- ) as a result of too high or too low
Note
This complaint may also arise if there is too much refrigerant oil
in the circuit (when changing the AC compressor, for example,
the quantity of refrigerant oil was not modified)
⇒ “1.5 Replace components”, page 55 .
On an air conditioning system which otherwise functions perfect‐
ly, water sprays out of the vents (the dash panel or in the footwell):
– Check that the condensation water drain is has been laid cor‐
rectly; it must not be crushed or bent ⇒ Heating, Air Condi‐
tioning; Rep. gr. 87 .
– Check the condensation water drain valve; it must not be stuck
with wax or underbody sealant and must open and close cor‐
rectly ⇒ Heating, Air Conditioning; Rep. gr. 87 .
– Check the plenum chamber cover; it must not be damaged
and must be installed correctly (no water may flow into the
evaporator) ⇒ Heating, Air Conditioning; Rep. gr. 87 .
– Check the water drainage openings of the plenum chamber;
they must not be blocked (e.g. by leaves) ⇒ Heating, Air Con‐
ditioning; Rep. gr. 87 .
Note
Installation location and other notes for these components ⇒
Heating, Air Conditioning; Rep. gr. 87 .
1.3.3 Odour from the heating and air condi‐
tioning unit
Is the odour coming from the evaporator or heat exchanger?
♦ Fishy odour
1. Refrigerant circuit 43
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– Due
to leaktightness at the cooling system of the engine or the
heat exchanger in the heating and air conditioning unit.
Note
If a weak fishy odour can be detected when the temperature is
set to “cold” or a stronger odour occurs when the temperature is
set to “warm”, check the heat exchanger for leak tightness.
♦ Odours after the clutch is burnt
♦ Evaporations from footmats, subsequently fitted protective
seat covers etc.
♦ Foul, mouldy odour
– Due to accumulation and deposit of leaves, tree needles, etc.
in the plenum chamber.
Note
Clean plenum chamber.
– Use water which cannot drain out the plenum chamber.
Note
Check installation location: in plenum chamber.
♦ Odour from the heating and air conditioning unit
Note
Odours which can occur in the heating and air conditioning unit,
can be detected in the fresh as well as re-circulating air mode.
– Due to excessive condensation water in the heating and air
conditioning unit.
Note
Check condensation water drain.
– Caused by an old or heavily soiled dust and pollen filter.
Note
Check dust and pollen filter.
– Due to deposits on the fins of the evaporator
Note
Clean the evaporator with the ultrasonic air conditioning system
cleaning device or the suction-feed spray gun and applicable
spray lance.
44 Rep. gr.87 - Air conditioning system
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Ultrasonic air conditioning system cleaning device
– The ultrasonic air conditioning system cleaning device is
placed in the footwell on the front passenger side and atom‐
ises the AeroClean agent. AeroClean neutralises microbes
and bacteria in the heating and air conditioning unit.
Operating instructions come with the device.
For the latest equipment, see ⇒ Electronic Catalogue of Original
Parts “ETKA” /
Spraying the evaporator with the suction-feed spray gun and
spray lance
The evaporator is sprayed directly with Contra Sept using the
spray lance (approx. 10 bar). Aero-Clean neutralises the germs
and bacteria directly on the evaporator.
To access the evaporator, preparation and various spray lances
are required.
There are vehicle-specific operating instructions with the cleaning
solution for the evaporator ⇒ Electronic Catalogue of Original
Parts “ETKA” .
1.4 Identifying leaks
⇒ “1.4.1 General information about finding leaks in the refrigerant
circuit”, page 45
⇒ “1.4.2 Detecting leaks on refrigerant circuits with an electronic
leak detector”, page 46 .
⇒ “1.4.3 Searching for leaks with the UV leak detection system”,
page 48 .
⇒ “1.4.4 Detecting leaks by means of vacuum testing with the AC
service station or pressure testing”, page 54
1.4.1 General information about finding leaks
in the refrigerant circuit
Note
♦
Minor leaks can be detected for example with an electronic
leak detector or a UV lamp.
♦
There are 2 different procedures to search for leaks in the re‐
frigerant circuit in this workshop manual. Both procedures
have been tested and are reliable under different operating
conditions if followed correctly and depending on the problem.
♦
There are many procedures available on the market to find
leaks in refrigerant circuits. However, they are not always re‐
liable and, if they are not carried out according to the instruc‐
tions, they may also identify leaks in various components of
the refrigerant circuit, even though they are leak tight. In ad‐
dition, during certain procedures, components of the refriger‐
ant circuit can be damaged or initially damaged.
♦ If leaks are found on some components, the components must
not be repaired, but have to be replaced with original parts.
♦ A leaking refrigerant circuit must not be filled with refrigerant,
so evacuate an empty refrigerant circuit and check it for leaks
before filling with refrigerant
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
1. Refrigerant circuit 45
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Caution
♦ Chemical agents must not be used to seal leaks on a re‐
frigerant circuit.
♦ If it is suspected that chemical agents have been filled into
the vehicle refrigerant circuit to seal leaks, do not connect
the AC service station and do not drain the refrigerant.
♦ Chemical agents (leakstop additives) used to seal leaks
on a refrigerant circuit usually react with the ambient air
and the humidity in air to form deposits.
♦ Deposits of these chemical substances in the refrigerant
circuit cause functional problems in the valves and other
components with which they come into contact, and in the
AC service station . These deposits cannot be completely
removed from the components again (even by cleaning/
flushing). The refrigerant circuit can therefore only be re‐
paired by replacing all components that have come into
contact with the substance.
♦ The Škoda company does not use chemicals to seal leaks
on refrigerant circuits.
1.4.2 Detecting leaks on refrigerant circuits with an electronic leak detector
Special tools and workshop equipment required
♦ Electronic leak detector or commercially available
Note
♦
Leaks on an R1234yf refrigerant circuit can only be found with
electronic leak detectors that have been designed for refrig‐
erant R1234yf.
♦
The different refrigerants have a different molecular structure.
The sensors of the electronic leak detectors are specifically
designed for the molecules. If an electronic leak detector is
used that is not specifically designed for refrigerant R1234yf,
it does not detect refrigerant R1234yf or only when there is a
large concentration of the refrigerant R1234yf near to the leak
points. Therefore, electronic leak detectors that are only de‐
signed for refrigerant R134a must not be used to detect leaks
in an R1234yf refrigerant circuit.
♦
Depending on the design of the heating and air conditioning
unit, it is also possible to find a leak on the evaporator by hold‐
ing the test probe of the leak detector into the heating and air
conditioning unit through the connection for the glove com‐
partment cooling or, if the condensation water drain has been
detached, by holding the test probe at the open connection for
the condensation water drain of the heating and air condition‐
ing unit.
46 Rep. gr.87 - Air conditioning system
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Detecting leaks in a refrigerant circuit that is completely empty
because of leaking
Note
When detecting leaks, proceed as follows to ensure that only as
much refrigerant escapes into the atmosphere as is absolutely
necessary to detect leak points in a completely empty refrigerant
circuit:
– Evacuate the refrigerant circuit with the AC service station
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
Note
♦
If a more significant leak is found during evacuation, locate
and eliminate it as described in
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
♦
If no leak is found during evacuation or there is a leak that is
so small that the leak point cannot be found by means of vac‐
uum testing, then proceed as follows:
– If the refrigerant circuit is completely empty, fill approx. 10%
of the filling capacity of refrigerant and perform leak detection
as for a refrigerant circuit filled with refrigerant
Performing leak detection on a refrigerant circuit filled with refrig‐
erant
– Switch off ignition.
– Operate the leak detector according to the relevant operating
instructions.
– Always hold the test prod below the suspected leakage.
If the number of knocking noises increases or a whining tone oc‐
curs, as a result of the design, the leak point has been found ⇒
Leak detector operating instructions
Note
♦
Refrigerant gas quickly floats away with the movement of the
⇒ page 47 .
air. Therefore avoid any draught during leak detection.
♦
Refrigerant gas is heavier than air and therefore sinks down
where it escapes from the circuit.
1. Refrigerant circuit 47
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1.4.3 Searching for leaks with the UV leak de‐
tection system
Note
♦
Some leaks are difficult to detect with an electric leak detector
or even cannot be found with an electric leak detector. To de‐
tect these leaks, perform leak detection with the leak detection
system ⇒ Electronic Catalogue of Original Parts “ETKA” .
♦
If there is a leak on the refrigerant circuit, refrigerant oil also
escapes with the refrigerant. This oil normally stays near the
leak point. For this oil to be visible under UV light, a small
amount of fluorescent liquid must be put into the refrigerant
circuit. This liquid (PAG oil with an additive that fluoresces un‐
der UV light) is put into the refrigerant circuit and distributes
through the system with the refrigerant oil when the air condi‐
tioning system is switched on.
♦
The air conditioning system must be operated for at least 60
minutes so that the added additive is distributed throughout
the refrigerant circuit (the AC compressor must run). Depend‐
ing on the size of the leak, the leak point will already be visible
under UV light in this time.
♦
The refrigerant oil with the additive that fluoresces under UV
light can be applied directly when the circuit is open or forced
in via the service connector after the circuit has been emptied
using the AC service station .
♦
If the leak detection additive is put into the refrigerant circuit
via the service connector, a small quantity of leak detection
additive is left in the service connector. Carefully remove the
remaining amount so that it is not mistaken for a leak point
during subsequent leak detection.
♦
If a component in the circuit that is filled with the leak detection
additive is replaced, clean the connections to other compo‐
nents after you have assembled the refrigerant circuit. During
subsequent leak detection, the residue of the leak detection
additive at the connections could be mistaken for a leak point.
♦
When emptying the refrigerant circuit, refrigerant oil and there‐
fore leak detection additive also enters the AC service station .
The refrigerant oil is separated from the refrigerant in the oil
separator of the AC service station and removed from the AC
service station using the draining device. The drained refrig‐
erant oil must not be refilled. It must be replaced with fresh
refrigerant oil.
♦
If a leak detection liquid has already been added to a refrig‐
erant circuit during an earlier repair, note the following: Only
add new leak detection liquid if the refrigerant oil is replaced.
If only some of the refrigerant oil has been replaced, only a
corresponding amount of leak detection liquid must be added.
For example, if 100 ml of refrigerant oil has been replaced for
a vehicle with a 250 ml-capacity, only top up with 1 ml (cm3)
of leak detection additive.
♦
Certain materials and their compounds (e.g. oxidation prod‐
ucts on components made of aluminium, anti-corrosion waxes
etc.) also fluoresce under UV light.
♦
Depending on the design of your AC service station , the leak
detection additive can also be added directly via the service
station; follow the operating instructions for the AC service
station ⇒ AC service station operating instructions.
48 Rep. gr.87 - Air conditioning system
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Leak detection on an empty, leaking refrigerant circuit
– When detecting leaks, proceed as follows to ensure that only
as much refrigerant escapes into the atmosphere as is abso‐
lutely necessary to detect leak points in a completely empty
refrigerant circuit:
– Evacuate the refrigerant circuit with the AC service station
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
Note
If a more significant leak is found during evacuation, locate and
eliminate it as described in
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 and
⇒ “1.4.4 Detecting leaks by means of vacuum testing with the AC
service station or pressure testing”, page 54 .
If no leak is found during evacuation or there is a leak that is so
small that the leak point cannot be found during evacuation, then
proceed as follows:
Note
♦
Only use UV leak detection additive that is approved for re‐
frigerant R1234yf.
♦
The UV leak detection additive partly consists of refrigerant oil.
Only use UV leak detection additives that use the refrigerant
oil for refrigerant R1234yf as vehicle. The refrigerant oil with
UV leak detection additive developed for refrigerant R134a
must not be used.
♦
Different refrigerant oils (PAG oils) are used for refrigerant cir‐
cuits with refrigerants R1234yf and R134a, so always check
you are using the right leak detection additive (PAG oil) with
an additive that fluoresces under UV light.
♦
Add UV leak detection additive to the refrigerant circuit using
the AC service station ⇒ page 49 .
♦
Add UV leak detection additive to the refrigerant circuit using
the leak detection system ⇒ page 52 .
– Fill the refrigerant circuit with the specified quantity of UV leak
detection additive and refrigerant
⇒ “2.6 Filling the refrigerant circuit”, page 92 and ⇒ Heating,
Air Conditioning; Rep. gr. 00 .
– Operate
the AC compressor switched on.
– Find leak with the UV leak detection system
Adding UV leak detection additive using the AC service station
– Fill UV leak detection additive and the specified quantity of
refrigerant
tion
Heating, Air Conditioning; Rep. gr. 00 .
the air conditioning system for at least 60 minutes with
into the refrigerant circuit using the AC service sta‐
⇒ “2.6 Filling the refrigerant circuit”, page 92 and ⇒
⇒ page 49 ,
⇒ page 52 .
1. Refrigerant circuit 49
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Note
♦
The quantity of UV leak detection additive that is filled for a
refrigerant circuit with a refrigerant oil volume of up to 150
cm3 is 3.0+/- 0.5 ml (cm3). If the volume of refrigerant oil in the
refrigerant circuit is greater, more UV leak detection additive
must be added, as appropriate, e.g. 5.0 ± 0.5 ml (cm3) for a
refrigerant circuit with a volume of refrigerant oil of 250 cm3.
When adding the UV leak detection additive using an AC serv‐
ice station , the quantity set on the AC service station may be
different, so always follow the applicable operating instructions
⇒ AC service station operating instructions .
♦
The volume of refrigerant oil in the refrigerant circuit is noted
in the vehicle-specific instructions ⇒ Heating, Air Conditioning;
Rep. gr. 00 .
