Volkswagen Golf Service & Repair Manual: Removing and installing refrigerant shut-off valve for high-voltage battery
heat exchanger -N542
| – |
Observe safety precautions
→ Chapter „Safety precautions when handling refrigerants“. |
| – |
Comply with notes
→ Chapter „Working on refrigerant circuit“. |
| – |
Observe safety precautions when working in the vicinity of
high-voltage components
→ Chapter „Safety precautions when working in the vicinity of
high-voltage components“. |
| – |
Observe the risk category of the high-voltage system
→ Rep. gr.00. |
| – |
Drain refrigerant circuit. |
Risk of freezing injury caused by escaping pressurised refrigerant.There
is a risk of injury to the skin and parts of the body due to
freezing.Always wear safety gloves.Always wear safety goggles.Extract
refrigerant, and open the refrigerant circuit immediately afterwards.If
more than 10 minutes passed since the refrigerant has been extracted, do
not open the refrigerant circuit prior to extracting refrigerant anew.
Due to re-evaporation, pressure will be built up in the refrigerant
circuit. |
|
|
| – |
Disconnect connector -A- from
-N542--B-. |
| – |
Loosen union nuts -C-.
Counterhold on -N542--B- while
doing so. |
| – |
Remove refrigerant line -D-
from heat exchanger for high-voltage battery
→ Chapter. |
|
|
|
| – |
Remove shut-off valve -N542--D-. |
| Installation is carried out in the reverse order. When
installing, note the following. |
 Note
| Adhere to the installation instruction for seals
-B-
→ Chapter. |
| Following attachment, check the routing of the refrigerant
lines. They must be inserted in the holders provided and not
make contact with other components. |
| – |
Renew seals -B-; for correct
version refer to
→ Electronic Parts Catalogue. |
|
|
|
| – |
Check restrictor in refrigerant line
-D- (leading to heat exchanger for high-voltage battery)
for soiling
→ Chapter. |
| – |
Screw on union nuts -C- to stop
by hand.
|
| – |
Install refrigerant line -D- to
heat exchanger for high-voltage battery
→ Chapter. |
| – |
Tighten union nuts -C-.
Counterhold on -N542--B- while
doing so, and make sure that refrigerant lines are routed free
of stress. |
Note
| When tightening the union nuts, make sure that the
refrigerant lines remain free of stress. |
| Following attachment, check the routing of the refrigerant
lines. They must be inserted in the holders provided and not
make contact with other components. |
| Also refer to the notes on commissioning of air conditioning
system after filling
→ Air conditioning system with refrigerant R134a; Rep. gr.00. |
| – |
Evacuate and charge refrigerant circuit
→ Air conditioner with refrigerant R134a; Rep. gr.00. |
| – |
Read event memory of operating unit, Climatronic control
unit -J255-, and clear any faults which may have been stored
vehicle diagnostic tester in “Guided fault finding” mode. |
|
|
|
|
Component |
Specified torque |
| Union nuts
-C- |
16.5 Nm |
Removing
–
Observe safety precautions
→ Chapter „Safety precautions when handling refrigerants“.
...
Special tools and workshop equipment
required
Hose clamps, up to 25 mm -3094-
Engine bung set -VAS 6122-
...
Other materials:
Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003
–
Apply handbrake.
–
Vehicles with automatic gearbox, move selector lever to
position “P” or “N”.
–
Vehicles with manual gearbox, move gear lever to neutral
position.
...
Notes on safety
Safety precautions during a road test
using test and measuring equipment
Observe the following if test and measuring equipment is
required during a road test:
Risk of accidents due to distraction and inadequate securing ...
Safety regulations for crash sensors (pressure sensors) for front side
airbags
The side airbag crash sensors respond to changes in pressure
and must therefore be treated with particular caution. Observe
the following:
The correct installation position is vitally important: only
install in the specified ...
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Removing and installing refrigerant shut-off valve for heater and air
conditioner unit -N541
Removing and installing heat exchanger for high-voltage battery