Volkswagen ID.3: Air conditioner. Valve unit of heat pump

Volkswagen ID.3 (E11, E12) 2020-2024 Service Manual / Heating, ventilation, air conditioning system / Heating, air conditioning system / Air conditioner. Valve unit of heat pump

Assembly overview - heat pump valve unit
Removing and installing heat pump valve unit
Removing and installing refrigerant expansion valve 1 N636
Removing and installing refrigerant expansion valve 2 N637
Removing and installing refrigerant expansion valve 3 N638
Removing and installing refrigerant shut-off valve 1 N696
Removing and installing refrigerant shut-off valve 2 [N640]
Removing and installing refrigerant shut-off valve 3 N641
Removing and installing refrigerant shut-off valve 4 [N642]
Removing and installing refrigerant shut-off valve 5 N643

Assembly overview - heat pump valve unit

Assembly overview - heat pump valve unit, components

1 - Guide sleeve

❏ 3x

2 - Rubber bush

❏ 3x

3 - Bolt

❏ 11x

❏ 8 Nm

4 - Bracket

5 - Bolt

❏ 3x

❏ 20 Nm

6 - Refrigerant expansion valve 1 -N636-

❏ → Rep. gr.87; Removing and installing refrigerant expansion valve 1 N636

7 - Refrigerant shut-off valve 1 -N696-

❏ → Rep. gr.87; Removing and installing refrigerant shut-off valve 1 N696

8 - Refrigerant expansion valve 3 -N638-

❏ → Rep. gr.87; Removing and installing refrigerant expansion valve 3 N638

9 - Refrigerant expansion valve 2 -N637-

❏ → Rep. gr.87; Removing and installing refrigerant expansion valve 2 N637

10 - Electrical wiring for refrigerant pressure and temperature sender 4 -G828-

11 - Refrigerant shut-off valve 5 -N643-

❏ → Rep. gr.87; Removing and installing refrigerant shut-off valve 5 N643

12 - Refrigerant shut-off valve 4 -N642-

❏ → Rep. gr.87; Removing and installing refrigerant shut-off valve 4 N642

13 - Electrical wiring for heat pump valve unit

14 - Refrigerant shut-off valve 2 -N640-

❏ → Rep. gr.87; Removing and installing refrigerant shut-off valve 2 N640

15 - Refrigerant shut-off valve 3 -N641-

❏ → Rep. gr.87; Removing and installing refrigerant shut-off valve 3 N641

16 - Electrical wiring for refrigerant pressure and temperature sender 2 -G826-

17 - Electrical wiring for refrigerant pressure and temperature sender 5 -G829-

18 - High-voltage battery heat exchanger

❏ → Rep. gr.87; Removing and installing heat exchanger for high-voltage battery

19 - Dryer

❏ → Rep. gr.87; Removing and installing dryer

20 - Retainer

21 - Flexible joint

❏ 3 Nm

22 - Nut

❏ 15 Nm

Assembly overview - refrigerant lines inside heat pump valve unit

1 - Refrigerant line

2 - Bolt

❏ Applies to all connections in illustration

❏ Renew after removing

❏ Hexagon bolt: 13 Nm

❏ Twelve-point bolt: 5 Nm +90°

3 - Seal

❏ Applies to all connections in illustration

❏ Renew after removing

4 - Retaining element

❏ Applies to all connections in illustration

❏ Renew after removing

5 - Refrigerant line

6 - Dryer

❏ → Rep. gr.87; Removing and installing dryer

7 - Refrigerant line

8 - Refrigerant line

9 - Refrigerant line

10 - Heat pump valve unit

❏ → Rep. gr.87; Removing and installing heat pump valve unit

11 - High-voltage battery heat exchanger

❏ → Rep. gr.87; Removing and installing heat exchanger for high-voltage battery

12 - Refrigerant line

Assembly overview - refrigerant lines at heat pump valve unit

1 - Refrigerant line

❏ → Rep. gr.87; Removing and installing refrigerant line between expansion valve N636/N696 and heat condenser