♦
If a UV leak detection additive has already been added to a
refrigerant circuit during an earlier repair, note the following:
Only add more UV leak detection additive if the refrigerant oil
is replaced. If only part of the refrigerant oil has been replaced,
only top up a corresponding amount of UV leak detection ad‐
ditive. For example, if 50 ml of refrigerant oil has been replaced
for a vehicle with a 150 ml-capacity, only top up with 1.0 ml
(cm3) of leak detection additive.
The leak detection system consists of the following components:
♦ Cleaning agent -3♦ UV leak detection lamp -4♦ UV absorbing goggles -5♦ Stickers -6♦ Protective gloves -8-
Note
Items -1-, -2- and -7- can be ignored.
Special tools and workshop equipment required
♦ Leak detection system
♦ AC service station with the ability to add UV leak detection
additive to the refrigerant circuit ⇒ Electronic Catalogue of
Original Parts “ETKA”
♦ Approved leak detection additive ⇒ Electronic Catalogue of
Original Parts “ETKA”
– Evacuate refrigerant circuit and fill with UV leak detection ad‐
ditive ⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 and
⇒ “2.6 Filling the refrigerant circuit”, page 92 .
– Wait until the pressures on the high- and low-pressure sides
have equalised.
– Disconnect the AC service station from the refrigerant circuit
and switch off
50 Rep. gr.87 - Air conditioning system
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⇒ “2.8 Switching off the AC service station and disconnecting
it from the refrigerant circuit”, page 94 .
1. Refrigerant circuit 51
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– Attach a sticker near the service connectors with a note that
UV leak detection additive has been added to this refrigerant
circuit.
– Remove the residues of the UV leak detection additive from
the service connector, e.g. using absorbent paper, and clean
the area with cleaning agent - VAS 6201/3- .
– Close the service connector with the screw cap.
– Start up the air conditioning system.
Note
♦
The air conditioning system must be operated for at least 60
minutes so that the added additive is distributed throughout
the refrigerant circuit (the AC compressor must run). Depend‐
ing on the size of the leak, the leak point will already be visible
under UV light in this time.
♦
Depending on the size and the location of the leak, it might
take several days until enough refrigerant oil escapes with the
UV leak detection additive escapes and the leak point can be
detected.
– Search for a leak on the refrigerant circuit using the UV lamp
⇒ page 52 .
Adding UV leak detection additive to the refrigerant circuit using
the leak detection system
– Remove the residues of the UV leak detection additive from
the service connector, e.g. using absorbent paper, and clean
the area with cleaning agent .
– Close the service connector with the screw cap.
– Start up the air conditioning system.
Note
♦
The air conditioning system must be operated for at least 60
minutes so that the added additive is distributed throughout
the refrigerant circuit (the AC compressor must run). Depend‐
ing on the size of the leak, the leak point will already be visible
under UV light in this time.
♦
Depending on the size and the location of the leak, it might
take several days until enough refrigerant oil with the additive
escapes and the leak point can be detected.
– Search for a leak on the refrigerant circuit using the UV lamp
⇒ page 52 .
Searching for leaks from the refrigerant circuit using the UV lamp
WARNING
Risk of eye injury from UV light.
♦ Wear safety goggles.
♦ Never look directly at the UV lamp.
♦ Never point the UV lamp at other people.
– Switch off ignition.
52 Rep. gr.87 - Air conditioning system
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Note
♦
After adding the UV leak detection additive, the air condition‐
ing system must be operated for at least 60 minutes so that
the added additive is distributed throughout the refrigerant cir‐
cuit (the AC compressor must run). Depending on the size of
the leak, the leak point will already be visible under UV light in
this time.
♦
Depending on the size and the location of the leak, it might
take several days until enough refrigerant oil with the additive
escapes and the leak point can be detected.
♦
In case of leaks on the evaporator, the additive may be washed
away with the condensation water and flows out via the con‐
densation water drain. On most vehicles the evaporator is not
accessible without extensive preliminary work, therefore if a
test is carried out e.g. on the condensation water drain, this
could provide an indication of a leaking evaporator. In this
case, however, the additive has to have been in the refrigerant
circuit for a longer period of time (several days).
♦
The safety goggles protect the eyes and increase the fluores‐
cence of the UV leak detection additive when exposed to UV
light.
♦
Depending on the accessibility of various parts of the refriger‐
ant circuit, it may be necessary to remove certain parts of the
vehicle (e.g. the bumper or the air filter).
♦
Only small amounts of refrigerant oil reach certain points of
the refrigerant circuit when the air conditioning system is op‐
erated (e.g. a filler cap installed on the top of a fluid reservoir
mounted on the condenser). If there is a leak at these points,
it may take longer until enough refrigerant with refrigerant oil
and additive escapes to fluoresce under the UV lamp and in‐
dicate a leak. It may therefore be appropriate to use an elec‐
tronic leak detector to detect leaks at these points
⇒ “1.4.2 Detecting leaks on refrigerant circuits with an elec‐
tronic leak detector”, page 46 .
– Park the vehicle in a darker area of the workshop (in daylight
or under strong lighting the effect of the UV light is reduced).
– Check that the various parts of the refrigerant circuit are ac‐
cessible and remove the parts around the refrigerant circuit
that obstruct the view of the parts of the refrigerant circuit (e.g.
the noise insulation and the bumper).
– Wear safety goggles to protect your eyes.
– Connect the UV lamp to a 12 V battery (vehicle battery). Check
the polarity of the connections is correct.
– Switch on the UV lamp and point it at the parts of the refrigerant
circuit. Points where refrigerant, refrigerant oil and therefore
UV leak detection additive has escaped will glow under UV
light (fluoresce).
1. Refrigerant circuit 53
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1.4.4 Detecting leaks by means of vacuum testing with the AC service station or pressure testing
All vehicles
WARNING
Risk of frostbite through refrigerant escaping under pressure!
This may cause frostbite on the skin and other parts of the
body.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Evacuate the refrigerant circuit and immediately open the
refrigerant circuit.
♦ If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure builds up in the refrigerant cir‐
cuit as a result of secondary evaporation.
– Switch off ignition.
♦ Detecting leaks by means of vacuum testing with the AC serv‐
ice station or pressure testing
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87
Note
♦
Minor leaks from the refrigerant circuit (less than 100 g refrig‐
erant lost per year) cannot normally be detected by means of
vacuum testing or pressure testing. The incoming volume of
air or escaping volume of nitrogen is too small to detect the
defects from noise.
♦
Minor leaks from the refrigerant circuit (less than 100 g refrig‐
erant lost per year) cannot normally be detected by means of
vacuum testing or pressure testing, depending on local con‐
ditions (local noise, location of the leak etc.). The incoming
volume of air or escaping volume of nitrogen may be too small
to make a noise that would allow the defects to be detected.
♦
Major leaks from the refrigerant circuit (e.g. chipped condens‐
er, loss of more than 100 g of refrigerant per day) can be
detected – depending on local conditions – from the noise that
is generated during vacuum testing or pressure testing at the
point of defect
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
54 Rep. gr.87 - Air conditioning system
Page 59
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1.5 Replace components
⇒ “1.5.1 General instructions for replacing components”,
page 55
⇒ “1.5.2 Replacing leaking or damaged components; empty re‐
frigerant circuit (except AC compressor and fluid reservoir)”, page
57
⇒ “1.5.3 Replacing leaking or damaged components; filled refrig‐
erant circuit (except AC compressor and fluid reservoir)”,
page 59
⇒ “1.5.4 Replacing the AC compressor without needing to clean
the refrigerant circuit”, page 59 .
⇒ “1.5.5 Replacing the AC compressor because of a leak or in‐
ternal damage”, page 60
1.5.1 General instructions for replacing com‐
ponents
• All the parts of the refrigerant circuit that are sent in for quality
monitoring must be closed (use original screw caps of the
spare part).
• Replace damaged or leaking components of the refrigerant
circuit ⇒ “1.5 Replace components”, page 55 .
• All the components of the refrigerant circuit that are sent in for
quality monitoring must be closed (use original screw caps of
the spare part).
• The spare parts (AC compressor, fluid reservoir, evaporator
and
condenser) used to be filled with nitrogen gas. This filling
of nitrogen gas escapes uniformly, more specifically, the pres‐
sure of the nitrogen filling is now so low that when opening for
the first time, it is no longer noticeable that gas escapes.
• On vehicles with an AC compressor without magnetic clutch,
the engine must only be started if the refrigerant circuit is fully
assembled (the AC compressor always runs when the engine
is running).
• The AC compressor with AC compressor regulating valve N280- (without AC magnetic clutch - N25- ) is switched to
internal lubrication if the refrigerant circuit is empty, so that
only a very small quantity of oil is pumped out of the AC com‐
pressor into the circuit.
1. Refrigerant circuit 55
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Note
♦
The following spare parts (AC compressor, AC reservoir,
evaporator and condenser) may be filled with nitrogen gas, but
not always. When unscrew the plugs from the spare part,
therefore, there may be no audible or only a scarcely audible
equalisation of pressure.
♦
Depending on where and for how long they have been stored,
there may also be no audible or only a scarcely audible equal‐
isation of pressure when you unscrew the plugs on compo‐
nents that were filled with nitrogen by the manufacturer, so that
it is not possible to determine whether the component is leak‐
ing. For example, the nitrogen in the component may escape
through the shaft seal of a spare part AC compressor over
time, although the AC compressor is not leaking.
♦
As spare parts are stored for long periods of time and at dif‐
ferent location, gas may or may not escape when the compo‐
nent is opened for the first time (even for spare parts with the
same number). You should therefore always remove the caps
on the connections of spare parts with care and allow the ni‐
trogen to dissipate slowly.
♦
An expansion valve and a fluid reservoir with desiccator car‐
tridge are installed in the refrigerant circuit ⇒ Heating, Air
Conditioning; Rep. gr. 87 .
♦
Replace the desiccator cartridge or components with a desic‐
cator bag (fluid reservoir) after cleaning the refrigerant circuit
(flushing with refrigerant R1234yf
⇒ “1.6 Clean the refrigerant circuit.”, page 61 ); keep the new
desiccator closed for as long as possible, to minimise the ab‐
sorption of moisture.
♦
Replace the desiccator cartridge or components with a desic‐
cator bag (fluid reservoir), if required for specific plans or if the
refrigerant circuit has been open for longer period of time and
moisture has got into the desiccator (e.g. after an accident)
⇒ “1.5.2 Replacing leaking or damaged components; empty
refrigerant circuit (except AC compressor and fluid reservoir)”,
page 57 .
♦
The length of time that a refrigerant circuit may be open without
having to replace the component with the desiccator bag (fluid
reservoir) depends substantially on local environmental con‐
ditions. At a high ambient temperature and high humidity, or if
the vehicle e.g. has been outside or transported while exposed
(subject to rain and mist), the period is significantly shorter
than for a vehicle that has been in a heated, dry warehouse.
The size of the opening through which any humidity can enter
the circuit also has an influence on the period of time that an
open refrigerant circuit may be left until the component with
the desiccator bag must be replaced
⇒ “1.5.2 Replacing leaking or damaged components; empty
refrigerant circuit (except AC compressor and fluid reservoir)”,
page 57 .
♦
Close open connections and lines (prevent moisture absorp‐
tion).
Note
Contaminated refrigerant oil must be disposed of as used oil of
unknown origin (according to local regulations) ⇒ Škoda-Serv‐
iceNet .
56 Rep. gr.87 - Air conditioning system
Page 61
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1.5.2 Replacing leaking or damaged compo‐
nents; empty refrigerant circuit (except
AC compressor and fluid reservoir)
The refrigerant circuit is completely empty (e.g. because of a ma‐
jor leak or a burst hose line)
♦ Follow the general instructions for replacing components
⇒ “1.5.1 General instructions for replacing components”, page
55
Note
♦
If there is only a minor leak and the refrigerant has only esca‐
ped slowly (e.g. through a small leak point), not enough re‐
frigerant oil escapes and not enough moisture enters the
circuit to prevent the air conditioning system functioning cor‐
rectly after repair.
♦
Only perform the steps marked with a * if there is a major leak
(e.g. after an accident).
AC compressor
– Remove the defective component * ⇒ Heating, Air Condition‐
ing; Rep. gr. 87 .
– Remove AC compressor * ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
1. Refrigerant circuit 57
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– Remove the oil drain plug -B- / -D- from the AC compressor
-A-.*
Note
♦
The type of oil drain plug -B- / -D- and seal -C- / -E- varies
(depending on the manufacture of the AC compressor) ⇒
Heating, Air Conditioning; Rep. gr. 87 .
♦
When you install the oil drain plug -B- / -D-, note the correct
typing for (depending on the manufacture of the AC compres‐
sor and the type of oil drain plug) ⇒ Heating, Air Conditioning;
Rep. gr. 87 (vehicle-specific workshop manual).
♦
On a Denso AC compressor, for example, there is a sealing
ring -E- installed on the oil drain plug -D-; replace it ⇒ Heating,
Air Conditioning; Rep. gr. 87 and ⇒ Electronic Catalogue of
Original Parts “ETKA” .
♦
On a Denso AC compressor, for example, there is a sealing
ring -E- installed on the oil drain plug -D-; replace it ⇒ Heating,
Air Conditioning; Rep. gr. 87 and ⇒ Electronic Catalogue of
Original Parts “ETKA” . Tightening torque ⇒ Heating, Air Con‐
ditioning; Rep. gr. 87 .
♦
To speed up evacuation of the refrigerant oil, rotate the AC
compressor e.g. using the belt pulley or clutch disk of the
magnetic clutch.
