Volkswagen ID.3: Air conditioner. Refrigerant circuit

• Cleaning refrigerant circuit
• Block diagram for cleaning (flushing circuits) - refrigerant circuit with expansion valve and receiver
• Block diagram for cleaning (flushing circuits) - vehicles with high-voltage system (without additional air conditioner functions)
• Block diagram for cleaning electrically driven air conditioner compressor

Cleaning refrigerant circuit

Cleaning refrigerant circuit

General notes on cleaning

♦ The refrigerant circuit must be cleaned in order to remove moisture and impurities (e.g. abrasion from a defective air conditioner compressor) and old refrigerant oil while ensuring the greatest possible cleanliness, avoiding unnecessary loss of refrigerant and extensive assembly work, and ensuring environmental compatibility.

Important

Clean (flush) refrigerant circuit in the following situations:

● If there is any dirt or similar in the refrigerant circuit.

● If the refrigerant circuit has been left open for longer than the normal assembly time (e.g. following an accident).

● If it is uncertain how much refrigerant oil is in the refrigerant circuit.

● If it is uncertain what type of refrigerant oil the refrigerant circuit has been filled with.

● If the air conditioner compressor had to be renewed due to internal damage (e.g. noise or no output) → Rep. gr.87; Renewing air conditioner compressor.

● If required after renewing certain components according to the vehicle-specific Workshop Manual.

Procedure

– Perform vehicle-specific procedure for cleaning refrigerant circuit → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Cleaning refrigerant circuit.

– Clean refrigerant circuit with air conditioner service station → Rep. gr.87; Cleaning refrigerant circuit.

– Depending on refrigerant circuit design, the following components must be renewed after refrigerant circuit has been cleaned fully → Heating, air conditioning; Rep. gr.87; Refrigerant circuit:

♦ Receiver

♦ Desiccant bag/desiccant cartridge in receiver

♦ Renew additional components after flushing depending on the vehicle and the complaint → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Cleaning refrigerant circuit

– Check expansion valve for dirt or corrosion. Renew expansion valve if necessary → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Removing and installing expansion valve.

– Adjust quantity of refrigerant oil in refrigerant circuit depending on complaint → Rep. gr.87; Renewing components and → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities.

– → Rep. gr.87; Charge refrigerant circuit.

– → Rep. gr.87; Start up air conditioner after charging.

Block diagram for cleaning (flushing circuits) - refrigerant circuit with expansion valve and receiver

Block diagram for cleaning (flushing circuits) - refrigerant circuit with expansion valve and receiver

1 - Air conditioner service station

2 - Refrigerant hose of air conditioner service station

❏ From high-pressure side of air conditioner service station (generally red) to connection for low-pressure side of air conditioner compressor at refrigerant circuit (larger diameter)

3 - Adapter for connection (low-pressure side) at refrigerant circuit

❏ Adapter -VAS 6338/12-

❏ Use between refrigerant hose -2- and adapter -VAS 6338/48- -3-

❏ Depending on adapter version, an additional adapter may be required to connect filler hose of air conditioner service station

4 - Connection (low-pressure side) at refrigerant circuit

❏ Connect to adapter -3-

5 - Adapter for removed expansion valve

6 - Evaporator

7 - Connection to receiver

❏ Not fitted on all vehicles

❏ Not fitted on vehicles with a desiccant cartridge in the receiver on the condenser or with a receiver installed in the condenser → Heating, air conditioning; Rep. gr.87; Refrigerant circuit

8 - Adapter for bridging removed receiver

❏ Not required for all vehicles

9 - Filler hose

❏ E.g. filler hose from adapter set for refrigerant circuit -VAS 6338/1-

10 - Condenser

❏ If the receiver is attached directly to the condenser, flush the system before removing and renewing the receiver → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

❏ If a receiver with desiccant cartridge is fitted on the condenser, remove desiccant cartridge and seal receiver → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Removing and installing desiccant bag/desiccant cartridge.

❏ If the receiver is integrated into the condenser and the desiccant cartridge cannot be renewed separately or is not available separately, renew condenser with receiver/desiccant cartridge after flushing → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

11 - Connection (high-pressure side) at refrigerant circuit

❏ Connect to -12-

12 - Adapter for connection (high-pressure side) at refrigerant circuit

❏ Adapter -VAS 6338/3-

13 - Filler hose to refrigerant circuit flushing device

❏ From connection (high-pressure side) of air conditioner compressor at refrigerant circuit (smaller diameter) to inlet of flushing device

14 - Flushing device

❏ Different versions and designs

❏ With filter, sight glass, safety valve, heater, refrigerant vessel etc. (depending on version)

❏ Depending on the design of the air conditioner service station and the refrigerant circuit flushing device, a non-return valve may be fitted at the outlet of the refrigerant circuit flushing device (to guarantee the correct direction of refrigerant flow when flushing).