2 - Refrigerant line

❏ → Rep. gr.87; Removing and installing refrigerant line between expansion valve N638/N637 and evaporator

3 - Refrigerant line

❏ → Rep. gr.87; Removing and installing refrigerant line between condenser/gas cooler and refrigerant shut-off valve 2 N640

4 - High-voltage battery heat exchanger

❏ → Rep. gr.87; Removing and installing heat exchanger for high-voltage battery

5 - Refrigerant line

❏ → Rep. gr.87; Removing and installing refrigerant line between refrigerant shut-off valve 3 N641 and heat condenser

6 - Refrigerant line

❏ → Rep. gr.87; Removing and installing refrigerant line between air conditioner compressor VX81 and valve block N641/N640

7 - Retaining element

❏ Applies to all connections in illustration

❏ Renew after removing

8 - Seal

❏ Applies to all connections in illustration

❏ Renew after removing

9 - Bolt

❏ Applies to all connections in illustration

❏ Renew after removing

❏ 5 Nm +90°

10 - Heat pump valve unit

❏ → Rep. gr.87; Removing and installing heat pump valve unit

11 - Refrigerant line

❏ → Rep. gr.87; Removing and installing refrigerant line between heat pump valve unit and evaporator

Removing and installing heat pump valve unit

Special tools and workshop equipment required

♦ ESD workplace -VAS 6613-

♦ engine bung set -VAS 6122-

Removing

Immediately seal open lines and connections with clean plugs from engine bung set -VAS 6122-.

When renewing several components of heat pump valve unit at the same time:

– Observe procedure for renewal of refrigerant circuit components → General information – air conditioning systems with refrigerant R744; Rep. gr.87; Renewing components; Renewing components.

Continued

– Carry out function “Open electrically actuated valves to drain, evacuate or charge refrigerant circuit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

– → Air conditioning systems with refrigerant R744 – General notes; Rep. gr.87; Working with air conditioner service station; Draining refrigerant circuit.

– → Rep. gr.19; Cooling system/coolant; Draining coolant.

– Remove air intake box of heater and air conditioning unit → Rep. gr.87; Removing and installing air intake unit of heater and air conditioning unit.

– Detach coolant expansion tank, and lay it slightly aside → Rep. gr.19; Cooling system/coolant; Removing and installing coolant expansion tank.

– Remove front underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing front underbody cladding.

– Remove lock carrier → General body repairs, exterior; Rep. gr.50; Lock carrier; Removing and installing lock carrier.

– Separate coolant hose -1- and lay to one side.

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 bolt -2-.

– Pull off refrigerant line -3-.

Right-hand drive vehicles:

– Remove air conditioner compressor → Rep. gr.87; Removing and installing air conditioner compressor VX81.

All vehicles (continued)

– Mark (to avoid interchanging) and disconnect electrical connector -3-.

– Unscrew bolt -2-.

– Pull off refrigerant line -1-.

– Unscrew bolts -3-.

– Pull off refrigerant line -1- and -2-.

– Loosen clips -3-.

– Pull off coolant hoses -1- and -2-.

– Mark (to avoid interchanging) and disconnect electrical connectors -1- and -2-.

– Unscrew bolts -1-, -2-, -3- and -4-.

– Pull off refrigerant lines.

– Unscrew bolts -2-, -3- and -4- from bracket of heat pump valve unit -1-.

– Remove valve unit of heat pump -1- upwards.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

Installing

Install in reverse order of removal, observing the following:

– Install seals and captive fasteners free of oil.

After renewal of several components of heat pump valve unit at the same time:

– Carry out adaption routine for refrigerant oil capacity in refrigerant circuit → General information – air conditioning systems with refrigerant R744; Rep. gr.87; Renewing components.