♦
Tip used refrigerant oil out of the AC compressor *
⇒ “1.5.4 Replacing the AC compressor without needing to
clean the refrigerant circuit”, page 59 (for disposal, see ⇒
Škoda-ServiceNet ).
All vehicles
Note
♦
Then add the volume of new refrigerant oil to the AC com‐
pressor that corresponds to the refrigerant oil volume in the
replacement compressor * ⇒ Heating, Air Conditioning; Rep.
gr. 00 .
♦
Use different refrigerant oils and quantities for different AC
compressors ⇒ Heating, Air Conditioning; Rep. gr. 00 .
♦
To ensure that the AC compressor is lubricated for first use,
at least 40 cm3 of refrigerant oil must be added to the AC
compressor, the rest can be added e.g. to the new AC/fluid
reservoir or a refrigerant line ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
♦
If dirt has penetrated into the AC compressor when the refrig‐
erant circuit was open (e.g. during an accident), the AC com‐
pressor must be replaced ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
♦
Cleaning refrigerant circuit (flushing with refrigerant R1234yf)
* ⇒ “1.6 Clean the refrigerant circuit.”, page 61 .
– Replace desiccator cartridge ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Assemble the refrigerant circuit, evacuate and fill again
⇒ “2 Working with the A/C service station”, page 77 .
58 Rep. gr.87 - Air conditioning system
Page 63
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1.5.3 Replacing leaking or damaged compo‐
nents; filled refrigerant circuit (except
AC compressor and fluid reservoir)
Refrigerant is still in the refrigerant circuit (e.g. in the case of a
minor leak)
♦ Follow the general instructions for replacing components
⇒ “1.5.1 General instructions for replacing components”, page
55 .
– Drain refrigerant circuit
⇒ “2 Working with the A/C service station”, page 77 .
– Remove
air and collect any refrigerant oil which flows out.
– The quantity of refrigerant oil that has been blown out (plus 20
cm3 for evaporator, plus 10 cm3 for condenser, refrigerant
lines and refrigerant hoses) must be added as fresh refrigerant
oil to the new component.
Dispose of used refrigerant oil (according to local regulations) ⇒
Škoda-ServiceNet .
defective component, blow through with compressed
Note
– Assemble the refrigerant circuit, evacuate and fill
⇒ “2 Working with the A/C service station”, page 77 .
1.5.4 Replacing the AC compressor without
needing to clean the refrigerant circuit
♦ Follow the general instructions for replacing components
⇒ “1.5.1 General instructions for replacing components”, page
55
For example, in the event of external damage following an acci‐
dent
– Emptying a refrigerant circuit
⇒ “1.6 Clean the refrigerant circuit.”, page 61
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Remove
Air Conditioning; Rep. gr. 87 .
There are different types of oil drain plug and seal (a seal or a
sealing ring may be installed; it must be replaced)
⇒ “1.5.2 Replacing leaking or damaged components; empty re‐
frigerant circuit (except AC compressor and fluid reservoir)”, page
57 and ⇒ Electronic Catalogue of Original Parts “ETKA” .
the oil drain plug from the AC compressor ⇒ Heating,
Note
– To speed up evacuation of the refrigerant oil, rotate the AC
compressor e.g. using the clutch disc of the magnetic clutch.
– Tip used refrigerant oil out of the AC compressor and dispose
of it * ⇒ Škoda-ServiceNet (according to local regulations).
– Remove the oil drain plug from the replacement compressor,
take out the refrigerant oil and only add a quantity fresh re‐
frigerant oil equal to the quantity of oil that you have tipped out
(from the defective AC compressor)
⇒ “1.5.2 Replacing leaking or damaged components; empty
1. Refrigerant circuit 59
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refrigerant circuit (except AC compressor and fluid reservoir)”,
page 57 .
Note
♦
For example, 50 cm3 of refrigerant oil has been tipped out of
the defective AC compressor and 100 cm3 of refrigerant oil
has been tipped out of the replacement AC compressor (a
small amount of refrigerant oil remains in the AC compressor).
In this case, add 50 cm3 of refrigerant oil to the AC compressor
to be installed (the refrigerant oil tipped out of the replacement
compressor must not be used).
♦
Use different refrigerant oils and quantities for different AC
compressors ⇒ Heating, Air Conditioning; Rep. gr. 00 .
♦
If a larger quantity of refrigerant oil (more than approx./ 50
cm3) has been tipped out of the defective AC compressor, the
rest of the refrigerant oil can also be added to the evaporator
or AC/fluid reservoir/internal heat exchanger ⇒ Heating, Air
Conditioning; Rep. gr. 87 .
– Assemble the refrigerant circuit, evacuate and fill
⇒ “2 Working with the A/C service station”, page 77 .
1.5.5 Replacing the AC compressor because of a leak or internal damage
♦ Follow the general instructions for replacing components
⇒ “1.5.1 General instructions for replacing components”, page
55
Replacing the AC compressor e.g. because of noise from the AC
compressor or lack of power of the AC compressor
– Drain refrigerant circuit
⇒ “2 Working with the A/C service station”, page 77 .
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Clean the refrigerant circuit (flush with refrigerant R1234yf)
⇒ “1.6 Clean the refrigerant circuit.”, page 61 .
Note
♦
If there is internal damage (to the AC compressor), check the
refrigerant hoses and condenser. If, for example, swarf has
got into the compressor, clean the refrigerant hoses and con‐
denser (flush with refrigerant R1234yf
⇒ “1.6 Clean the refrigerant circuit.”, page 61 ) and if neces‐
sary replace the refrigerant hoses.
♦
On some vehicles (e.g. vehicles with 2 evaporators), the quan‐
tity of refrigerant oil and the refrigerant circuit may be larger
than the quantity in the replacement compressor. For these
vehicles, add the remaining quantity of refrigerant oil to the
refrigerant circuit ⇒ Heating, Air Conditioning; Rep. gr. 00
(vehicle-specific workshop manual).
– Replace desiccator cartridge ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Check the expansion valve for contamination or corrosion and
replace if necessary ⇒ Heating, Air Conditioning; Rep. gr. 87 .
60 Rep. gr.87 - Air conditioning system
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– Assemble the refrigerant circuit, evacuate and fill
⇒ “2 Working with the A/C service station”, page 77 .
1.6 Clean the refrigerant circuit.
⇒ “1.6.1 General information about cleaning the refrigerant circuit
”, page 61
⇒ “1.6.2 Preparing to clean the refrigerant circuit (to flush with
refrigerant R1234yf)”, page 63
⇒ “1.6.3 Procedure for cleaning the refrigerant circuit”,
page 64
⇒ “1.6.4 Schematic diagrams for cleaning (circuits to be flushed)
- refrigerant circuit with expansion valve and fluid reservoir”, page
65
⇒ “1.6.5 Adapter for setting up the rinsing cycles”, page 68
⇒ “1.6.6 General information about blowing through with com‐
pressed air or nitrogen”, page 70
⇒ “1.6.7 Blowing through the refrigerant circuit with compressed
air and nitrogen”, page 73
1.6.1 General information about cleaning the refrigerant circuit
Note
♦
If it is suspected that chemical agents (leakstop additives)
have been added to the refrigerant circuit that you want to flush
to seal leaks, do not connect the AC service station to the re‐
frigerant circuit and do not flush the refrigerant circuit.
♦
Chemical agents (leakstop additives) used to seal leaks form
deposits in the refrigerant circuit which impair the function of
the air conditioning system and lead to a failure of the air con‐
ditioning system (and the AC service station).
♦
The customer must be informed that there are agents present
in the air conditioning system that are not approved by Škoda
Auto and you therefore cannot flush this air conditioning sys‐
tem or repair it.
1. Refrigerant circuit 61
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Note
♦
Škoda Auto does not use chemicals (leakstop additives) to
seal leaks on refrigerant circuits.
♦
Chemical agents (leakstop additives) used to seal leaks on a
refrigerant circuit usually react with the ambient air and the
humidity in air to form deposits in the refrigerant circuit (and in
the AC service station ), which cause valves and other com‐
ponents that come into contact with the deposits to malfunc‐
tion. These deposits cannot be completely removed from the
components again (even by flushing). The refrigerant circuit
can therefore only be repaired by replacing all components
that have come into contact with the substance.
♦
Chemical agents (leakstop additives) used to seal leaks on a
refrigerant circuit normally cannot be identified from the out‐
side. The applicable labels that are supposed to be attached
to show they have been added are also typically not present.
Therefore be careful with a vehicle, whose past you are not
familiar with.
♦
If there is no suitable AC service station available for refriger‐
ant R1234yf, the refrigerant circuit may also be flushed with
the AC service station for refrigerant R134a and with refriger‐
ant R134a. At present, refrigerant R134a may be used to clean
the refrigerant circuit ⇒ Air conditioning system with refriger‐
ant R134a; Rep. gr. 87 .
♦
If the gas analysis shows that the refrigerant R1234yf is con‐
taminated by another gas, it must be extracted from the re‐
frigerant circuit and disposed of as a gas of unknown
composition in accordance with statutory provisions
⇒ “2.12 Filling contaminated refrigerant into a recycling cylin‐
der for analysis, treatment or disposal”, page 101 .
♦
When refrigerant is contaminated, decomposition products
can form and collect in the refrigerant oil, which cannot be
drained with the refrigerant. The contaminated refrigerant oil
must be removed in this case by flushing the refrigerant circuit
with refrigerant.
• To remove moisture, contamination (e.g. grit from a defective
AC compressor) as well as used refrigerant oil in a clean re‐
frigerant-saving and environmentally friendly manner without
extensive disassembly and reassembly work, the refrigerant
circuit is cleaned with refrigerant R1234yf (flushed with refrig‐
erant R1234yf).
The refrigerant circuit must be cleaned (flushed) with refrigerant
R1234yf:
– If there is dirt or other contamination in the circuit.
– If, when evacuating a leak-tight refrigerant circuit, the vacuum
is not maintained at the gauge (there is moisture in the refrig‐
erant circuit and this generates pressure).
– If the refrigerant circuit has been left open for longer than nor‐
mally required for repairs (e.g. following an accident).
– If pressure and temperature measurements in the circuit indi‐
cate that there is humidity in the refrigerant circuit.
– There is doubt about the volume of refrigerant oil in the refrig‐
erant circuit.
– Under certain conditions, if contaminated refrigerant R1234yf
has been added to the refrigerant circuit
⇒ “1.5 Replace components”, page 55 and
62 Rep. gr.87 - Air conditioning system
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⇒ “2.3 Performing gas analysis for the refrigerant”,
page 82
Note
If contaminated refrigerant has been identified and the compo‐
nents of the refrigerant circuit exhibit internal damage (e.g. cor‐
rosion on the inside of the refrigerant lines or inner layer of the
refrigerant hoses has become detached), flushing the refrigerant
circuit may not be adequate. In this case, you must replace all the
components of the refrigerant circuit (a gas was added that has
seriously damaged components).
– The AC compressor has to be replaced because of internal
damage (e.g. noise or lack of power)
⇒ “1.5 Replace components”, page 55 .
is required in the vehicle-specific workshop manual after re‐
– It
placing certain components.
Required tools
♦ AC service station with flushing device (this AC service station
has the additional “flush refrigerant circuit” function and the
applicable flushing device for refrigerant circuits) ⇒ Electronic
Catalogue of Original Parts “ETKA” .
♦ Adapter case of the motor car set - VAS6338/1-
⇒ “1.6.5 Adapter for setting up the rinsing cycles”, page 68
and ⇒ Electronic Catalogue of Original Parts “ETKA” .
Note
♦
If you do not have access to an AC service station with flushing
device ⇒ Electronic Catalogue of Original Parts “ETKA” , de‐
pending on the design of your AC service station you can also
use it to flush the refrigerant circuit with the flushing device for
refrigerant circuits ⇒ Electronic Catalogue of Original Parts
“ETKA” , but flushing must then be performed manually ⇒ op‐
erating instructions for the flushing device .
♦
In the adapter case of the motor car set - VAS6338/1- , you
will also find a short filler hose with 5/8 -18 UNF connections
and large inside diameter (commercially available hose).
1.6.2 Preparing to clean the refrigerant circuit
(to flush with refrigerant R1234yf)
– Drain refrigerant circuit
⇒ “2.4 Exhaust refrigerant circuit.”, page 84 .
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 (vehicle-specific workshop manual).
– Remove the desiccator cartridge from the fluid reservoir and
close the reservoir again ⇒ Heating, Air Conditioning; Rep.
gr. 87 (vehicle-specific workshop manual).
Note
Depending on the design, there may be an additional filter ele‐
ment in the fluid reservoir with desiccator cartridge, which must
be replaced, if necessary, with the desiccator cartridge ⇒ Elec‐
tronic Catalogue of Original Parts “ETKA” .
1. Refrigerant circuit 63
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– Remove the expansion valve ⇒ Heating, Air Conditioning;
Rep.
gr. 87 and install an applicable adapter from the adapter
case of the motor car set - VAS6338/1- .
Note
If there is no adapter in the adapter case of the motor car set VAS6338/1- for the expansion valve, the removed expansion
valve can also be drilled out (the old expansion valve normally
has to be replaced and is therefore no longer required).
♦ Clean the refrigerant circuit (flush)
⇒ “2.11 Clean the refrigerant circuit.”, page 98 .
Drill out the expansion valve:
– You must not damage the sealing surfaces of the expansion
valve. Refrigerant may escape if the sealing surfaces are
damaged.
Note
♦
Before drilling out, remove the control element and drill out the
expansion valve e.g. with a suitable drill (drill diameter e.g. 6.0
mm).
