Volkswagen Tiguan Service and Repair Manual: A/C Service Station, Working with

Important Information when Working with the A/C Service Station

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.

Note the following when operating the A/C service station -VAS6007A-. This also applies to other service stations.

Refer to the Workshop Equipment Catalog.

• The filters and dryers installed must be replaced at the latest on completion of the service life specified in the relevant operating instructions.
• Only refrigerant oils that are approved for the refrigerant circuit in that vehicle may be added.

Refer to the Parts Catalog.

Extracted refrigerant must not be reused under the following conditions, even after cleaning in the station:

• In the case of A/C compressor damage in which the refrigerant was disintegrated due to overheating.
• In the case of dark, sticky deposits in the refrigerant circuit (these can only be found after opening the system).
• If there is any doubt as to the composition of the refrigerant extracted from the refrigerant circuit.

The A/C service station is to be drained in all these cases. Refer to → Chapter "Discharge Refrigerant Circuit with A/C Service Station", the system cleaned if necessary and the filters, dryers and refrigerant oil replaced.

For example, within Germany, contaminated refrigerant can be returned to the supplier in recycling containers for recycling or for environmentally safe disposal. Other or additional regulations may apply in other countries.

Commercially available A/C service stations can be classified in 2 groups:

1. A/C service stations which clean extracted refrigerant for reuse (extraction and recycling stations) such as the A/C service station -VAS6007A-.
2. A/C service stations which transfer extracted refrigerant to recycling containers (for large-scale recycling). These are referred to as extraction systems.

A/C Service Station, Connecting for Measuring and Testing

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.
• Work procedure may vary depending on the type of tools selected (the tool-specific operating instructions should therefore be followed).

Note

The work procedure is always to be performed as described in the operating instructions for the A/C Service Station -VAS6007A- (or subsequent models).

The charging hoses are to be connected as follows to prevent the ingress of air or moisture into the refrigerant circuit:

• Turn off the ignition.
• Connect the A/C service station to the power supply.
• Remove the cap from the service connections or connections with a valve (see vehicle-specific refrigerant circuit).
• Evacuate the filler hose.

Note

Connect filler hose with quick-release couplings to refrigerant circuit service connections.

Caution

Never open valves on low or high-pressure side with engine running. Otherwise, compressor or service station could be destroyed by a "short circuit" between high and low-pressure sides of refrigerant circuit if air conditioning system is switched on.

• Only tighten the handwheel in the quick-release coupling just enough so the service connection is open. Watch the pressure gauge and do not place too much pressure on the valve.
• Start the engine and perform the planned tests and measurements.
• Compare values determined to specified measured values.
• Loosen the handwheel to close the quick-release coupling before disconnecting it.

Discharge Refrigerant Circuit with A/C Service Station

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.

WARNING

High voltage within the high voltage system. Danger of electric shock in the A/C compressor!

Disable high voltage system.

• Work procedure may vary depending on the type of tools selected (the tool-specific operating instructions should therefore be followed).
• The refrigerant circuit is to be discharged if parts of the refrigerant circuit are to be removed, if there is any doubt about the quantity of refrigerant in the circuit or if safety precautions so require.
• All the necessary usage information for working with the refrigerant service station can be found in the service station operating instructions.

Draining:

• Turn off the ignition.
• Connect A/C service station in line with operating instructions to vehicle service connections.

Note

• There is a possibility of refrigerant oil being extracted from the refrigerant circuit together with the refrigerant. To ensure compressor lubrication, the refrigerant oil in the circuit must be topped up with fresh oil.
• On vehicles with an A/C compressor without a magnetic clutch (with A/C Compressor Regulator Valve -N280-), the engine should run < 10 minutes with the refrigerant circuit empty and closed (the A/C compressor also runs continuously). The engine RPM must not exceed 2000 RPM.
• On vehicles equipped with an A/C compressor with A/C clutch, the engine must be started since the A/C Pressure Switch -F129- or High Pressure Sensor -G65- (checks whether refrigerant is present in the circuit) switches off the A/C clutch as soon as there is no refrigerant in the refrigerant circuit.

Refrigerant Circuit with A/C Service Station, Draining

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.
• The work procedure is always to be performed as described in the operating instructions for the A/C service station.
• The procedure described here is for the A/C Service Station -VAS6007A-.

Before filling the refrigerant circuit with refrigerant, it should be evacuated (vacuum) for 45 minutes on systems with 1 evaporator and 60 minutes on systems with 2 evaporators. Moisture is also extracted from the circuit.

Leaks may be found when evacuating the refrigerant circuit.

Evacuating:

Caution

• Do not start the engine during the evacuation process or when there is a vacuum in the refrigerant circuit.
• The A/C compressor could be damaged if the engine is started when there is a vacuum in the refrigerant circuit.
• Only start the engine when the refrigerant circuit is filled.

• Turn off the ignition.
• Check refrigerant oil quantity in refrigerant circuit if necessary, see vehicle-specific repair manual.
• Connect the A/C service station to the power supply.
• Check the amount of refrigerant in the A/C service station.
• Connect charging hose of A/C service station to vehicle refrigerant circuit with quick-release coupling adapter. Refer to vehicle-specific refrigerant circuit.
• Only tighten the handwheel on the quick-release coupling adapter just enough so the valves in the service connections are securely open. Do not put too much pressure on the valve.

Note

If pressure is to be measured after charging system on vehicles with a service connection on one side of the refrigerant circuit only, use valve adapter and charging hose with valve opener .

• Initiate the vacuum phase on the A/C service station. The refrigerant circuit is automatically evacuated. Check the preset evacuating time if necessary.