Continued

– Carry out function “Open electrically actuated valves to drain, evacuate or charge refrigerant circuit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

– → Air conditioning systems with refrigerant R744 – General notes; Rep. gr.87; Working with air conditioner service station; Charging refrigerant circuit.

– → Rep. gr.19; Cooling system/coolant; Filling cooling system

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

♦ → Rep. gr.87; Assembly overview - refrigerant lines

♦ → Rep. gr.87; Assembly overview - air intake box of heater and air conditioning unit

Removing and installing refrigerant expansion valve 1 N636

Special tools and workshop equipment required

♦ ESD workplace -VAS 6613-

Available versions

Variante A - up to approx. 10/2023, identifiable by pressure sender aligned horizontally in refrigerant line -1- → Anchor

Variante B - as of approx. 11/2023, identifiable by pressure sender aligned vertically -2- → Anchor

Removing and installing, version A

Removing

Refrigerant expansion valve 1 -N636- and refrigerant shut-off valve 1 -N696- cannot be renewed individually.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

– Unscrew bolts -1-, -2- and -3-.

– Mark (to avoid interchanging) and disconnect electrical connectors -2-.

– Unscrew bolts -3-.

– Remove refrigerant expansion valve 1 -N636- and refrigerant shut-off valve 1 -N696- -1-.

Installing

Install in reverse order of removal, observing the following:

– Install seals and captive fasteners free of oil.

When renewing expansion valve/shut-off valve:

– Carry out function “Addressing routine for refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

Removing and installing, version B

Removing

Refrigerant expansion valve 1 -N636- and refrigerant shut-off valve 1 -N696- cannot be renewed individually.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

– Unscrew bolts -1-, -2- and -3-.

– Mark (to avoid interchanging) and disconnect electrical connectors -2-.

– Unscrew bolts -3-.

– Remove refrigerant expansion valve 1 -N636- and refrigerant shut-off valve 1 -N696- -1-.

Installing

Install in reverse order of removal, observing the following:

– Install seals and captive fasteners free of oil.

When renewing expansion valve/shut-off valve:

– Carry out function “Addressing routine for refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

Removing and installing refrigerant expansion valve 2 N637

Special tools and workshop equipment required

♦ ESD workplace -VAS 6613-

Removing

Refrigerant expansion valve 2 -N637- and refrigerant expansion valve 3 -N638- cannot be renewed separately.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit on ESD workplace -VAS 6613-.

– Remove bolts -1-, -2- and -3-.

– Mark electrical connectors -2- to avoid interchange and unplug them.

– Remove bolts -3-.

– Detach refrigerant expansion valve 2 -N637- and refrigerant expansion valve 3 -N638- -1-.

Installing

Installation is carried out in reverse order; note the following:

– Install seals and retaining elements, making sure they are free of oil.

If expansion valves have been renewed:

– Perform function “Addressing refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Starting diagnosis.

Continued

Tightening torques

♦ → Rep. gr.87; Exploded view - heat pump valve unit

Removing and installing refrigerant expansion valve 3 N638

Removing and installing

Refrigerant expansion valve 3 -N638- is removed together with refrigerant expansion valve 2 -N637- and cannot be renewed separately → Rep. gr.87; Removing and installing refrigerant expansion valve 2 N637.

Removing and installing refrigerant shut-off valve 1 N696

Removing and installing

Refrigerant shut-off valve 1 -N696- is removed together with refrigerant expansion valve 1 -N636- and cannot be renewed separately → Rep. gr.87; Removing and installing refrigerant expansion valve 1 N636.

Removing and installing refrigerant shut-off valve 2 [N640]

Special tools and workshop equipment required

♦ ESD workplace -VAS 6613-

♦ counterhold tool -T10630-

Available versions

Variante A - up to approx. 10/2023, identifiable by pressure sender aligned horizontally in refrigerant line -1- → Anchor

Variante B - as of approx. 11/2023, identifiable by pressure sender aligned vertically -2- → Anchor

Removing and installing, version A

Removing

Refrigerant shut-off valve 2 -N640- and refrigerant shut-off valve 3 -N641- cannot be renewed individually.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

– Insert counterhold tool -T10630- -4-.