♦
Before drilling out, some parts may have to be removed from
the expansion valve, depending on design.
♦
Expansion valves come in various different designs and with
different configurations. For type -A-, for example, -B-, -C- and
-D- have to be removed. Then disconnect the part -E- (the
control element) from the component -D-. After doing so, use
a suitable drill to drill out the expansion valve in the area of
-F-.
♦
For type -G-, for example, remove parts -H-, -I- and -K-, then
drill out the area -L- with a suitable drill.
– Clean the drilled out expansion valve from machining residues
(swarf).
– Re-install parts -B-, -C- and -D- for type -A- or part -H- for type
-G-.
1.6.3 Procedure for cleaning the refrigerant
circuit
Note
The procedure is automatic according to the program on the AC
service station ⇒ AC service station operating instructions .
♦ After switching on, the circuit to be flushed (refrigerant circuit
with connection hoses and the flushing device for refrigerant
circuits) is evacuated first, while the refrigerant circuit is tested
for leaks as well (depending on the type of AC service station ,
it may be necessary to continue to the next step manually).
♦ Once the refrigerant circuit has been checked for leaks by
evacuating the circuit, the system then checks that the refrig‐
erant circuit has been assembled correctly by adding a small
amount of refrigerant (pressure testing).
64 Rep. gr.87 - Air conditioning system
Page 69
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♦ After pressure testing, the refrigerant is extracted, the refrig‐
erant
circuit is evacuated again if necessary and the cleaning
process (flushing process) begins.
♦ A specific volume of refrigerant (e.g. 3 kg, depending on in‐
ternal volume of the circuit to be flushed) or enough refrigerant
so that the refrigerant circuit and the inspection glasses of the
flushing device for refrigerant circuits are completely filled with
liquid refrigerant (depending on the design of the AC service
station , you can see that e.g. no more refrigerant is flowing in
after a certain time) is added to the refrigerant circuit via the
high-pressure side of the AC service station (opposite to the
normal flow direction of the air conditioning system and there‐
fore on the low-pressure side of the refrigerant circuit of the
vehicle).
♦ After adding the specified volume of refrigerant, for example,
the heating of the flushing device for refrigerant circuits is
switched on, depending on the version of the AC service sta‐
tion and the flushing device for refrigerant circuits (only if the
refrigerant is drained off as a gas from the flushing device for
refrigerant circuits).
♦ After the refrigerant has been drained off, the heating of the
flushing device for refrigerant circuits (if present) is switched
off, the refrigerant circuit is again briefly evacuated depending
on the version and, after the evacuation, the refrigerant oil
drained out of the refrigerant circuit is removed by the AC
service station .
♦ The sequence of filling with refrigerant and draining off (and
evacuating) is repeated three times (altogether it is performed
four times).
♦ After extracting for the fourth time, the circuit to be flushed is
evacuated depending on the design of the AC service station .
1.6.4 Schematic diagrams for cleaning (cir‐
cuits to be flushed) - refrigerant circuit
with expansion valve and fluid reservoir
♦ With 1 or 2 evaporators
Note
♦
The arrows in the following figures point in the flow direction
of the refrigerant when flushing (the refrigerant flows out op‐
posite to the flow direction in the air conditioning system when
flushing, therefore the high-pressure side of the AC service
station is connected to the low-pressure connection of the re‐
frigerant circuit to the AC compressor).
♦
This schematic diagram shows a refrigerant circuit with ex‐
pansion valve and condenser. The condenser includes a res‐
ervoir with desiccator cartridge (currently, no Škoda vehicle
with refrigerant R1234yf has a separately installed fluid reser‐
voir).
♦
The expansion valve is removed and is replaced by an adapter
from the adapter case of the motor car set - VAS6338/1- (other
adapters are added gradually to the set).
♦
Depending on the design of the AC service station , non-return
valves may be installed between the refrigerant circuit and the
AC service station (to ensure the correct flow direction of the
refrigerant when flushing).
1. Refrigerant circuit 65
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1 - A/C service station
❑
with electronics and a
program for flushing, AC
service station with
flushing device ⇒
(Tools; workshop equip‐
ment/tools; air condi‐
tioning/heating)
❑ If an AC service station
without a program for
flushing is used, the pro‐
cedure must be per‐
formed manually (evac‐
uate, flush at least 4
times with at least 3 kg
of refrigerant each time
and then drain and
evacuate the refrigerant
again).
2 - Refrigerant hose on the AC
service station
❑ From the high-pressure
side of the AC service
station (usually red in
colour) to the connec‐
tion for the low-pressure
side of the AC compres‐
sor on the refrigerant cir‐
cuit (larger diameter)
3 - Adapter to connect to the
low-pressure side on the refrig‐
erant circuit
❑ Different designs de‐
pending on the vehicle
⇒ “1.6.5 Adapter for set‐
ting up the rinsing cy‐
cles”, page 68
❑ from
❑ Depending on the design of the adapter, an additional adapter is required to connect the filler hose of
adapter case of the
motor car set - VAS6338/1-
the AC service station
Note
The filler hose of the AC service
♦
station has an SAE J639 M12 x
1.5-6G external thread; the
adapter to connect to the lowpressure side has a 5/8 -18 UNF
external thread. To be able to
connect the two components,
therefore, an additional adapter
is therefore required ⇒ Electron‐
ic Catalogue of Original Parts
“ETKA” (Tools, workshop equip‐
ment/tools; air conditioning/heat‐
ing).
♦
To achieve as rapid a flow veloc‐
ity as possible, the service cou‐
pler of the filler hose is removed
for flushing (there are restrictions
in the service coupler, which sig‐
nificantly reduce the flow veloci‐
ty).
66 Rep. gr.87 - Air conditioning system
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4 - Connection to the low-pressure side on the refrigerant circuit
❑
Different designs depending on the vehicle
⇒ “1.6.5 Adapter for setting up the rinsing cycles”, page 68
5 - Adapter for the installed expansion valve
❑
Different designs depending on the vehicle
⇒ “1.6.5 Adapter for setting up the rinsing cycles”, page 68
❑
from adapter case of the motor car set - VAS6338/16 - Evaporator
7 - Condenser
❑ with reservoir and desiccator cartridge (close the fluid reservoir again after removing the desiccator car‐
tridge) ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehicle-specific workshop manual)
8 - Fluid reservoir with desiccator cartridge and strainer
❑ Remove the desiccator cartridge and strainer from the reservoir before flushing the refrigerant circuit ⇒
Heating, Air Conditioning; Rep. gr. 87 (vehicle-specific workshop manual)
9 - Plug of the fluid reservoir
❑ different versions depending on the vehicle and the type of condenser ⇒ Heating, Air Conditioning; Rep.
gr. 87 (vehicle-specific workshop manual)
10 - Connection to the high-pressure side on the refrigerant circuit
❑ Different designs depending on the vehicle
⇒ “1.6.5 Adapter for setting up the rinsing cycles”, page 68
11 - Adapter to connect to the high-pressure side on the refrigerant circuit
❑
Different designs depending on the vehicle
⇒ “1.6.5 Adapter for setting up the rinsing cycles”, page 68
❑
from adapter case of the motor car set - VAS6338/112 - Filler hose of the flushing device for refrigerant circuits
❑ from the connection to the high-pressure side of the AC compressor on the refrigerant circuit (smaller
diameter) to inlet of flushing device for the refrigerant circuits
13 - Flushing device for the refrigerant circuits
❑ For different versions and different design, e.g. the flushing device for refrigerant circuits , see ⇒ Elec‐
tronic Catalogue of Original Parts “ETKA” (Tools; workshop equipment/tools; air conditioning/heating)
❑ with filter, inspection glass, safety valve, heating, refrigerant cylinder etc. (depending on the version)
❑ Depending on the design of the AC service station and the flushing device for refrigerant circuits, a non-
return valve may be installed on the outlet of the flushing device for refrigerant circuits (to ensure the
correct flow direction of the refrigerant when flushing).
❑ Depending on the flushing device, there may be a 5/8-18 UNF external thread or a high-pressure service
coupler for R134a or R1234yf at the outlet to the AC service station
Note
To connect the flushing device to
♦
the AC service station , flushing
devices with an 5/8-18 UNF ex‐
ternal thread or a connection for
a R134a low-pressure service
coupler require additional adapt‐
ers to connect the R1234yf lowpressure service coupler or the
filler hose for the AC service sta‐
tion (with an SAE J639 M12 x
1.5-6G external thread) to the
outlet of the flushing device.
1. Refrigerant circuit 67
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♦
The filler hose of the AC service
station has an SAE J639 M12 x
1.5-6G external thread. Depend‐
ing on the design, there may be
a service connector for an SAE
J639 low-pressure service cou‐
pler for refrigerant R1234yf, an
SAE J639 M12 x 1.5-6G internal
thread, a service connector for a
R134a low-pressure service
coupler 5/8 -18 UNF external
thread on the flushing device for
refrigerant circuits. To be able to
connect the two components,
therefore, an additional adapter
is therefore required ⇒ Electron‐
ic Catalogue of Original Parts
“ETKA” .
♦
As the refrigerant is only drawn
from the AC service station at
low flow velocity, the low-pres‐
sure service coupler can be used
in this case.
14 - Refrigerant hose on the AC service station
❑ From the low-pressure side of the AC service station (usually blue in colour) to the outlet of the flushing
device for refrigerant circuits.
1.6.5 Adapter
♦ The table below lists various adapters which are necessary for
connecting the AC service station to the refrigerant circuit for
flushing and to bridge the removed fluid reservoir or AC res‐
ervoir and the expansion valve (vehicle-specific).
♦ If a flushed refrigerant circuit is not reassembled immediately
after
flushing, leave the adapters on the connections and close
the connections on the adapters with the screw caps - VAS
6338/30- .
♦ Depending on the design of the AC compressor and the date
of manufacture, there are different types of connection and
sealing technology on the refrigerant circuit ⇒ AC service sta‐
tion; Rep. gr. 87 (vehicle-specific workshop manual).
Block or screw connections
– Screw -A– Block connection -BBlock connections have different types of seal
for setting up the rinsing cycles
68 Rep. gr.87 - Air conditioning system
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– Block connection with radial-seal connection -A- (with guide
made of plastic or metal -B-)
– Block connection with axial-seal connection -C-
Octavia III, Superb III, Yeti
Vehicle Adapters for the connections
to the AC compressor
Octavia III,
Superb III
♦ Adapter -VAS6338/3-
high-pressure side
♦ Adapter -VAS6338/12-
low-pressure side
Fabia III, Rapid
Vehicle Adapters for the connections
to the AC compressor
Fabia III,
Rapid
♦ High-pressure side (ex‐
6Q0 820 808) adapt‐
cept
er -VAS6338/3-
♦ High-pressure side - A/C
compressors 6Q0 820
808 - adapter VAS6338/2-
♦ Low-pressure side -
adapter -VAS6338/12-
Adapter for bridging the reser‐
voir with desiccator
– Remove desiccator bag
and strainer from the reser‐
voir. Screw in the screw cap
again and flush the circuit
with condenser. After the
flushing, install a new des‐
iccator cartridge and a
strainer.
Condenser with integrated res‐
ervoir with desiccator
– Before flushing remove the
desiccator cartridge, on the
condensers “Modine” also
strainer and the contain‐
the
er.
– After the flushing, install a
new desiccator cartridge
and a strainer (condensers
Modine).
Miscellaneous
– Replace expansion valve
with adapter VAS6338/38- , VAS6338/18- or a reworked
(drilled out) expansion
valve, see
⇒ “1.6.2 Preparing to clean
the refrigerant circuit (to
flush with refrigerant
R1234yf)”, page 63 .
– Check expansion valve af‐
ter flushing (corrosion, dirt),
replace if necessary.
Miscellaneous
– Replace expansion valve
with adapter VAS6338/34- , VAS6338/39-
or a reworked
(drilled out) expansion
valve, see
⇒ “1.6.2 Preparing to clean
the refrigerant circuit (to
flush with refrigerant
R1234yf)”, page 63 .
Check expansion valve af‐
–
ter flushing (corrosion, dirt),
replace if necessary.
1. Refrigerant circuit 69
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Vehicle Adapters for the connections
to the AC compressor
Citigo ♦ Adapter -VAS6338/3-
high-pressure side
♦ Adapter -VAS6338/12-
low-pressure side
Condenser with integrated res‐
ervoir with desiccator
– Flush circuit with reservoir
with desiccator.
–
Install a new reservoir with
desiccator after flushing.
1.6.6 General information about blowing
through
To remove moisture, contamination (e.g. grit from a defective AC
compressor)
saving and environmentally friendly manner without extensive
disassembly and reassembly work, the refrigerant circuit is
cleaned with refrigerant R1234yf (flushed with refrigerant
R1234yf)
The refrigerant circuit must be blown through with compressed air
and nitrogen, for example, if only individual parts are to be
cleaned.
as well as used refrigerant oil in a clean refrigerant-
⇒ “1.6 Clean the refrigerant circuit.”, page 61 .
with compressed air or nitrogen
Miscellaneous
– Replace expansion valve
with adapter VAS6338/36- , VAS6338/34(drilled out) expansion
valve, see
⇒ “1.6.2 Preparing to clean
the refrigerant circuit (to
flush with refrigerant
R1234yf)”, page 63 .
–
Check expansion valve af‐
ter flushing (corrosion, dirt),
replace if necessary.
or a reworked
70 Rep. gr.87 - Air conditioning system
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Note
♦
The refrigerant circuit should only be blown through with com‐
pressed air and then with nitrogen if there is no way to flush
the refrigerant circuit or the effort to flush individual compo‐
nents would be too great (e.g. minor contamination and hu‐
midity can be blown out of the refrigerant lines quickly).
