Volkswagen ID.3: Air conditioner. Renewing components

Volkswagen ID.3 (E11, E12) 2020-2024 Service Manual / Heating, ventilation, air conditioning system / General information - air conditioning systems with R134a&R1234yf refrigerant / Air conditioner. Renewing components

Renewing components - empty refrigerant circuit
Renewing components - charged refrigerant circuit
Renewing air conditioner compressor without having to clean refrigerant circuit
Renewing air conditioner compressor due to leakage or internal damage
Renewing receiver

Renewing components - empty refrigerant circuit

♦ This procedure should not be used for renewing the air conditioner compressor and receiver.

♦ If there is only a minor leak (microleak) and the refrigerant only escapes slowly over an extended period, it is unlikely that moisture has entered the refrigerant circuit and this should not be a concern. The refrigerant circuit does not have to be cleaned in this case → Chapter „Renewing components - charged refrigerant circuit“.

♦ If there is a major leak and refrigerant oil has escaped, a large amount of moisture will have entered the refrigerant circuit. The refrigerant circuit must therefore be cleaned.

♦ Clean the refrigerant circuit if there is a major leak and an undefined amount of refrigerant oil has escaped.

♦ Clean the refrigerant circuit if the refrigerant circuit remained open over a longer period and moisture was able to enter it.

Procedure

Important

● Refrigerant circuit completely empty (e.g. in the event of a major leak or a burst hose)

– Remove faulty component → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

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

Electrically driven air conditioner compressor:

– Clean air conditioner compressor to remove refrigerant oil from it → Rep. gr.87; Cleaning electrically driven air conditioner compressor.

– Pour entire specified quantity of oil (fresh refrigerant oil) into high-pressure and low-pressure connection of air conditioner compressor → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities.

All vehicles (continued)

Mechanically driven air conditioner compressor

– Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Removing and installing air conditioner compressor.

– Remove oil drain plug -2-.

♦ Design of oil drain plug -2- and seal -3- varies depending on manufacturer → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Assembly overview - air conditioner compressor.

– Pour old refrigerant oil out of air conditioner compressor -1-. Turn pulley or magnetic clutch plate while emptying in order to empty air conditioner compressor as thoroughly as possible.

– Check seal -3- for damage.

♦ Seal -3- for oil drain plug -2- may be reused if it is not available as a replacement part.

– Pour entire specified quantity of oil (fresh refrigerant oil) into hole for oil drain plug of air conditioner compressor -1- → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities.

– Check oil drain plug for leaks after charging refrigerant circuit → Chapter „Locating leaks using electronic leak detector“.

All vehicles (continued)

– Renew desiccant cartridge / receiver → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

– Assemble refrigerant circuit.

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

Tightening torques

♦ → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Assembly overview - air conditioner compressor

Renewing components - charged refrigerant circuit

Procedure

Important

● Refrigerant circuit still contains refrigerant (e.g. in the event of a minor leak)

● This procedure should not be used for renewing the air conditioner compressor and receiver.

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

Renewing evaporator:

– Remove evaporator → Heating, air conditioning; Rep. gr.87; Front heater and air conditioning unit; Removing and installing evaporator.

– Balance out amount of refrigerant oil in component. To do so, add refrigerant oil according to specification when charging refrigerant circuit → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities after renewing components.

Continued

Renewing condenser:

– Renew condenser → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Removing and installing condenser.

Continued

Renewing heat exchanger (e.g. heat exchanger for high-voltage battery, heat condenser):

– Renew faulty component → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

Continued

Renewing refrigerant lines:

– Remove refrigerant line and collect escaping refrigerant oil.

– When charging refrigerant circuit, add quantity of refrigerant oil equivalent to amount of refrigerant oil collected. For lines longer than 50 cm, add an additional 5 ml of refrigerant oil.

