VW Golf manuals

Volkswagen Golf Service & Repair Manual: Purging electrical air conditioner compressor

Vehicles with high-voltage system
Observe the additional warning instructions for working on vehicles with high-voltage system → Electrical system; Rep. gr.93.
  WARNING
Risk of injury due to unexpected engine start
When working on a high-voltage vehicle, switch off the ignition, and deposit the ignition key somewhere outside the passenger compartment.
  WARNING
Handling high-voltage cables:
Do not support yourself or your tools on high-voltage cables and their components --> risk of damage to the insulation.
High-voltage cables must not be extensively bent or kinked --> risk of damage to the insulation.
The round high-voltage connectors are colour-coded with a coloured ring on the outside and mechanically coded with respective guide lugs. Always observe the coding when connecting the round high-voltage connectors in order to prevent any mechanical damage to the high-voltage connectors.
  DANGER!
Hazardous voltage resulting from damaged high-voltage components
Observe the following when working in the vicinity of high-voltage components and cables:
Work involving metal-removing, deforming and sharp-edged tools or heat sources such as welding, soldering, hot air and thermal bonding is not permitted.
Before starting work, carry out a visual check on the high-voltage components in the area of work.
When working in the engine compartment, carry out a visual check on the power and control electronics for electric drive -JX1-, the electric drive motor -V141-, the air conditioner compressor -V470- and the high-voltage cables.
When working on the underbody, carry out a visual check on the high-voltage cables and covers.
When working on the rear end, carry out a visual check on the high-voltage cables and the maintenance connector for high-voltage system - TW -.
Carry out a visual check on all potential equalisation lines.
When carrying out the visual check, observe the following:
The high-voltage components must not reveal any external damage.
The insulation of the high-voltage cables and the potential equalisation lines must not be damaged.
The high-voltage cables must not show any unusual deformations.
Each high-voltage component must be clearly identified with a red warning sticker.
If repair work in the vicinity of high-voltage components and cables is necessary, “carry out a visual check for damage on high-voltage components and cables”, and “observe the general warning instructions for work on the high-voltage system” → Electrical system; Rep. gr.93.
If repair work on high-voltage components is necessary, de-energise the high-voltage system → Electrical system; Rep. gr.93, and “observe the general warning instructions for work on the high-voltage system” → Electrical system; Rep. gr.93.
  Note
The electrical air conditioner compressor must be purged, if you suspect that there is too much refrigerant oil in the refrigerant circuit or if contaminated refrigerant oil (contaminated with moisture) must be extracted from the air conditioner compressor. In these cases the refrigerant circuit must be purged as well in order to clean the refrigerant circuit and to re-establish the correct amount of refrigerant oil.
If an electrical air conditioner compressor is renewed without having a mechanical fault (e.g. defective printed circuit board), the amount of refrigerant oil from this electrical air conditioner compressor must be determined.
  Note
The air conditioner compressor must be purged in order to extract the refrigerant oil which needs to be determined.
Purge the air conditioner compressor in normal direction of flow (from low-pressure inlet to high-pressure outlet).
In order to purge as much refrigerant oil from the air conditioner compressor as possible make sure that the high-pressure outlet of the air conditioner compressor is in the lowest position possible.
If an air conditioner service station without purging programme is used, the sequence has to be carried out manually (evacuate, purge 3 times with at least 2 kg of refrigerant each time and extract refrigerant again, evacuate).
Determined amount e.g. 50 cmі
Then, remove as much refrigerant oil from the new air conditioner compressor as is necessary to ensure that only the same amount of refrigerant oil which has been purged from the old air conditioner compressor remains in the new one (plus 10 cm 3). If, for example, the new original air conditioner compressor is filled with e.g. 200 cm3 of refrigerant oil, then remove only 140 cm3.
–  Pour old refrigerant oil out of air conditioner compressor. Handling refrigerant → Volkswagen ServiceNet; Service handbook; Environmental protection; Waste disposal; Current situation; Disposal channels; Disposal of used oils; Refrigerant oils.
  Note
If the amount of refrigerant oil which can be removed from the new air conditioner compressor is not sufficient, the new air conditioner compressor must be purged. After the new air conditioner compressor has been purged, fill the amount of refrigerant oil which has been determined when purging the old air conditioner compressor.
   

Purging electrical air conditioner compressor

1 -  Air conditioner service station
  Note
The air conditioner compressor is purged manually.
–  Extract refrigerant, if there is any in the system.
–  Empty the used-oil container of the air conditioner service station.
  Note
Some air conditioner service stations first separate the oil in the vacuum phase and then fill it into the used-oil container.
–  At the air conditioner service station, set the amount of refrigerant to 2 kg and the amount of oil to 0.
–  Connect purging device for refrigerant circuits -VAS 6336/1- or purging device for refrigerant circuits -VAS 6337/1- between air conditioner service station and return line for refrigerant circuit.
–  Evacuate the refrigerant circuit for 10 minutes. Then observe the vacuum gauge. If the vacuum persists, fill 2 kg of R134a refrigerant into the circuit. Then, extract and evacuate again and repeat the process.
2 -  Refrigerant hose of air conditioner service station
From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of the purging device for refrigerant circuits
3 -  Purging device for refrigerant circuits
Different versions and different design e.g. purging device for refrigerant circuits -VAS 6336/1- or purging device for refrigerant circuits -VAS 6337/1-.
With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).
Depending on the design of the air conditioner service station and the purging device for refrigerant circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits (to assure the correct direction of refrigerant flow during purging).
4 -  Charging hose of flushing device for refrigerant circuits
From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller diameter) to inlet of purging device for refrigerant circuits -VAS 6336/1- or purging device for refrigerant circuits -VAS 6337/1-.
5 -  Adapter to connection for high-pressure side on refrigerant circuit
Adapter -VAS 6338/3- from adapter set for refrigerant circuits -VAS 6338/1-
  Note
If the adapter -VAS 6338/40- is available, the charging hose can be connected directly to the air conditioner compressor.
6 -  High-pressure side refrigerant line from air conditioner compressor
  Note
Will not be used if the adapter -VAS 6338/40- is available.
–  Pull the centring pin out of the refrigerant line so that the adapter -VAS 6338/3- fits properly.
7 -  Electrical air conditioner compressor
Purge the air conditioner compressor in normal direction of flow (from low-pressure inlet to high-pressure outlet).
In order to purge as much refrigerant oil from the air conditioner compressor as possible make sure that the high-pressure outlet of the air conditioner compressor is in the lowest position possible.
8 -  Low-pressure side refrigerant line to air conditioner compressor
  Note
Will not be used if the adapter -VAS 6338/41- is available.
–  Pull the centring pin out of the refrigerant line so that the adapter -VAS 6338/6- fits properly.
9 -  Adapter to connection for low-pressure side on refrigerant circuit
Adapter -VAS 6338/6- from adapter set for refrigerant circuits -VAS 6338/1-
  Note
If the adapter -VAS 6338/41- is available, the charging hose can be connected directly to the air conditioner compressor.
10 -  Refrigerant hose of air conditioner service station
From high-pressure side of the air conditioner service station (usually coloured in red) for connection to low-pressure line or directly to air conditioner compressor using adapter -VAS 6338/41-.
Principle circuit diagrams for various purging circuits
  Note The arrows in the following illustrations show the direction of flow of the refrigerant during purging. The refrigerant flows against the di ...

Adapters for setting up purging circuits
The following table contains the various adapters that are necessary to connect the air conditioner service station to the refrigerant circuit for purposes of purging ...

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