♦
Blowing through the entire refrigerant circuit with compressed
air and nitrogen requires considerably more work than clean‐
ing (flushing) with refrigerant R1234yf. When flushing with
refrigerant R1234yf, the components are also cleaned signif‐
icantly better, therefore, flushing should always be performed
for any issue (blowing through should only be performed for
specific issues and single components).
♦
Under certain conditions, it may be sufficient to blow through
specific components (e.g. specific refrigerant lines or refriger‐
ant hoses) with compressed air (e.g. to force out old refrigerant
oil from specific remove components) or with nitrogen (to dry
specific components).
♦
Certain types of contamination cannot be removed or can only
be removed partially from the refrigerant circuit with com‐
pressed air; these types of contamination can be removed e.g.
by cleaning (flushing) with refrigerant R1234yf
⇒ “1.6 Clean the refrigerant circuit.”, page 61 .
♦
The maximum working pressure when blowing through (with
compressed air or nitrogen) must not be greater than 15 bar
(this is the pressure in a full refrigerant circuit at an ambient
temperature of approximately 60°C; if necessary also use a
pressure reducer for compressed air).
♦
If the gas analysis shows that the refrigerant R1234yf is con‐
taminated by another gas, it must be extracted from the re‐
frigerant circuit and disposed of as a gas of unknown
composition in accordance with statutory provisions
⇒ “2.12 Filling contaminated refrigerant into a recycling cylin‐
der for analysis, treatment or disposal”, page 101 .
♦
When refrigerant is contaminated, decomposition products
can form and collect in the refrigerant oil, which cannot be
drained with the refrigerant. The contaminated refrigerant oil
must be removed in this case by flushing the refrigerant circuit
with refrigerant
⇒ “1.6 Clean the refrigerant circuit.”, page 61 .
♦
If there is no suitable AC service station available for refriger‐
ant R1234yf, the refrigerant circuit may also be cleaned (flush‐
ed) with the AC service station for refrigerant R134a and with
refrigerant R134a. At present, refrigerant R134a may be used
to clean the refrigerant circuit ⇒ Air conditioning system with
refrigerant R134a; Rep. gr. 87 .
WARNING
Risk of injury from fuel escaping under high pressure.
♦ Use the pressure reducer for the nitrogen cylinder.
– Always clean the components in direction opposite to flow of
the refrigerant.
– Extract the mixture of refrigerant, refrigerant oil and com‐
pressed air/nitrogen that comes out of the components using
an extraction system.
1. Refrigerant circuit 71
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Note
Compressed air and nitrogen cannot be blown through the ex‐
pansion valve and AC compressor.
– In the case of condensers that have a desiccator cartridge in
the integrated fluid reservoir, the desiccator cartridge must be
removed.
Note
Depending on the design, there may be an additional filter ele‐
ment in fluid reservoirs where the desiccator cartridge can be
replaced separately, which must be replaced, if necessary, along
with the desiccator cartridge.
– First, blow out old refrigerant oil and dirt using compressed air,
then blow through the components with nitrogen (clean, blow
out old refrigerant oil or dehumidify).
– Adapter to connect the pressure hose to the refrigerant circuit
adapter case of the motor car set - VAS6338/1- .
To ensure no oil or moisture is transferred from the compressed
air system into the refrigerant circuit, note the following.
♦ The compressed air must pass through a compressed-air
cleaning system to be cleaned and dried. You must therefore
use a filter and desiccator for compressed air (scope of deliv‐
ery same as tool for paint work) ⇒ Electronic Catalogue of
Original Parts “ETKA” .
♦ For refrigerant lines with thread or union nut at the connection,
use the adapter from the refrigerant circuit adapter set - V.A.G
1785- ( adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- )
to connect the 5/8 -18 UNF filling hoses (some of these adapt‐
ers are also included in the adapter case of the motor car set
- VAS6338/1- ).
♦ For refrigerant lines without thread or union nut at the con‐
nection (to connect adapters), use adapters from the adapter
case of the motor car set - VAS6338/1- or commercially avail‐
able air gun with rubber mouthpiece.
Note
Compressed air or nitrogen coming out of components must be
extracted by a suitable system (e.g. workshop extraction system).
The refrigerant circuit (or individual parts) must be blown through:
♦ if it is not possible to flush with refrigerant R1234yf or flushing
is not the best option
♦ if there is dirt or other contamination in specific parts of the
circuit
♦ if, during evacuation of a leak-tight refrigerant circuit, the vac‐
uum is not maintained at the gauge (there is moisture in the
refrigerant circuit and this generates pressure)
♦ if the refrigerant circuit has been left open for longer than the
standard assembly time (e.g. following an accident)
♦ if pressure and temperature measurements in the circuit indi‐
cate that there is humidity in the refrigerant circuit
72 Rep. gr.87 - Air conditioning system
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♦ there is any doubt about the oil volume in the refrigerant circuit
♦ the AC compressor needed to be replaced because of internal
damage (in this case it is preferable to flush with refrigerant
R1234yf)
♦ it is required in the workshop manual after replacing certain
components
Note
Certain types of contamination and old refrigerant oil cannot be
removed or can only be removed partially from the refrigerant cir‐
cuit with compressed air or nitrogen; these types of contamination
can be removed e.g. by flushing with refrigerant R1234yf
⇒ “1.6 Clean the refrigerant circuit.”, page 61 .
♦ Blowing through the refrigerant circuit with compressed air and
nitrogen
⇒ “1.6.7 Blowing through the refrigerant circuit with com‐
pressed air and nitrogen”, page 73
1.6.7 Blowing through the refrigerant circuit with compressed air and nitrogen
Note
♦
On vehicles without a thread to connect the VAG adapter 1785- to the refrigerant lines, an air gun with rubber mouth‐
piece or an adapter from the adapter case of the motor car set
- VAS6338/1- , for example, must be used to blow through the
individual components. If using an air gun with rubber mouth‐
piece, make sure in particular that the connections are not
damaged (crushed or scratched).
♦
The evaporator must be blown through via the low-pressure
line connection (large diameter) once the expansion valve or
the restrictor has been removed.
♦
Always blow through the components against the flow direc‐
tion of the refrigerant.
♦
Check expansion valve; replace if corroded or contaminated.
♦
If there are dark, sticky deposits in the components and the
deposits cannot be removed with compressed air, flush these
components with refrigerant R1234yf or replace them.
♦
Thin, light grey deposits on the inside (of the pipe) do not hin‐
der the operation of the components.
After blowing through the refrigerant circuit:
– Replace the desiccator cartridge and strainer in the fluid res‐
ervoir ⇒ Heating, Air Conditioning; Rep. gr. 87 (vehiclespecific workshop manual) and ⇒ Electronic Catalogue of
Original Parts “ETKA” .
– Depending on the issue, replace the AC compressor ⇒ Heat‐
ing, Air Conditioning; Rep. gr. 87 (vehicle-specific workshop
manual) and ⇒ Electronic Catalogue of Original Parts “ETKA”
or drain the remaining refrigerant oil from the removed AC
compressor
with the specified quantity of fresh refrigerant oil ⇒ Heating,
Air
Conditioning; Rep. gr. 87 (vehicle-specific workshop man‐
ual) and ⇒ Heating, Air Conditioning; Rep. gr. 87 .
⇒ “1.5 Replace components”, page 55 and re-fill
1. Refrigerant circuit 73
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Note
♦
There is a specific quantity of refrigerant oil in the replacement
compressor.
♦
If the AC compressor is not to be replaced, add refrigerant oil
as per the specified filling volume (tip out refrigerant oil and
add the specific volume to the AC compressor or the refriger‐
ant circuit again) ⇒ “1.5 Replace components”, page 55 , ⇒
Heating, Air Conditioning; Rep. gr. 00 .
– Assemble the entire refrigerant circuit again ⇒ Heating, Air
Conditioning; Rep. gr. 87 (vehicle-specific workshop manual).
– Evacuate and fill the refrigerant circuit as specified
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 and
⇒ “2.6 Filling the refrigerant circuit”, page 92 .
– Operate the air conditioning system as specified ⇒ Heating,
Air Conditioning; Rep. gr. 87 and
⇒ “2.7 Operate the air conditioning system after filling”,
page 94
1.7 Checking pressures with the pressure gauge
⇒ “1.7.1 Indicator on pressure gauges”, page 74
⇒ “1.7.2 Pressure gauges allow to carry out the following inspec‐
tion and measurement work”, page 75
1.7.1 Indicator on pressure gauges
1 - Temperature scale for refrigerant R1234yf (CF3CF = CH2)
in °C
2 - Pressure scale in bar overpressure
Note
♦
The pressure is stated in different units; 1 MPa (mega Pascal)
equals 10 bar overpressure or 145 psi; 1 bar absolute pressure
approximately equals the ambient pressure (atmospheric
pressure) at 0 bar overpressure.
♦
This illustration shows a pressure gauge showing the pressure
on the low-pressure side; the indicator is in bar overpressure
(which you can see from “-1” on the scale).
The pressure gauges can have one or more temperature scales
in addition to the pressure scale. The values of the scale for
R1234yf are as per the vapour pressure table. As various refrig‐
erants build up different vapour pressures at the same tempera‐
ture, every temperature scale is marked for the corresponding
refrigerant.
♦ Pressure gauges allow the following inspection and measure‐
ments to be performed
⇒ “1.7.2 Pressure gauges allow to carry out the following in‐
spection and measurement work”, page 75 .
74 Rep. gr.87 - Air conditioning system
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1.7.2 Pressure gauges allow to carry out the following inspection and measurement work
Pressure and temperature measurement on the refrigerant circuit
♦ The high-pressure gauge measures the pressure (and the
temperature), which spreads uniformly from the outlet of the
AC compressor via the condenser up to the restriction (re‐
strictor or expansion valve) when the air conditioning system
is switched on.
♦ The low-pressure gauge measures the pressure (and the tem‐
perature), which spreads uniformly from the restriction (re‐
strictor or expansion valve) via the evaporator up to the inlet
of the AC compressor when the air conditioning system is
switched on.
Note
The interdependence described on the pressure gauges, be‐
tween pressure and temperature, only exists where liquid or
vapour is contained in the refrigerant circuit, however not gas. In
the gaseous condition, the temperature is around 10 °C to 30 °C
higher than the pressure gauge indicates.
Evidence of refrigerants in a closed reservoir
In a closed reservoir or in the refrigerant circuit, refrigerant
R1234yf is present if the temperature reading of the pressure
gauge corresponds to the temperature of the refrigerant (station‐
ary liquid takes on ambient temperature).
A closed reservoir or a switched off refrigerant circuit is empty if
the temperature reading of the pressure gauge lies below the
temperature of the refrigerant.
Note
♦
The interdependence described on the pressure gauges, be‐
tween pressure and temperature, does no longer exist if no
liquid is contained and the pressure only builds up through
gas.
♦
As a pressures of refrigerant R1234yf and R134a are very
close to each other across a large range of temperatures, it is
not possible to distinguish between the refrigerants by meas‐
uring the pressure. It is possible to distinguish between the
refrigerants e.g. by gas analysis
⇒ “6.2.16 Analysis of refrigerant R1234yf”, page 23 .
1. Refrigerant circuit 75
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76 Rep. gr.87 - Air conditioning system
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2 Working with the A/C service station
⇒ “2.1 Working with the A/C service station”, page 77
⇒ “2.2 Connecting the AC service station to the refrigerant circuit”,
page 79
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82
⇒ “2.4 Exhaust refrigerant circuit.”, page 84
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87
⇒ “2.6 Filling the refrigerant circuit”, page 92
⇒ “2.7 Operate the air conditioning system after filling”,
page 94
⇒ “2.8 Switching off the AC service station and disconnecting it
from the refrigerant circuit”, page 94
⇒ “2.9 Filling refrigerant into the reservoir”, page 96
⇒ “2.10 Draining the A/C service station”, page 97
⇒ “2.11 Clean the refrigerant circuit.”, page 98
⇒ “2.12 Filling contaminated refrigerant into a recycling cylinder
for analysis, treatment or disposal”, page 101
⇒ “2.13 Check pressures”, page 106
2.1 Working with the A/C service station
Note
♦
If it is suspected that chemical agents (leakstop additives)
have been added to the refrigerant circuit that you want to ex‐
tract from, do not connect the AC service station to the refrig‐
erant circuit and do not flush the refrigerant circuit.
♦
Chemical agents (leakstop additives) used to seal leaks form
deposits in the refrigerant circuit which impair the function of
the air conditioning system and lead to a failure of the air con‐
ditioning system (and the AC service station ).
♦
The customer must be informed that there are agents present
in the air conditioning system that have not been approved by
Volkswagen/Audi and the air conditioning system can there‐
fore not be emptied and repaired.
♦
Commercially available chemicals (leakstop additives) to seal
leaks on refrigerant circuits are not approved by Škoda Auto.
There are no tests for the long-term endurance, effectiveness
or material compatibility of these chemicals, so that it is not
possible to guarantee that the air conditioning system or the
AC service station will not be damaged or malfunction.
♦
Commercially available leakstop additives have different
physical and chemical properties, which can permanently re‐
duce the ability the air conditioning system and the AC service
station to function and even cause the system to fail com‐
pletely.
♦
Škoda Auto does not use chemicals (leakstop additives) to
seal leaks on refrigerant circuits.