❏ Depending on the flushing device, the outlet to the air conditioner service station may have a 5/8 -18 UNF external thread or a connection for an R134a or R1234yf high-pressure service coupling.

❏ Additional adapters are required to flush devices with a 5/8 -18 UNF external thread or a connection for an R134a low-pressure service coupling in order to connect the R1234yf low-pressure service coupling or the filler hose for the air conditioner service station (with M12 x 1.5 6G external thread according to SAE J639) to the outlet of the flushing device.

❏ The filler hose for the air conditioner service station has an M12 x 1.5 6G external thread according to SAE J639. Depending on the version, the refrigerant circuit flushing device may have a service connection for a low-pressure service coupling according to SAE J639 for refrigerant R1234yf, an M12 x 1.5 6G internal thread according to SAE J639, a service connection for an R134a low-pressure service coupling, or a 5/8 -18 UNF external thread. Therefore, an additional adapter may be required in order for both components to be connected → Electronic parts catalogue.

15 - Refrigerant hose of air conditioner service station

❏ From low-pressure side of air conditioner service station (generally blue) to outlet of flushing device

16 - Adapter for sealing outlet to second evaporator

❏ Required on some equipment versions

17 - Adapter for sealing outlet to second evaporator

❏ Required on some equipment versions

18 - Connection (low-pressure side) at refrigerant circuit to second evaporator

❏ Required on some equipment versions

19 - Connection (high-pressure side) at refrigerant circuit to second evaporator

❏ Required on some equipment versions

20 - Adapter for expansion valve (removed) at second evaporator

❏ Required on some equipment versions

21 - Second evaporator

❏ Fitted depending on equipment

Block diagram for cleaning (flushing circuits) - vehicles with high-voltage system (without additional air conditioner functions)

Block diagram for cleaning (flushing circuits) - vehicles with high-voltage system (without additional air conditioner functions)

♦ On vehicles with an evaporator and a heat exchanger, the circuit to the heat exchanger must be separated from the circuit of the first evaporator using manual shut-off valves and flushed in a separate operation.

♦ The section with the evaporator in the heater and air conditioning unit is cleaned in the first flushing cycle, then the section with the heat exchanger for high-voltage battery / evaporator in the battery cooling module is cleaned.

♦ The layout of the different flushing circuits for these vehicles is similar to the layout on a vehicle with two evaporators.

♦ If a vehicle-specific description of the procedure for cleaning the refrigerant circuit is available, it must be used → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Cleaning refrigerant circuit.

Block diagram for cleaning electrically driven air conditioner compressor

Block diagram for cleaning electrically driven air conditioner compressor

1 - Air conditioner service station

2 - Refrigerant hose

❏ From high-pressure side of air conditioner service station to connection for low-pressure side of air conditioner compressor (larger diameter)

3 - Adapter for connection (low-pressure side) at air conditioner compressor

❏ Different versions, e.g. adapter -VAS 6338/41- from adapter set for refrigerant circuit -VAS 6338/1-

❏ Use between refrigerant hose -2- and adapter -VAS 6338/48- -3-

4 - Refrigerant line

❏ Not required

❏ Adapter -3- is connected directly to air conditioner compressor

5 - Air conditioner compressor

❏ Air conditioner compressor is flushed in direction of flow (from low-pressure end inlet to high-pressure end outlet)

6 - Refrigerant line

❏ Not required

❏ Adapter -3- is connected directly to air conditioner compressor

7 - Adapter for connection (high-pressure side) at air conditioner compressor

❏ Different versions depending on vehicle, e.g. adapter -VAS 6338/40- from adapter set for refrigerant circuit -VAS 6338/1-

8 - Filler hose to flushing device

❏ From connection (high-pressure side) of air conditioner compressor at refrigerant circuit (smaller diameter) to inlet of flushing device

9 - Refrigerant circuit flushing device

❏ Different versions of refrigerant circuit flushing device with different designs → Electronic parts catalogue

❏ Depending on the design of the air conditioner service station and refrigerant circuit flushing device, a connection for a service coupling may be installed at the outlet and possibly the inlet of the flushing device.

❏ If there is a service connection with valve at the outlet of the flushing device, this valve must be fully open when the service coupling is connected. If the valve is only partially open, this results in a constriction.

❏ If there is a connection for a service coupling at the inlet of the flushing device, modify the inlet so that the refrigerant hose from the vehicle can be connected directly.

10 - Refrigerant hose of air conditioner service station

❏ From low-pressure side of air conditioner service station to outlet of flushing device

Air conditioner. Air quality improvement systemAir conditioner. Renewing components