– Unscrew bolts -1-, -2-, -3- and -5-.

– Pull off refrigerant lines.

– Mark (to avoid interchanging) and disconnect electrical connectors -2-.

– Unscrew bolts -3-.

– Remove refrigerant shut-off valve 2 -N640- and refrigerant shut-off valve 3 -N641- -1-.

Installing

Install in reverse order of removal, observing the following:

– Install seals and captive fasteners free of oil.

– When tightening bolts -3-, use counterhold tool -T10630-.

If shut-off valve have been renewed:

– Carry out function “Addressing routine for refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

Removing and installing, version B

Removing

Refrigerant shut-off valve 2 -N640- and refrigerant shut-off valve 3 -N641- cannot be renewed individually.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

– Unscrew bolts -1-, -2-, -3- and -4-.

– Remove refrigerant lines.

– Mark (to avoid interchanging) and disconnect electrical connectors -2-.

– Unscrew bolts -3-.

– Remove refrigerant shut-off valve 2 -N640- and refrigerant shut-off valve 3 -N641- -1-.

Installing

– Install seals and captive fasteners free of oil.

If shut-off valve have been renewed:

– Carry out function “Addressing routine for refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

Removing and installing refrigerant shut-off valve 3 N641

Removing and installing

Refrigerant shut-off valve 3 -N641- is removed together with refrigerant shut-off valve 2 -N640- and cannot be renewed separately → Rep. gr.87; Removing and installing refrigerant shut-off valve 2 N640.

Removing and installing refrigerant shut-off valve 4 [N642]

Special tools and workshop equipment required

♦ ESD workplace -VAS 6613-

Available versions

Variante A - up to approx. 10/2023, identifiable by pressure sender aligned horizontally in refrigerant line -1- → Anchor

Variante B - as of approx. 11/2023, identifiable by pressure sender aligned vertically -2- → Anchor

Removing and installing, version A

Removing

Refrigerant shut-off valve 4 -N642- and refrigerant shut-off valve 5 -N643- cannot be renewed individually.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

– Unscrew bolts -2-, -3- and -4-.

– Pull off refrigerant line -1-.

– Unscrew bolts -1- and -2-.

– Mark (to avoid interchanging) and disconnect electrical connectors -2-.

– Unscrew bolts -3-.

– Remove refrigerant shut-off valve 4 -N642- and refrigerant shut-off valve 5 -N643- -1-.

Installing

Install in reverse order of removal, observing the following:

– Install seals and captive fasteners free of oil.

If shut-off valve have been renewed:

– Carry out function “Addressing routine for refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

Removing and installing, version B

Removing

Refrigerant shut-off valve 4 -N642- and refrigerant shut-off valve 5 -N643- -1- cannot be renewed individually.

– Remove heat pump valve unit → Rep. gr.87; Removing and installing heat pump valve unit.

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place heat pump valve unit onto ESD workplace -VAS 6613-.

– Unscrew bolts -2-, -3- and -4-.

– Pull off refrigerant line -1-.

– Unscrew bolts -1- and -2-.

– Mark (to avoid interchanging) and disconnect electrical connectors -2-.

– Unscrew bolts -3-.

– Remove refrigerant shut-off valve 4 -N642- and refrigerant shut-off valve 5 -N643- -1-.

Installing

Install in reverse order of removal, observing the following:

– Install seals and captive fasteners free of oil.

If shut-off valve have been renewed:

– Carry out function “Addressing routine for refrigerant valves” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.87; Assembly overview – heat pump valve unit

Removing and installing refrigerant shut-off valve 5 N643

Removing and installing

Refrigerant shut-off valve 5 -N643- is removed together with refrigerant shut-off valve 4 -N642- and cannot be renewed separately → Rep. gr.87; Removing and installing refrigerant shut-off valve 4 N642.