2. Working with the A/C service station 77
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♦
Chemical agents (leakstop additives) used to seal leaks on a
refrigerant circuit usually react with the ambient air and the
humidity in air to form deposits in the refrigerant circuit (and in
the AC service station ), which cause valves and other com‐
ponents that come into contact with the deposits to malfunc‐
tion. These deposits can no longer be completely removed
from the components (even by flushing).
♦
Chemical agents (leakstop additives) used to seal leaks on a
refrigerant circuit normally cannot be identified from the out‐
side. The applicable labels that are supposed to be attached
to show they have been added are also typically not present.
Therefore be careful with a vehicle, whose past you are not
familiar with.
♦
Reservoirs are available on the accessories market with inte‐
grated filters that are supposed to remove these chemical
agents (leakstop additives to seal leaks). Since Škoda Auto
does not know the composition and therefore the physical and
chemical properties of these agents, it is not possible to com‐
ment on the effectiveness and the deposition rate of these
filters.
If the refrigerant circuit if the air conditioning system needs to be
repaired on a vehicle with a refrigerant circuit that contains chem‐
ical agents (leakstop additives) that have been added to seal
leaking components (or even if you only suspect that such agents
have been added), inform the customer (vehicle owner) of the
following:
♦ The refrigerant in the air conditioning system cannot be ex‐
tracted because chemicals (leakstop additives) have been
added, which may damage the AC service station . To extract
the refrigerant, the refrigerant can be drained into a recycling
cylinder, as for contaminated refrigerant
⇒ “2.12 Filling contaminated refrigerant into a recycling cylin‐
der for analysis, treatment or disposal”, page 101 . If that is
not
possible, a company must be employed to extract the con‐
taminated refrigerant with suitable equipment and then treat
(or dispose of) the refrigerant from the refrigerant circuit (e.g.
a local waste disposal company that disposes of refrigerants).
♦ To repair the air conditioning system properly, all parts of the
refrigerant circuit that have come into contact with the leakstop
additive must be replaced. Specific parts of the refrigerant cir‐
cuit (e.g. the AC compressor regulating valve - N280- ) may
already have been damaged by the leakstop additive or may
be damaged once the system is operated again and then fail
after a short period of time. Deposits of leakstop additive in the
parts of the refrigerant circuit may also detach at a later time
and then may cause the air conditioning system to fail again
(it is currently not possible to clean these components com‐
pletely with workshop equipment).
♦ Contaminated refrigerant may make all the liquid added to
your AC service station unusable.
♦ Before extracting with a suitable testing device, check the
composition of the refrigerant in the refrigerant circuit
⇒ “2.3 Performing gas analysis for the refrigerant”,
page 82 .
♦ Extract contaminated refrigerant into a recycling cylinder and
send
the cylinder back to your gas supplier for analysis, treat‐
ment or disposal.
78 Rep. gr.87 - Air conditioning system
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Note
♦
Contaminated refrigerant may change the way in which the air
conditioning system functions and/or destroy parts of the re‐
frigerant circuit.
♦
Mixtures of different types of refrigerants (e.g. refrigerant
R1234yf with an unknown proportion of refrigerant R134a)
must not be added to a vehicle that has been type-tested with
refrigerant R1234yf.
Further instructions for working with the AC Service station
Note the following information when operating the AC service
station (currently available AC service station ⇒ Electronic Cata‐
logue of Original Parts “ETKA” ):
♦ The installed filters and desiccators must be replaced at the
latest after reaching the operating time specified in the related
operating instructions.
♦ If an AC service station is also used to clean (flush) the refrig‐
erant circuit, the installed filters and desiccators must be re‐
placed sooner.
♦ Only add refrigerant oils to the reservoir that are approved for
the vehicle-specific refrigerant circuit (if necessary, add the
refrigerant oil directly to the refrigerant circuit) ⇒ Electronic
Catalogue of Original Parts “ETKA” .
♦ Depending on the design of the AC service station and the
work to be performed, a specific minimum quantity of refriger‐
ant, refrigerant oil and UV leak detection additive must be
present in the reservoirs of the AC service station ⇒ AC serv‐
ice station operating instructions .
If there is any doubt about the composition of the refrigerant ex‐
tracted from the refrigerant circuit, it must not be re-used even
after it has been cleaned in the AC service station
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82 .
♦ If the wrong refrigerant has been added to the AC service sta‐
tion by mistake, it must be emptied
⇒ “2.4 Exhaust refrigerant circuit.”, page 84 and
⇒ “2.2 Connecting the AC service station to the refrigerant cir‐
cuit”, page 79 ; if necessary the system must be cleaned and
filters and the desiccators as well as the added refrigerant
the
oil must be replaced.
♦ Contaminated refrigerant can be returned to the supplier of the
refrigerant in recycling cylinders for treatment or ecological
disposal (different or additional directives may apply in specific
countries).
2.2 Connecting
refrigerant circuit
Connect
• Depending on the type of the selected tools, the work proce‐
dure may vary. Therefore, follow the tool-specific operating
instructions.
Note
The work procedure must always be carried out as described in
the operating instructions for the AC service station ⇒ AC service
station operating instructions .
the AC service station to the
2. Working with the A/C service station 79
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To ensure that no air or humidity can pass through the filling hoses
into the refrigerant circuit, they must be connected according to
the following work procedure:
– Switch off ignition.
– Connect the AC service station to the voltage supply.
– Switch
relevant operating instructions ⇒ AC service station operating
instructions .
– Unscrew the screw caps from the service connectors (see ve‐
hicle-specific refrigerant circuit) ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– If necessary, evacuate the filling hoses.
– Connect the quick couplers to the service connectors of the
refrigerant circuit.
on the AC service station and operate according to the
Caution
There is a risk of damaging the AC compressor or the AC serv‐
ice station.
When the air conditioning system is switched on, a short-circuit
may occur between the high- and low-pressure sides when the
valves are opened.
♦ When the air conditioning system is switched on, never
open the valves on the high- or low-pressure sides.
– Carefully
just until the valve of the service connector is definitely open
(observe the pressure gauge, do not apply excess pressure to
the valve).
– Perform gas analysis with the AC service station (only neces‐
sary if refrigerant is to be extracted or the pressures in the
refrigerant circuit are to be checked)
⇒ “2.3 Performing gas analysis for the refrigerant”,
page 82 .
turn in the handwheel of the on the low-pressure side
Note
Connect the gas analyser or the AC service station to the refrig‐
erant circuit as per the applicable operating instructions, then
operate ⇒ Gas analyser operating instructions
⇒ “2.2 Connecting the AC service station to the refrigerant circuit”,
page 79 and /or ⇒ AC service station operating instructions .
If gas analysis shows that the refrigerant in the circuit does not
comply with the specifications:
– Carefully turn in the handwheel of the on the high-pressure
side just until the valve of the service connector is definitely
open (observe the pressure gauge, do not apply excess pres‐
sure to the valve).
– Complete the relevant work on the refrigerant circuit with the
AC service station .
80 Rep. gr.87 - Air conditioning system
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Note
♦
If the gas analysis shows that the refrigerant R1234yf is con‐
taminated, extract the refrigerant from the refrigerant circuit
and send it back e.g. to your gas supplier for treatment (or
disposal)
⇒ “2.12 Filling contaminated refrigerant into a recycling cylin‐
der for analysis, treatment or disposal”, page 101 ,
⇒ “6.1 Principles of the air-conditioning technology”,
page 14 .
♦
If it is not possible to transfer the contaminated refrigerant im‐
mediately from the refrigerant circuit of the vehicle to a recy‐
cling cylinder: Unscrew the handwheel of the quick coupler
adapter on the low-pressure side (close) and switch off the AC
service station (if necessary, also disconnect from the power
supply). Then disconnect the quick coupler adapter on the lowpressure side from the vehicle. Finally, disconnect the quick
coupler adapter on the low-pressure side from the filler hose
for the AC service station e.g. from an extraction hose of the
workshop extraction system and allow the contaminated re‐
frigerant to flow out of the filler hose into the extraction hose
of the workshop extraction system. To prepare the AC service
station for operation again, re-attach the quick coupler adapter
of the low-pressure side to the filler hose on the AC service
station and evacuate with the AC service station as per the
applicable operating instructions ⇒ AC service station oper‐
ating instructions .
– Complete the relevant work on the refrigerant circuit with the
AC service station .
♦
⇒ “2.3 Performing gas analysis for the refrigerant”,
page 82
♦ ⇒ “2.4 Exhaust refrigerant circuit.”, page 84
♦ ⇒ “2.5 Evacuating the refrigerant circuit.”, page 87
♦ ⇒ “2.6 Filling the refrigerant circuit”, page 92
♦ ⇒ “2.8 Switching off the AC service station and disconnecting
it from the refrigerant circuit”, page 94
♦ ⇒ “2.9 Filling refrigerant into the reservoir”, page 96
♦ ⇒ “2.10 Draining the A/C service station”, page 97
♦ ⇒ “2.13 Check pressures”, page 106
2. Working with the A/C service station 81
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2.3 Performing gas analysis for the refriger‐
ant
Note
♦
The refrigerant that is used must have a certain purity to run
the air conditioning system.
♦
Contamination with other refrigerants or gases can cause
damage and therefore failure of the air conditioning system.
♦
Contaminated refrigerant must be returned e.g. to your gas
supplier to be treated (or disposed of) as a gas of unknown
composition in accordance with statutory provisions.
♦
To make sure that liquid components (e.g. droplets of refrig‐
erant oil) in the extracted refrigerant gas does not cause the
gas analysis result to be false, filters are installed in the gas
analyser to filter out the droplets of liquid. Replace the filters
as specified in the operating instructions for the gas analyser
or AC service station ⇒ Gas analyser operating instructions
or ⇒ AC service station operating instructions .
– Connect the gas analyser or the AC service station to the re‐
frigerant circuit as per the applicable operating instructions,
then operate ⇒ Gas analyser operating instructions
⇒ “2.2 Connecting the AC service station to the refrigerant cir‐
cuit”, page 79
tions .
– Perform gas analysis as per the operating instructions.
and /or ⇒ AC service station operating instruc‐
Note
♦
The gas analysis may be incorrect if there is air in the refrig‐
erant hoses or the gas analysis procedure in the operating
instructions is not observed.
♦
Always carefully follow the operating instructions for the gas
analyser/ AC service station .
♦
Evacuate the refrigerant hoses of the AC service station be‐
fore connecting the service couplers to the refrigerant circuit/
a gas cylinder with refrigerant R1234yf (see operating instruc‐
tions for the gas analyser/ AC service station )
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82 .
The gas analysis may provide the following results:
♦ The analysed refrigerant R1234yf complies with the specifi‐
cations; the planned work can be performed with the AC
service station .
♦ An error occurred during the gas analysis. The error must be
identified and corrected, then the gas analysis must be repea‐
ted.
♦ The analysed refrigerant R1234yf does not comply with the
specifications. The analysed refrigerant must be extracted as
a gas of unknown composition and returned e.g. to your gas
supplier to be treated (or disposed of).
82 Rep. gr.87 - Air conditioning system
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Note
♦
If contamination is identified when analysing refrigerant that
e.g. is to be extracted from a vehicle refrigerant circuit: You
may also perform a gas analysis e.g. with refrigerant from a
supply cylinder from your gas supplier to verify the results.
♦
Because of the purity required for refrigerant R1234yf, even
small amounts of ambient air in the filling hoses of the AC
service station can lead to incorrect results. Therefore, there
is a procedure for most AC service stations which involves re‐
peating gas analysis twice more before OK result is shown ⇒
AC service station operating instructions .
♦
You can easily check that you will gas analyser is working
correctly e.g. by using ambient air (unscrew the service cou‐
pler from the refrigerant hose that is to be used for gas analysis
and perform gas analysis with an open refrigerant hose). The
analyser should then indicate that the analysed gas is not OK.
♦
This gas analysis procedure has been developed for the au‐
tomotive workshop; it does not provide definite information
about the specific composition of the refrigerant. This gas
analysis can therefore only provide information about the pro‐
portion of refrigerant R1234yf in the analysed refrigerant. If the
proportion of R1234yf is less than 95%, the refrigerant no lon‐
ger complies with the specifications and may damage parts of
the refrigerant circuit. There is currently no gas analysis avail‐
able for workshops that can also identify the exact composition
of the analysed refrigerant. Gas analyses that can be used to
determine the exact composition of gases involve expensive
devices and costly procedures and can typically only be per‐
formed in dedicated test environments.
If contaminated refrigerant is identified by the gas analysis, sneak
to the customer before any other work and inform the customer
following:
There is contaminated refrigerant or refrigerant of unknown com‐
position in the refrigerant circuit of the customer’s vehicle, which
does not comply with the vehicle manufacturers specifications.
This refrigerant:
♦ Must be extracted as a refrigerant of unknown composition
and returned e.g. to your gas supplier to be analysed and
treated (or disposed of).
♦ May be the cause of a malfunction or already have damaged
the refrigerant circuit so much that a malfunction may occur in
the near future.
♦ Depending on its composition, using contaminated refrigerant
may invalidate the vehicle’s approval certificate.
♦ If the contaminated refrigerant causes internal damage to the
refrigerant circuit (e.g. if the products of decomposition of the
contaminated refrigerant have attacked parts of the refrigerant
circuit
⇒ “1.5 Replace components”, page 55
circuit can only be repaired 100% if all parts that have come
into contact with the contaminated refrigerant are replaced.
You can assess the internal condition of the refrigerant circuit
e.g. by visually inspecting specific components (e.g. the con‐
dition of the internal surface of removed refrigerant lines and
refrigerant hoses, of the internal surface of the fluid reservoir
and the condition of the removed desiccator cartridge).