Continued

Renewing other components:

– Renew faulty component → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

– Check whether it is necessary to add a specific amount of refrigerant oil for the component → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities after renewing components . Add the specified amount of refrigerant oil when filling refrigerant circuit.

Note

For certain components (e.g. valve block), it is necessary to add a defined amount of refrigerant oil after renewing the component. This amount of refrigerant oil compensates for the refrigerant oil removed with the old part. The amount of refrigerant oil lost when discharging must also be added when filling the refrigerant circuit.

Continued

– Charge refrigerant circuit and add required amount of refrigerant oil → Rep. gr.87; Charging refrigerant circuit.

Renewing air conditioner compressor without having to clean refrigerant circuit

Special tools and workshop equipment required

♦ platform scales -VAS 231 007-

♦ This procedure should be used if, for example, there is external damage to the air conditioner compressor or an electrical fault in the electrical air conditioner compressor.

♦ If information on refrigerant oil capacity is not provided on new air conditioner compressor → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities.

Procedure

– Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Removing and installing air conditioner compressor.

– Compare type of refrigerant oil in old and new air conditioner compressor.

Important

● If there are different refrigerant oils in the air conditioner compressors, the existing refrigerant oil must be removed from the refrigerant circuit. In this case, use procedure for renewing air conditioner compressor → Chapter „Renewing air conditioner compressor due to leakage or internal damage“.

Electrical air conditioner compressor without weight specification on type plate of air conditioner compressor:

– Determine amount of refrigerant oil (amount of oil 1) in air conditioner compressor that is to be renewed as follows:

♦ Use both connections to pour refrigerant oil out of old air conditioner compressor into a clean container. When doing so, move air conditioner compressor in circles to ensure it is emptied as fully as possible.

♦ Weigh refrigerant oil that has been poured out using platform scales -VAS 231 007-.

♦ Clean old air conditioner compressor to remove remaining refrigerant oil → Rep. gr.87; Cleaning electrically driven air conditioner compressor.

♦ Determine amount of oil 1. To do so, add together weights of refrigerant oil that was poured out and refrigerant oil that was flushed out.

♦ 1 cm3 of refrigerant oil is equivalent to a weight of 1 g.

– Check old refrigerant oil that was poured out for discolouration and metal particles.

Important

● If discolouration (dark grey to black colour) or metal particles are identified, clean refrigerant circuit and renew air conditioner compressor according to procedure “Renewing air conditioner compressor due to leakage or internal damage” → Chapter „Renewing air conditioner compressor due to leakage or internal damage“.

– Determine amount of refrigerant oil to be removed from new air conditioner compressor (amount of oil 2) as follows:

♦ Amount of oil 2 = amount of oil Label of new air conditioner compressor — amount of oil 1

– Pour excess refrigerant oil (amount of oil 2) out of new air conditioner compressor via low-pressure and high-pressure connections.

♦ Example: If a total of 60 cm3 of refrigerant oil was removed from the defective air conditioner compressor and the label on the new air conditioner compressor specifies that it has a capacity of 200 cm3, 140 cm3 of refrigerant oil must be poured out of the new air conditioner compressor.

Continued

Electrical air conditioner compressor with weight specification on type plate of air conditioner compressor:

Important

● The tare weight (weight without refrigerant oil, bolts and caps) of the air conditioner compressor and the amount of refrigerant oil in the air conditioner compressor are specified on the type plate of the air conditioner compressor.

● The amount of refrigerant oil in the air conditioner compressor is given in cm3. 1 cm3 of refrigerant oil weighs 1 g. As a result, mass m Oil in new air conditioner compressor would be 200 g if an amount of 200 cm3 is specified.

– Weigh removed air conditioner compressor using platform scales -VAS 231 007- (m Old air conditioner compressor).

Important

● Air conditioner compressor must be clean.

● Air conditioner compressor must be weighed without refrigerant lines, bolts, plugs and brackets. Retainers for securing electrical wiring remain on air conditioner compressor.

