Volkswagen ID.3: Air conditioner. Working with air conditioner service station

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. Working with air conditioner service station

Connecting air conditioner service station to refrigerant circuit
Performing gas analysis on refrigerant
Discharging refrigerant circuit
Evacuating refrigerant circuit
Charging refrigerant circuit
Starting up air conditioner after charging
Disconnecting air conditioner service station from refrigerant circuit
Decanting contaminated refrigerant into recycling cylinder using extraction unit VAS 581 011

Connecting air conditioner service station to refrigerant circuit

Special tools and workshop equipment required

♦ air conditioner service station

Important

● The procedure may vary depending on the air conditioner service station used; therefore observe the operating instructions → operating instructions.

Procedure

Vehicles with high-voltage system:

– Deactivate auxiliary air conditioner function → Owner's Manual.

All vehicles (continued)

– Switch off ignition.

– Start up air conditioner service station in accordance with corresponding operating instructions → operating instructions.

– Unscrew caps on service connections → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

– Check service connections of refrigerant circuit for dirt or corrosion and clean if necessary.

♦ Dirt or a rough surface on service connections due to corrosion can damage the seals and therefore cause premature failure of the quick-release couplings.

– Connect quick-release couplings to service connections (low and high pressure) of refrigerant circuit but do not screw in handwheels of quick-release couplings.

– Perform required work with air conditioner service station → Rep. gr.87; Working with the air conditioner service station.

Performing gas analysis on refrigerant

Special tools and workshop equipment required

♦ air conditioner service station

♦ gas analysis device

♦ The purpose of the gas analysis is to ensure the refrigerant meets the required level of purity, to identify contaminated refrigerant and to protect the air conditioner service station.

♦ It is not permissible to extract refrigerant from the air conditioner service station without performing a gas analysis first.

♦ The vehicle’s type approval is rendered invalid if the wrong refrigerant is used.

– Connect gas analysis device or air conditioner service station according to operating instructions and start it up → operating instructions.

– Perform gas analysis according to operating instructions → operating instructions.

Important

● A minimum pressure is required in the refrigerant circuit (e.g. higher than 2.5 bar with ambient temperature of 20 °C) for the gas analysis.

● Depending on the type of air conditioner service station or gas analysis device used, it may not be possible to perform a gas analysis if there is so little refrigerant remaining in the refrigerant circuit that it is not possible to build up sufficient pressure → operating instructions.

Important

During gas analysis, the following limit values apply for clean refrigerant R1234yf:

● Extracted refrigerant gas must consist of a minimum of 95 % refrigerant R1234yf.

● Proportion of foreign gases (oxygen, nitrogen, water vapour, other refrigerants) must be below 5 %.

If refrigerant does not meet specifications

– Return contaminated refrigerant to gas supplier for analysis, treatment or disposal → Rep. gr.87; Decanting contaminated refrigerant into recycling cylinder for analysis, treatment or disposal.

If the gas analysis reveals that the refrigerant is contaminated or that its composition is unclear, the customer must be informed of the following before continuing with work:

♦ If the wrong refrigerant has been used in the refrigerant circuit, the refrigerant circuit must be assessed and corresponding measures must be taken.

Continued

– Perform work with air conditioner service station → Rep. gr.87; Working with the air conditioner service station.

Discharging refrigerant circuit

Special tools and workshop equipment required

♦ air conditioner service station

Procedure

Important

● The procedure may vary depending on the air conditioner service station → operating instructions.

Vehicles with high-voltage system:

– Deactivate auxiliary air conditioner function → Owner's Manual.

All vehicles (continued)

Vehicles with high-voltage system on which electrically operated valves in refrigerant circuit are closed when not receiving current:

– Perform function “Opening electrically actuated valves in refrigerant circuit for extracting, evacuating and charging” with → Vehicle diagnostic tester → Heating, air conditioning; Rep. gr.00; Electrical components; Starting diagnosis.

Note

If this function has to be performed, it is described in the Workshop Manual for the specific vehicle.

All vehicles (continued)

– → Rep. gr.87; Connect air conditioner service station to refrigerant circuit.

Vehicles with refrigerant R1234yf:

– → Rep. gr.87; Perform gas analysis on refrigerant.

All vehicles (continued)

Vehicles without external receiver or with external receiver and refrigerant oil quantity of less than 1000 g:

– Select high-pressure and low-pressure connection on air conditioner service station to discharge refrigerant circuit.

– Set pressure build-up test.

Important

● Time: 2 minutes

NOTICE

Risk of damage to air conditioner compressor if there is vacuum in the refrigerant circuit.

– Never start the power unit when the refrigerant circuit is empty.

– Dissipate vacuum in refrigerant circuit by operating valves in service connections.

– Discharge refrigerant circuit with air conditioner service station.

♦ Depending on the version of the air conditioner service station, this may produce a vacuum in the refrigerant circuit when extracting refrigerant (residual pressure below approx. 300 mbar).