♦ If the contaminated refrigerant has damaged the inside of the
refrigerant circuit (e.g. the AC compressor has failed because
of damaged control elements or as a result of overheating, the
refrigerant oil has discoloured more than normal, but the parts
conveying refrigerant have not been attacked
), the refrigerant
2. Working with the A/C service station 83
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⇒ “1.5 Replace components”, page 55
can be re-filled after the circuit has been flushed (replace AC
compressor, desiccator and expansion valve). However, be‐
cause it is not possible to assess the long-term effect of the
contaminated refrigerant on the refrigerant oil or the parts of
the refrigerant circuit, it is also not possible in these circum‐
stances to guarantee that the parts of the refrigerant circuit will
continue to function in future.
♦ If the contaminated refrigerant has not damaged the inside of
the refrigerant circuit (e.g. the refrigerant oil has not discol‐
oured more than normal, the parts of the refrigerant circuit
have not been attacked), the refrigerant circuit can be re-filled
after replacing the desiccator and flushing the refrigerant cir‐
cuit for a longer time (at least 1 hour). However, because it is
not possible to assess the long-term effect of the contaminated
refrigerant on the refrigerant oil or the parts of the refrigerant
circuit, it is also not possible in these circumstances to guar‐
antee that the parts of the refrigerant circuit will continue to
function in future
Note
♦
If there is an issue that has been caused by the contaminated
⇒ “1.5 Replace components”, page 55 .
), the refrigerant circuit
refrigerant (e.g. leaking seals and hoses, damage to the AC
compressor, or contaminated refrigerant oil), the refrigerant
circuit must be flushed, and all parts that have been damaged
by the contaminated refrigerant (seals, hoses, fluid reservoir
and/or desiccator cartridge, expansion valve and AC com‐
pressor) must be replaced. It is found that the contaminated
refrigerant has also attacked other parts (e.g. the internal sur‐
faces of the refrigerant pipes and refrigerant hoses), the entire
refrigerant circuit must be replaced. Then re-fill the refrigerant
circuit with clean refrigerant. Finally, check that the air condi‐
tioning system is functioning correctly. Inform the customer of
the fact that the refrigerant circuit was filled with contaminated
refrigerant, including to protect yourself against liability.
♦
If there is an issue that has been caused by the contaminated
refrigerant (e.g. no or limited cooling capacity) and no other
issues are identified on the refrigerant circuit or the refrigerant
has to be extracted for work in the area of the refrigerant circuit,
proceed as follows after extracting the refrigerant. Remove the
desiccator and check the desiccator for contamination; also
check the refrigerant oil that is on or in the desiccator. If the
refrigerant oil is contaminated, dark or viscous or if there is dirt
deposited on the desiccator, flush the refrigerant circuit and
replace the parts as described above (damage which may
cause the air conditioning system to fail soon may already
have occurred). If the refrigerant oil is OK and the desiccator
is also not contaminated more than from normal operation,
replace the desiccator. Evacuate the refrigerant circuit for lon‐
ger than normal (at least 1 hour) and then re-fill with clean
refrigerant. Check operation of the air conditioning system. In‐
form the customer of the fact that the refrigerant circuit was
filled with contaminated refrigerant, including to protect your‐
self against liability.
2.4 Exhaust refrigerant circuit.
• Depending on the type of the selected tools, the work proce‐
dure may vary. Therefore, follow the tool-specific operating
instructions ⇒ AC service station operating instructions .
• The refrigerant circuit must be drained if parts of the refrigerant
circuit are to be removed, if there is any doubt about the vol‐
ume of refrigerant in the circuit, if contaminated refrigerant is
84 Rep. gr.87 - Air conditioning system
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identified by gas analysis or if required for other safety pre‐
cautions.
• All the essential operating instructions for work with the AC
service
station for refrigerant are provided in the operating in‐
structions for the AC service station ⇒ AC service station
operating instructions .
Empty
– Switch off ignition.
– Connect the AC service station to the voltage supply.
Note
– Operate the AC service station according to the relevant op‐
erating instructions.
– Unscrew the screw caps from the service connectors of the
refrigerant circuit (see vehicle-specific refrigerant circuit) ⇒
Heating, Air Conditioning; Rep. gr. 87 .
– Connect the AC service station to the refrigerant circuit
⇒ “2.2 Connecting the AC service station to the refrigerant cir‐
cuit”, page 79 .
– Use the AC service station to perform a gas analysis
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82 .
Note
♦
If the gas analysis shows that the refrigerant R1234yf is con‐
taminated, extract the refrigerant from the refrigerant circuit
and send it back e.g. to your gas supplier for analysis, treat‐
ment or disposal.
♦
Drain off contaminated refrigerant into a recycling cylinder and
send it back e.g. to your gas supplier for analysis, treatment
or disposal.
– Empty the refrigerant circuit with the aid of the AC service sta‐
tion according to the relevant operating instructions.
Caution
There is a risk of damaging the AC compressor when the re‐
frigerant circuit is empty.
♦ Never start the engine when the refrigerant circuit is emp‐
ty.
2. Working with the A/C service station 85
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Note
♦
It is always possible that some refrigerant oil will be extracted
from the refrigerant circuit with the refrigerant. To ensure that
the AC compressor is lubricated, the refrigerant oil in the circuit
must be topped up with fresh oil
⇒ “2.6 Filling the refrigerant circuit”, page 92 .
♦
On vehicles with an AC compressor without magnetic clutch
(with AC compressor regulating valve - N280- ) the engine
should only run with an empty refrigerant circuit when the re‐
frigerant circuit has been installed completely. Only run the
engine for as long as absolutely necessary and avoid high en‐
gine speeds (the AC compressor always runs with the engine).
♦
Depending on the design of the AC compressor, a valve may
be installed on the high-pressure side of the AC compressor,
which prevents liquid refrigerant flowing back into the AC com‐
pressor after the air conditioning system has been switched
off. If an AC compressor with such a valve is installed in a
vehicle with a refrigerant circuit with expansion valve, it may
take a relatively long time until the pressure on the high-pres‐
sure side falls (the expansion valve is cold and the pressure
on the low-pressure side increases rapidly after switching off,
the expansion valve closes and the refrigerant circuit can only
flow slowly to the low-pressure side). If the AC compressor is
switched on (or the refrigerant circuit is emptied via the lowpressure side), the pressure on the low-pressure side falls, the
expansion valve opens and the refrigerant can flow to the lowpressure side.
If work is to be performed on the vehicle after emptying and the
AC service station is required for the work:
– Disconnect the AC service station from the refrigerant circuit
and switch off
⇒ “2.8 Switching off the AC service station and disconnecting
it from the refrigerant circuit”, page 94 .
– Open the refrigerant circuit at the connection point.
WARNING
Risk of frostbite through refrigerant escaping under pressure!
This may cause frostbite on the skin and other parts of the
body.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Evacuate the refrigerant circuit and immediately open the
refrigerant circuit.
♦ If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure builds up in the refrigerant cir‐
cuit as a result of secondary evaporation.
– Complete the planned work on the refrigerant circuit.
If the refrigerant circuit is to be evacuated and re-filled after emp‐
tying ⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 :
86 Rep. gr.87 - Air conditioning system
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Note
After opening connection points on the refrigerant circuit, the open
lines and part connections must be closed so that humidity and
dirt cannot get into these parts.
2.5 Evacuating the refrigerant circuit.
• The work procedure must always be carried out as described
in the operating instructions for the AC service station ⇒ AC
service station operating instructions .
• The volume of refrigerant oil in the AC service station has been
checked
erating instructions .
Before the refrigerant circuit is filled with refrigerant, it must be
evacuated, i.e. under negative pressure. In addition, humidity is
drawn out of the circuit at the same time.
When the refrigerant circuit is evacuated, leaks may be identified
⇒ “1.4 Identifying leaks”, page 45 .
and corrected if necessary ⇒ AC service station op‐
Caution
There is a risk of damaging the AC compressor when there is
a vacuum in the refrigerant circuit.
♦ Never start the engine when there is a vacuum in the re‐
frigerant circuit.
Evacuating
• The refrigerant circuit is fully assembled.
– Switch off ignition.
– Connect the AC service station to the voltage supply.
– Operate the AC service station according to the relevant op‐
erating instructions ⇒ AC service station operating instruc‐
tions .
– Unscrew the screw caps from the service connectors of the
refrigerant circuit (see vehicle-specific refrigerant circuit) ⇒
Heating, Air Conditioning; Rep. gr. 87 .
– Connect the AC service station to the refrigerant circuit
⇒ “2.2 Connecting the AC service station to the refrigerant cir‐
cuit”, page 79 .
– Switch
cuit and perform the vacuum test.
on the AC service station , evacuate the refrigerant cir‐
2. Working with the A/C service station 87
Page 92
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Note
♦
The vacuum at the end of the evacuation procedure (vacuum
pump of the AC service station running) must be less than 5
mbar absolute pressure. If the pressure in the refrigerant cir‐
cuit does not fall below 5 mbar during evacuation, there are
various possible causes. These include e.g. a leak in the re‐
frigerant circuit or in the connection to the AC service station ,
the time set for the evacuation procedure is too short, or the
vacuum pump of the AC service station is not generating the
required vacuum.
♦
An absolute pressure of 5 mbar is equivalent to a vacuum of
975 mbar e.g. at an ambient pressure of 980 mbar.
♦
At the end of the vacuum/isolation test, the pressure in the
refrigerant circuit must not be greater than 20 mbar absolute
pressure. If the pressure in the refrigerant circuit increases to
more than 20 mbar during the vacuum/isolation test, the vac‐
uum pump is switched on and the procedure starts again from
the beginning ⇒ AC service station operating instructions . If
the pressure in the refrigerant circuit still does not fall below
20 mbar when the procedure is repeated for a second time,
there are various possible causes. These include e.g. a leak
in the refrigerant circuit or in the connection from the refriger‐
ant circuit to the AC service station or in the AC service station
itself, the time set for the evacuation procedure is too short
and the time set for the vacuum/isolation test is too long.
♦
If you suspect that there is a leak in the refrigerant circuit,
switch off the AC service station and leave it to stand for as
long as possible (e.g. at least 1 hour for the refrigerant circuit
leak test) ⇒ AC service station operating instructions .
♦
Depending on the design of the AC service station , the pres‐
sure in the refrigerant circuit is displayed directly, but the
station may also only display the current pressure when the
vacuum pump is running ⇒ AC service station operating in‐
structions . If an AC service station only display the ambient
pressure, the indicator for the pressure in the refrigerant circuit
depends on ambient pressure when the station is switched on
(if the ambient pressure is 980 mbar, a vacuum of 975 mbar
is equivalent to a residual pressure of 5 mbar absolute pres‐
sure).
♦
If the refrigerant circuit has been opened, small amounts of
humidity may have got into the refrigerant circuit with the am‐
bient air. In this case, the refrigerant circuit must be evacuated
for at least 30 minutes (pressure in refrigerant circuit before
filling is less than 20 mbar).
♦
If the refrigerant has been extracted (to check the filling vol‐
ume) and the refrigerant circuit is only being evacuated to be
then be re-filled (the refrigerant circuit has not been opened
and is leak-tight), you only need to evacuate the refrigerant
circuit for 5 minutes and do not need to set any time or only a
short time (e.g. 1 minutes) for the vacuum/isolation test (no air
or humidity has got into the refrigerant circuit).
♦
Depending on the volume of refrigerant oil in the refrigerant
circuit, the age and the service life of the vehicle, the type of
refrigerant circuit etc., it may also be the case that, on a leaktight refrigerant circuit, the specified absolute pressure in the
circuit rises above the specified 20 mbar during the vacuum
test as a result of refrigerant (potentially also humidity) that
evaporates from the refrigerant oil. If this is the case, repeat
the procedure if necessary and/or adjust the set times accord‐
ingly.
88 Rep. gr.87 - Air conditioning system
Page 93
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If the vacuum indicator does not change (and the pressure re‐
mains
below 20 mbar), the system is leak-tight and can be filled.
Note
♦
Depending on the type of AC service station , the current pres‐
sure in the refrigerant circuit is constantly displayed or only
displayed e.g. after the “Evacuate” function is switched of ⇒
AC service station operating instructions .
♦
The extensive evacuation may result in the refrigerant evap‐
orating from the refrigerant oil increasing the pressure in the
refrigerant circuit to 20-40 mbar (absolute pressure) during the
vacuum test. This does not indicate a leak in the refrigerant
circuit, but – depending on the type of AC service station – may
cause an error to be displayed. If necessary, evacuate the re‐
frigerant circuit again and observe the vacuum indicator for an
extended period of time; the system may only be filled once
the vacuum persists and you are sure that the refrigerant cir‐
cuit is leak-tight.
– Fill the refrigerant circuit using the AC service station
⇒ “2.6 Filling the refrigerant circuit”, page 92 .
If the vacuum does not persist or an adequate vacuum cannot be
generated, proceed as follows:
♦ If the pressure in the refrigerant circuit increase only slowly
– If you are not sure whether the refrigerant circuit is really leak-
– You should only fill the system if you are really sure that the
If a leak is identified when evacuating, proceed as follows:
♦ If there is a leak that is so large that so much air enters the
– Identify the leak point on the refrigerant circuit as follows:
evacuating e.g. because of refrigerant (or humidity) evap‐
after
orating from the refrigerant oil, evacuate the refrigerant circuit
again and observe the vacuum indicator for an extended pe‐
riod of time.
tight, evacuate it again and observe the vacuum indicator for
a longer period. Only fill the system if the vacuum remains
constant.
refrigerant circuit is leak-tight
⇒ “2.6 Filling the refrigerant circuit”, page 92 .
when it is evacuated that the AC service station cannot
circuit
generate a sufficient vacuum or the vacuum indicator, imme‐
diately after the AC service station is switched off, indicates
that air is entering and the vacuum is dissipating:
2. Working with the A/C service station 89
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90 Rep. gr.87 - Air conditioning system
Page 95
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Note
♦
A major leak can be identified, for example, by generating a
pressure of maximum 15 bar in the refrigerant circuit with clean
and dried compressed air or with nitrogen
⇒ “1.6.7 Blowing through the refrigerant circuit with com‐
pressed air and nitrogen”, page 73 . If the leak is large enough,
noise can be heard at the leak point, which is produced by the
escaping air or gas.