When the vacuum phase ends, the refrigerant circuit leak test begins. Pressure in bar (psi) and seconds are displayed.

Proceed as follows if the vacuum is not maintained:

• Initiate the vacuum phase on the A/C service station again. The refrigerant circuit is automatically evacuated. Check the preset evacuating time if necessary. Watch the vacuum indicator for an extended period of time. Only when the vacuum is maintained can the refrigerant circuit be charged.

If there is a leak that allowed enough air to enter during evacuation that the A/C service station cannot generate a sufficient vacuum or that the vacuum is lost immediately after switching the A/C service station off:

• Determine the location of the leak in the refrigerant circuit.

Refrigerant Circuit with A/C Service Station, Filling

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.

WARNING

High voltage within the high voltage system. Danger of electric shock in the A/C compressor!

Disable high voltage system.

• The work procedure is always to be performed as described in the operating instructions for the A/C service station.
• Before pouring in refrigerant, correct the quantity of refrigerant oil.
• The entire refrigerant charge can be added to either the high or low pressure side.

Refrigerant circuit, charging

• Turn off the ignition.
• Drain the refrigerant circuit with A/C service station.
• Screw out handwheel at quick-release coupling adapter (to close it).
• Allow refrigerant to flow into charging hose.
• Tighten the handwheel on the quick-release coupling adapter without putting too much pressure on the valve and add the specified amount of refrigerant.
• Switch off A/C service station.

Note

If A/C compressor was removed, it must be cranked by hand at ribbed belt pulley/freewheel approximately 10 rotations before bringing into operation for the first time. The electrically-driven A/C compressor is not affected by this. This prevents damage in the A/C compressor due to liquid when switching the A/C system on. If there is oil in the A/C compressor cylinder, it will be forced out.

• Start engine with compressor switched off (version with A/C clutch).
• Set the A/C compressor to minimum output, for example, "ECON" mode or A/C off (version with no A/C clutch with regulator valve).
• Wait until idle speed has stabilized.
• Switch on the compressor and operate the system for at least two minutes at idling speed.
• If necessary, check pressures in refrigerant circuit using A/C service station.
• Turn engine off.
• Screw out handwheel on quick-release coupling adapter.
• Disconnect charging hose from refrigerant circuit.
• Screw protective caps back on.

A/C System, Operating after Charging

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.

Note

If A/C compressor was removed, it must be cranked by hand at ribbed belt pulley/freewheel approximately 10 rotations before bringing into operation for the first time. This prevents damage in the A/C compressor due to liquid when switching the A/C system on. If there is oil in the A/C compressor cylinder, it will be forced out.

• Start engine with compressor switched off (version with A/C clutch).
• Set the A/C compressor to minimum output, for example, "ECON" mode or A/C off (version with no A/C clutch with regulator valve).
• Wait until idle speed has stabilized.
• Switch on the compressor and operate the system for at least two minutes at idling speed.
• If necessary, check pressures in refrigerant circuit using A/C service station.
• Turn engine off.
• Screw out handwheel on quick-release coupling adapter.
• Disconnect charging hose from refrigerant circuit.
• Screw protective caps back on.

Refrigerant in A/C Service station Container, Filling

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.
• The work procedure is always to be performed as described in the operating instructions for the A/C service station.
• A certain quantity of refrigerant is specified as charge for each air conditioning system. To ensure that the correct amount of refrigerant is added and the cooling output is not reduced, the charging cylinder stands on a scale indicating the weight.

A/C Service Station, Emptying

Caution

• If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, do not connect the A/C service station and do not extract the refrigerant.
• Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
• Inform that customer that there are substances in the A/C system that are no approved by Volkswagen. This A/C system cannot be drained or serviced in the workshop.

Note

• The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by VW Audi AG. There are no permanent- ,validity or material compatibility tests. Therefore damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
• The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
• VW does not approve the use of chemicals to seal leaks in the refrigerant circuit.
• Chemicals used to seal leaks in the refrigerant circuit often react with air and the moisture in it. They cause deposits in the refrigerant circuit and the A/C service station and malfunctions in valves and other components that they come in contact with. These deposits cannot be removed completely from the components.
• Chemicals used to seal leaks in the refrigerant circuit usually cannot be detected from outside. The label that should be applied to identify it is often missing. Therefore be careful when working with if you do not know its service history.
• Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Because VW does not approve the use of these chemicals, there is no evidence of the effectiveness of these filters.

Note

• If it is necessary to evacuate the A/C service station (e.g. because contaminated refrigerant was extracted), always replace all filters and dryers. Only remove the filters and dryers from their air-tight packaging immediately before installing them to prevent moisture from entering.
• Refrigerant containers filled with contaminated used refrigerant are referred to as "Recycling containers".
• Always evacuate recycling cylinders before first charging with refrigerant. Refrigerant cylinders in which there is air must not be filled with refrigerant.
• Different refrigerant types must not be mixed together. Refrigerant mixtures cannot be reprocessed but must be disposed of. If there is any doubt about the composition of the contents of the container, the refrigerant recycling company is to be informed accordingly.

WARNING

• When filling recycling containers (compressed-gas vessels), observe applicable regulations, technical rules and laws.
• Recycling containers are never to be overfilled. Overfilled containers do not have a sufficient gas cushion to accommodate the liquid expansion caused by the effects of heat. There is a danger of rupture.
• To ensure safety, make exclusive use of recycling containers fitted with a safety valve.
• Recycling containers must be weighed on calibrated scales during the filling process. The maximum permissible capacity is 75% (charge factor 0.75) of the charge weight indicated on the recycling container (the possibility of refrigerant oil entering the recycling container along with the refrigerant cannot be ruled out).