All vehicles (continued)

Vehicles with external receiver and refrigerant oil quantity of more than 1000 g:

– Select high-pressure and low-pressure connection on air conditioner service station to discharge refrigerant circuit.

– Set pressure build-up test.

Important

● Time: 10 minutes

NOTICE

Risk of damage to air conditioner compressor if there is vacuum in the refrigerant circuit.

– Never start the power unit when the refrigerant circuit is empty.

– Dissipate vacuum in refrigerant circuit by operating valves in service connections.

– Discharge refrigerant circuit with air conditioner service station.

♦ Depending on the version of the air conditioner service station, this may produce a vacuum in the refrigerant circuit when extracting refrigerant (residual pressure below approx. 300 mbar).

All vehicles (continued)

– Document amount of refrigerant oil that has been discharged from refrigerant circuit so that value can be used during subsequent charging.

Note

Depending on the version of the air conditioner service station, refrigerant oil equivalent to the amount discharged may be added automatically during charging in automatic mode (program for discharging and immediately recharging refrigerant) → operating instructions.

Important

The air conditioner compressor may only be operated under the following conditions when the refrigerant circuit is empty:

● Refrigerant circuit assembled completely

● Refrigerant circuit not under vacuum

● Avoid high engine/motor speeds

● Keep operating time short

If work is to be performed on vehicle after refrigerant circuit is discharged:

– → Rep. gr.87; Disconnect air conditioner service station from refrigerant circuit.

Continued

If refrigerant circuit is to be refilled directly afterwards:

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

Evacuating refrigerant circuit

Special tools and workshop equipment required

♦ air conditioner service station

NOTICE

Risk of damage to air conditioner compressor if there is vacuum in the refrigerant circuit.

– Never start the power unit when the refrigerant circuit is empty.

– Dissipate vacuum in refrigerant circuit by operating valves in service connections.

Important

● The procedure may vary depending on the air conditioner service station → operating instructions.

● Refrigerant circuit is evacuated via high-pressure and low-pressure connection.

● Refrigerant circuit assembled completely.

Procedure

Vehicles with high-voltage system:

– Deactivate auxiliary air conditioner function → Owner's Manual.

All vehicles (continued)

Vehicles with high-voltage system on which electrically operated valves in refrigerant circuit are closed when not receiving current

Note

If this function has to be performed, it is described in the Workshop Manual for the specific vehicle.

All vehicles (continued)

– Switch off ignition.

– → Rep. gr.87; Connect air conditioner service station to refrigerant circuit.

Refrigerant circuit has not been opened and leaks are not suspected:

– Evacuate refrigerant circuit and perform vacuum test.

Guide values:

♦ Vacuum time: 10 minutes

♦ Vacuum test/pressure build-up test: 5 minutes

Note

Depending on the air conditioner service station, there may be a minimum time that must be observed.

Important

● The pressure must be below 5 mbar absolute pressure at the end of the evacuation procedure.

● The pressure in the refrigerant circuit must not exceed 20 mbar absolute pressure at the end of the vacuum test/pressure build-up test.

Continued

Refrigerant circuit has been opened:

– Evacuate refrigerant circuit and perform vacuum test.

Guide values:

♦ Vacuum time: 30 minutes

♦ Vacuum test/pressure build-up test: 5 minutes

Note

Depending on the air conditioner service station, there may be a minimum time that must be observed.

Important

● The pressure must be below 5 mbar absolute pressure at the end of the evacuation procedure.

● The pressure in the refrigerant circuit must not exceed 20 mbar absolute pressure at the end of the vacuum test/pressure build-up test.

Continued

Possible causes if vacuum is not achieved during evacuation procedure:

♦ Time set for evacuation procedure too short

♦ Leak in refrigerant circuit → Rep. gr.87; Locating leaks

♦ Leak between vehicle and air conditioner service station

♦ Vacuum pump of air conditioner service station does not generate required vacuum

♦ Vacuum sensor of air conditioner service station is not calibrated correctly → operating instructions

Possible causes if vacuum is not achieved during vacuum test/pressure build-up test:

♦ Leak in refrigerant circuit → Rep. gr.87; Locating leaks

♦ Time set for evacuation procedure too short and time set for vacuum test/pressure build-up test too long

♦ Leak between vehicle and air conditioner service station

♦ Leak in air conditioner service station

Note

Even if there are no leaks in the refrigerant circuit, the specified absolute pressure in the refrigerant circuit may rise above 20 mbar during the vacuum test due to refrigerant or moisture evaporating out of the refrigerant oil or various other factors (e.g. quantity of refrigerant oil in the refrigerant circuit, vehicle’s age and mileage, refrigerant circuit design). If this is the case, repeat the process and/or adapt the preset times.

Charging refrigerant circuit

Special tools and workshop equipment required

♦ air conditioner service station

Important

● The procedure may vary depending on the air conditioner service station → operating instructions.

● Refrigerant circuit must be charged via high-pressure connection; low-pressure connection can generally remain connected → operating instructions.