♦
The compressed air or nitrogen can be introduced into the
closed, empty refrigerant circuit via service connector -B- by
attaching a quick coupler adapter -A-.
♦
Carefully turn in the handwheel -C- of the -A- until the valve of
the service connector -B- is definitely open (do not apply ex‐
cess pressure to the valve).
♦
The quick coupler adapter for the service connectors can be
connected to the workshop compressed air system, for exam‐
ple, with a modified filler hose -A- (e.g. with a SAE J639 M12
x 1.5-6G thread), depending on the thread on the quick coupler
adapter and with a suitable adapter -B-
⇒ “3.3 Tools that can be made instead of purchasing”,
page 135 . To ensure that no humidity, oil and dirt enters the
refrigerant circuit of the air conditioning system from the work‐
shop compressed air system, also use e.g. a combined fine
filter unit for compressed air system with oil, dirt and moisture
trap, as commonly used for painting systems, placing the filter
unit between the compressed air system and the filler hose
-A- ⇒ Electronic Catalogue of Original Parts “ETKA” .
♦
You can a pressurised gas cylinder filled with nitrogen -3- with
a pressure gauge with pressure reducer for nitrogen (maxi‐
mum reducing pressure: 15 bar) -1- via a filling hose -2- (e.g.
with a SAE J639 M12 x 1.5-6G thread) to the service connector
(to which you have connected a for service connectors) on the
closed refrigerant circuit
⇒ “3.2 Tools and materials, which are commercially available”,
page 135 .
– Slowly increase the pressure in the refrigerant circuit to max.
15 bar.
WARNING
Risk of injury from fuel escaping under high pressure.
♦ Use the pressure reducer for the nitrogen cylinder.
– Identify the leak point from the gas that escapes and causes
noise.
– Eliminate the leak point.
– Drain
♦ If there is a leak that is so small that no air or only a small
the refrigerant circuit and observe the vacuum indicator
again for several hours. Only fill the system if the vacuum re‐
mains constant.
volume of air enters the evacuated refrigerant circuit and the
AC service station can generate a sufficient vacuum (the vac‐
uum indicator does not change or rises only very slowly after
the AC service station is switched off, indicating that air is en‐
tering and the vacuum is dissipating through a small leak only):
2. Working with the A/C service station 91
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– Add
– If necessary, drain the refrigerant circuit
– Repair
– Evacuate the refrigerant circuit and observe the vacuum indi‐
If work is to be performed on the vehicle after evacuating and the
AC service station is required for the work:
– Disconnect the AC service station from the refrigerant circuit
100 grams of refrigerant to the circuit and look for any leak
point with an electronic leak detector
⇒ “1.4.2 Detecting leaks on refrigerant circuits with an elec‐
tronic leak detector”, page 46 or add refrigerant with UV dye
and look for the leak point on the refrigerant circuit with e.g.
the
leak detection system - VAS 6201- and eliminate the leak
⇒ “1.4.3 Searching for leaks with the UV leak detection sys‐
tem”, page 48 .
⇒ “2.4 Exhaust refrigerant circuit.”, page 84 .
the refrigerant circuit ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
cator again for an extended period of time. Only fill the system
if the vacuum remains constant
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
and switch off
⇒ “2.8 Switching off the AC service station and disconnecting
it from the refrigerant circuit”, page 94 .
Caution
There is a risk of damaging the AC compressor when there is
a vacuum in the refrigerant circuit.
♦ Never start the engine when there is a vacuum in the re‐
frigerant circuit.
– Make
If the refrigerant circuit is to be evacuated and re-filled after emp‐
tying and evacuating
⇒ “2.6 Filling the refrigerant circuit”, page 92 :
sure that the engine cannot be started until the refriger‐
ant circuit is filled.
2.6 Filling the refrigerant circuit
Note
♦
The entire filling volume of refrigerant can be added either to
the high-pressure side (recommended) or to the low-pressure
side; filling the refrigerant circuit via the high-pressure side is
described below.
♦
Filling volumes for refrigerant and refrigerant oil ⇒ Heating,
Air Conditioning; Rep. gr. 00 .
• The work procedure must always be carried out as described
in the operating instructions for the AC service station ⇒ AC
service station operating instructions .
• Before adding refrigerant, the volume of refrigerant oil must be
corrected ⇒ Heating, Air Conditioning; Rep. gr. 00 .
• When filling the refrigerant circuit, make sure that the AC serv‐
ice station is on the same level surface as the vehicle with the
refrigerant circuit to be filled (max. difference of 50 cm). If the
difference in height is too great, there may be discrepancies
between the displayed volume of refrigerant and the actual
volume that has been added, depending on the design of the
92 Rep. gr.87 - Air conditioning system
Page 97
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AC service station . The filling accuracy of the AC service sta‐
tion may vary.
• The refrigerant circuit is fully assembled ⇒ Heating, Air Con‐
ditioning; Rep. gr. 87 .
– Switch off ignition.
– Connect the AC service station to the voltage supply.
– Check
the volume of refrigerant, refrigerant oil and UV additive
for leak detection in the AC service station and top up if nec‐
essary ⇒ AC service station operating instructions .
– Operate the AC service station according to the relevant op‐
erating instructions ⇒ AC service station operating instruc‐
tions .
– Unscrew the screw caps from the service connectors of the
refrigerant circuit (see vehicle-specific refrigerant circuit) ⇒
Heating, Air Conditioning; Rep. gr. 87 .
– Connect the to the service connectors of the refrigerant circuit
⇒ “2.2 Connecting the AC service station to the refrigerant cir‐
cuit”, page 79 .
– Evacuate the refrigerant circuit with the AC service station
⇒ “2.5 Evacuating the refrigerant circuit.”, page 87 .
– Set the specified volume of refrigerant, if applicable the vol‐
ume of refrigerant oil to be topped up and the volume of UV
additive for leak detection on the AC service station ⇒ AC
service station operating instructions , ⇒ Heating, Air Condi‐
tioning; Rep. gr. 00 .
– Set the refrigerant to be added on the high-pressure side on
the
AC service station ⇒ AC service station operating instruc‐
tions .
When filling the refrigerant circuit on the low-pressure side, liquid
refrigerant can collect in the compression chamber of the AC
compressor.
– If it is necessary to fill the refrigerant circuit on the low-pressure
side, turn the AC compressor by hand through 10 rotates after
filling before first use (if necessary, remove e.g. the drive belt
to do so).
Note
♦
The refrigerant and refrigerant oil are added to the refrigerant
circuit on the high-pressure side.
♦
If there is no service connector on a vehicle on the high-pres‐
sure side of the refrigerant circuit, the refrigerant may also be
added via the service connector on the low-pressure side.
However, always note the settings and operating instructions
for the AC service station .
♦
If the direction of filling cannot be set on an AC service station ,
if necessary unscrew the handwheel on the quick coupler
adapter on the low-pressure side (close).
– Fill the refrigerant circuit with the specified volume of refriger‐
ant, if applicable the volume of refrigerant oil to be topped up,
and the volume of UV additive.
– Operate the air conditioning system after filling ⇒ Heating, Air
Conditioning ; Rep. gr. 87 and
⇒ “2.7 Operate the air conditioning system after filling”,
page 94 .
2. Working with the A/C service station 93
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2.7 Operate the air conditioning system af‐
ter filling
Note
If the mechanically drive AC compressor has been removed, it
must be turned by approx. 10 rotations by hand before it is first
operated (when being installed or after installation e.g. before po‐
sitioning the belt) so that it is not damaged by the impact of fluid
after the system is switched on for the first time (if there is refrig‐
erant oil in the AC compressor’s cylinder, it is pushed out by
rotating the compressor) ⇒ Heating, Air Conditioning; Rep. gr.
87 .
Starting the air conditioning system
– Switch on ignition.
– Set the air conditioning system to the lowest possible per‐
formance (e.g. “AC off” mode).
– Switch of the AC compressor (e.g. “AC off” mode).
– Start the engine while the AC compressor is switched off (e.g.
“AC off” mode).
– Wait until the idling speed has stabilised.
– Switch on the AC compressor and operate the system for at
least 2 minutes at idle speed.
– If necessary, check the pressures in the refrigerant circuit with
the AC service station
⇒ “2 Working with the A/C service station”, page 77 .
– Switch off engine.
– Disconnect the AC service station from the refrigerant circuit
and switch off
⇒ “2.8 Switching off the AC service station and disconnecting
it from the refrigerant circuit”, page 94 .
2.8 Switching
disconnecting it from the refrigerant cir‐
off the AC service station and
cuit
– Finish working with the AC service station .
– Switch off ignition.
– Unscrew
the handwheel on the quick coupler adapter (close).
94 Rep. gr.87 - Air conditioning system
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WARNING
Risk of frostbite through refrigerant escaping under pressure!
This may cause frostbite on the skin and other parts of the
body.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ If refrigerant escapes from the refrigerant line for more
than 1 second after turning out the handwheel of the serv‐
ice coupler, turn in the handwheel and replace the defec‐
tive valve.
♦ Evacuate the refrigerant circuit and immediately open the
refrigerant circuit.
♦ If more than 10 minutes have elapsed since evacuation
and the coolant circuit has not been opened, evacuate the
refrigerant again. Pressure builds up in the refrigerant cir‐
cuit as a result of secondary evaporation.
Different types of service couplers
♦ On one type of service couplers, the space between the valve
in
the service connector of the refrigerant circuit and the valve
in the service coupler is vented out when the handwheel is
unscrewed. On these service couplers, the valve in the service
connector of the vehicle and the valve in the service coupler
for the filler hose to the AC service station are only closed
when the handwheel of the service coupler is unscrewed. If
unscrewed further, the pressure is then dissipated (approx. 2
cm3 of refrigerant) via another valve that is also located in the
space between the two valves. If one of these two valves (the
valve on the vehicle’s service connector or the valve in the
service coupler for the filler hose) does not close correctly, all
the refrigerant can escape from the refrigerant circuit or the
filler hose.
♦ On the other type of service couplers, the space between the
valve in the service connector of the refrigerant circuit and the
valve in the service coupler is not vented out when the hand‐
wheel is unscrewed. For this design, there is a valve that is
closed when the service coupler is open, so that the pressure
can equalise between the chamber for the valve in the refrig‐
erant circuit’s service connector and the filler hose connected
to the service coupler. For this design, screwing the hand‐
wheel of the service coupler back in does not mean that
refrigerant escapes, so that the refrigerant in this can has to
be extracted back into the AC service station from the filler
hoses before the service couplers are uncoupled. If in this
case e.g. a larger volume of refrigerant is recovered after
pressure testing or after filling the refrigerant circuit (more than
approx. 50 g), this indicates that a valve in one of the service
connectors of the refrigerant circuit may not be leak-tight and
refrigerant is escaping from the vehicle’s refrigerant circuit
(extract refrigerant and replace the defective valve).
Before extracting the refrigerant back out of the filling hoses into
the AC service station , unscrew the handwheels of both service
couplers to the stop.
2. Working with the A/C service station 95
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Note
♦
The AC service station has a function that can be used to put
the station in a defined operating state when it is switched off.
This function is used to extract all the refrigerant from the filling
hoses back into the AC service station .
♦
If, when this function is active, the handwheels of both service
couplers are not unscrewed, refrigerant may be extracted from
the vehicle’s refrigerant circuit.
– Extract refrigerant from the two filling hoses with the AC serv‐
ice station according to the relevant operating instructions ⇒
AC service station operating instructions .
Note
♦
If, on an AC service station with a service coupler in which
pressure is not dissipated to the outside this procedure lasts
more than approx. 2 minutes or a large volume of refrigerant
is extracted, this indicates a defect in one of the valves in a
service connector.
♦
If, on an AC service station with a service coupler in which
pressure is dissipated to the outside this procedure lasts more
than approx. 2 minutes, this indicates a defect in one of the
valves in a service coupler.
Note
Refrigerant is extracted from the vehicle’s refrigerant circuit by
mistake
– First, unscrew the handwheels on the quick coupler adapter
(close).
– Then extract refrigerant from the two filling hoses with the AC
service station.
– Switch off the AC service station (if necessary, also disconnect
from the power supply) ⇒ AC service station operating in‐
structions .
– Disconnect the from the service connectors of the refrigerant
circuit.
– Screw on the screw caps of the service connectors (see ve‐
hicle-specific refrigerant circuit) ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
2.9 Filling refrigerant into the reservoir
– Connect the supply cylinder with fresh refrigerant R1234yf to
the service coupler on the low-pressure side to the AC service
station ⇒ AC service station operating instructions .
– Use the AC service station to perform gas analysis of the re‐
frigerant to be filled (from the supply cylinder)
⇒ “2.3 Performing gas analysis for the refrigerant”, page 82 .
• The work procedure must always be carried out as described
in the operating instructions for the AC service station ⇒ AC
service station operating instructions .
96 Rep. gr.87 - Air conditioning system
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