● Attachments that are included in the scope of delivery (such as brackets) must be removed.

– Determine amount of oil remaining in old air conditioner compressor (m Oil remaining in old air conditioner compressor) as follows:

♦ m Oil remaining in old air conditioner compressor = m Label of old air conditioner compressor — m Old air conditioner compressor

– Determine amount of refrigerant oil to be removed from new air conditioner compressor (m Refrigerant oil discharge amount) as follows:

♦ m Refrigerant oil discharge amount = m Oil in new air conditioner compressor — m Oil remaining in old air conditioner compressor

– Pour excess refrigerant oil out of new air conditioner compressor (m Refrigerant oil discharge amount) via low-pressure side.

Continued

Mechanically driven air conditioner compressor

– Drain refrigerant oil from defective air conditioner compressor and measure amount of oil.

♦ Remove oil drain plug from air conditioner compressor → Chapter „Renewing components - empty refrigerant circuit“.

♦ To accelerate discharging of refrigerant oil, rotate air conditioner compressor e.g. via clutch plate of magnetic clutch.

– Remove oil drain plug from new air conditioner compressor and drain refrigerant oil into a clean container → Chapter „Renewing components - empty refrigerant circuit“.

– Pour fresh refrigerant oil into compressor via hole for oil drain plug. Amount of oil corresponds to amount previously drained from defective air conditioner compressor.

♦ Example: If 40 cm3 of refrigerant oil has been drained from the defective air conditioner compressor and 100 cm3 of refrigerant oil has been drained from the replacement compressor, 40 cm3 of refrigerant oil must be poured into the new air conditioner compressor. (The refrigerant oil that was poured out of the new air conditioner compressor may be used.)

– After filling refrigerant circuit, check oil drain plug for leaks using an electronic leak detector or similar → Chapter „Locating leaks using electronic leak detector“.

Continued

– Assemble refrigerant circuit.

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

– Start up air conditioner compressor by performing “Basic setting, compressor run-in” function with → Vehicle diagnostic tester → Heating, air conditioning; Rep. gr.00; Electrical components; Starting diagnosis.

Renewing air conditioner compressor due to leakage or internal damage

♦ This procedure should be used if, for example, there are noises coming from the air conditioner compressor, there is no output from the air conditioner compressor or there is a leak in the air conditioner compressor resulting in an undefined amount of refrigerant oil escaping.

♦ If the leak is limited to refrigerant escaping from the air conditioner compressor, the compressor can be renewed without flushing the refrigerant circuit → Chapter „Renewing air conditioner compressor without having to clean refrigerant circuit“.

Procedure

– Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Removing and installing air conditioner compressor.

Electrical air conditioner compressor:

– Pour refrigerant oil out of defective air conditioner compressor into a clean container.

All vehicles (continued)

Mechanically driven air conditioner compressor

– Pour refrigerant oil out of defective air conditioner compressor into a clean container via oil drain plug → Chapter „Renewing components - empty refrigerant circuit“.

All vehicles (continued)

– Check old refrigerant oil for discolouration and metal particles.

Important

● If no discolouration (dark grey to black colour) or metal particles are identified, renew air conditioner compressor without cleaning refrigerant circuit → Chapter „Renewing air conditioner compressor without having to clean refrigerant circuit“.

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

– Make sure there is sufficient refrigerant oil in air conditioner compressor to achieve required quantity of refrigerant oil for refrigerant circuit. It may be necessary to add additional refrigerant oil on vehicles with additional elements (e.g. second evaporator) → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil capacities.

Important

● If additional refrigerant oil is required, add it when charging refrigerant circuit.

– Install air conditioner compressor → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Removing and installing air conditioner compressor.

– Renew expansion valve → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Removing and installing expansion valve.

– Depending on vehicle, it may be necessary to renew additional components after renewing air conditioner compressor → Heating, air conditioning; Rep. gr.87; Air conditioner compressor; Removing and installing air conditioner compressor.

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