● When filling refrigerant circuit, air conditioner service station and vehicle must be at same height (maximum difference: 50 cm). Depending on the air conditioner service station, having too great a height difference can cause the amount of refrigerant shown to differ from the amount poured in. This may affect the charging accuracy of the air conditioner service station.

Procedure

– Check fresh oil reservoir is filled with correct type of refrigerant oil and change oil in reservoir if necessary.

– Set air conditioner service station to charge refrigerant circuit via high-pressure side → operating instructions.

Note

If the charging direction cannot be set on air conditioner service station, unscrew (close) handwheel on quick release coupling adapter (low-pressure side).

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

– Set quantities for refrigerant, refrigerant oil that must be added and (if necessary) leak detection additive on air conditioner service station.

♦ Refrigerant → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant capacities

♦ Refrigerant oil → Heating, air conditioning; Rep. gr.00; Technical data; Refrigerant oil quantities and → Rep. gr.87; Renewing components

♦ Leak detection additive → Rep. gr.87; Locating leaks using UV leak detection system

– Start procedure for charging refrigerant circuit on air conditioner service station.

– Once charging procedure is complete, disconnect air conditioner service station from refrigerant circuit → Rep. gr.87; Disconnecting air conditioner service station from refrigerant circuit.

Vehicles with high-voltage system on which electrically operated valves in refrigerant circuit are closed when not receiving current:

– Perform “Activating electrically actuated valves in refrigerant circuit” function with → Vehicle diagnostic tester → Heating, air conditioning; Rep. gr.00; Electrical components; Starting diagnosis.

Note

Valves may be installed in the refrigerant circuit on vehicles with high-voltage system and additional air conditioner functions. It is important that no areas are blocked off to ensure the refrigerant circuit can be discharged, evacuated and charged correctly; these valves must therefore be closed after charging → Heating, air conditioning; Rep. gr.87; Refrigerant circuit

All vehicles (continued)

– Start up air conditioner depending on work performed → Rep. gr.87; Starting up air conditioner after charging.

Starting up air conditioner after charging

Observe any vehicle-specific special measures → Heating, air conditioning; Rep. gr.87; Refrigerant circuit.

Important

The function for starting up the air conditioner must be performed after the refrigerant circuit has been charged in the following cases:

● Air conditioner compressor was renewed and refrigerant circuit was flushed

● Refrigerant circuit was flushed

● Electrical air conditioner compressor was renewed

Procedure

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

– Open all dash panel vents and any vents in centre console.

– Perform functions for starting up air conditioner compressor using → Vehicle diagnostic tester → Heating, air conditioning; Rep. gr.00; Electrical components; Starting diagnosis.

– Start power unit and operate air conditioner compressor for at least 5 minutes at idling speed.

Disconnecting air conditioner service station from refrigerant circuit

Special tools and workshop equipment required

♦ air conditioner service station

Important

● The procedure may vary depending on the air conditioner service station used; therefore observe the operating instructions → operating instructions.

Procedure

– Complete work with air conditioner service station.

CAUTION

Risk of frostbite from escaping pressurised refrigerant

Risk of frostbite on skin and other parts of the body

– Put on protective gloves.

– Put on safety goggles.

– Extract/drain refrigerant and then immediately open up refrigerant circuit.

– Extract/drain refrigerant again if more than 10 minutes have passed since initial extraction and refrigerant circuit has not been opened up. Renewed evaporation has created pressure in the refrigerant circuit.

– Unscrew handwheels of service couplings.

– Disconnect quick-release couplings from vehicle.

– Screw caps onto service connections.

Decanting contaminated refrigerant into recycling cylinder using extraction unit VAS 581 011

Special tools and workshop equipment required

♦ Evacuated recycling cylinder for contaminated R1234yf. Commercially available from gas suppliers; recycling cylinders made of light metal alloys are not permitted due to the risk of chemical reactions with refrigerant components.

♦ air conditioner service station

♦ air conditioner service station R1234yf

♦ extraction unit -VAS 581 011-

Procedure

Vehicles with high-voltage system

– Deactivate auxiliary air conditioner function → Owner's Manual.

All vehicles (continued)

Vehicles with high-voltage system on which electrically operated valves in refrigerant circuit are closed when not receiving current

All vehicles (continued)

– Connect extraction unit -VAS 581 011- to vehicle and air conditioner service station R1234yf in accordance with → operating instructions.

– Transfer contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- in accordance with → operating instructions.

– Fill in form supplied with recycling cylinder for contaminated refrigerant and attach securely to cylinder.

– Return filled recycling cylinder via supplier, making sure to comply with the applicable regulations.

– Evacuate refrigerant circuit using air conditioner service station for at least one hour → Rep. gr.87; Evacuating refrigerant circuit.

Note

Through subsequent evacuation, the last residues of contaminated refrigerant, which could still be bound in the refrigerant oil, are removed at an absolute pressure of less than 10 mbar.