Service

Workshop Manual
Citigo 2012 ➤ , Fabia 2000 ➤ ,
Fabia II 2007 ➤ , Fabia II 2009 ➤ ,
Fabia II 2011 ➤ , Fabia III 2015 ➤ ,
Karoq 2018 ➤ , Kodiaq 2017 ➤ ,
Octavia 1997 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Octavia III 2013 ➤ ,
Octavia III 2014 ➤ , Rapid 2011 ➤ ,
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Roomster 2006 ➤ , Superb 2002 ➤ ,
Superb II 2008 ➤ , Superb III 2015 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤
Air conditioning system with refrigerant R134a
Edition 05.2017

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Service Department. Technical Information

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 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2017 ŠKODA AUTO a. s. D3E801B9571

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Air conditioning system with refrigerant R134a - Edition 05.2017

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes on the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Important instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Further documentation and information means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Principles of the air-conditioning technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Advantages of the air conditioning system - comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Operation of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Vapour pressure table for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.9 Evidence of leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 Refrigerant machine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.11 General occupational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.12 Using pressure tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.13 Safety precautions when working with extraction and filling systems . . . . . . . . . . . . . . . . 12
1.14 Safety measures when working on vehicles with air conditioning system and when using
refrigerant R 134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.15 Basics for working on the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 General instructions for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Components of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Extractor, filler and measurement valves for quick couplings of the AC service station on the
refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Pressures and temperatures in the refrigerant circuit and its arrangement . . . . . . . . . . . . 24
2.4by copyright.
Protected Switch and
Copying for sender on the refrigerant
private or commercial purposes, in partcircuit
or in whole,. is. not
. . permitted
................................ 28
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
2.5 Electrical components which are not fitted on the
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� refrigerant circuit . . . . . . . . . . . . . . . . . . 29
2.6 The inspection and measurement work can be performed using the pressure gauge . . . . 30
2.7 Air conditioning service and recycling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8 Repair and maintenance instructions for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Legal texts and legal regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 Verification procedure of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Important repair instructions for air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 Working with the A/C service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Important instructions for working with the A/C Service station . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Connecting the A/C service station to the refrigerant circuit for measuring and testing . . . . 38
5.3 Empty the refrigerant circuit with the A/C service station. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Evacuate the refrigerant circuit with the A/C service station. . . . . . . . . . . . . . . . . . . . . . . . . 39
5.5 Fill the refrigerant circuit with the A/C service station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Operate the air conditioning system after filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.7 Fill refrigerant into the reservoir (filling cylinder or reservoir bottle) of the A/C service
station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.8 Draining the A/C service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6 Leak detection on the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.1 Looking for leaks in the refrigerant circuit - important instructions . . . . . . . . . . . . . . . . . . . . 42
6.2 Leak detection on the refrigerant circuit with compressed air or nitrogen . . . . . . . . . . . . . . 43
6.3 Detecting leaks on the refrigerant circuit with the leak detector VAG1796 . . . . . . . . . . . . 45
6.4 Detecting leaks on the refrigerant circuit with the leak detector VAS 6196 or VAS 6201A
........................................................................ 45
7 Removing contaminants from the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.1 Cleaning the refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . . . . . 52
7.2 Cleaning refrigerant circuit with refrigerant R134a (flush) . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3 Principle circuit diagrams for different rinsing cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Contents i
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Air conditioning system with refrigerant R134a - Edition 05.2017

7.4 Adapter for setting up the rinsing cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8 Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.1 Possible complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.2 Temperature test of cooling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.3 Odour from the heating and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9 Check the pressure in the refrigerant circuit (with the A/C service station) . . . . . . . . . . . . 71
9.1 Test requirements before the pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.2 Check pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.3 Continuation of the test depending on the arrangement of the refrigerant circuit . . . . . . . . 74
9.4 Pressure test for vehicles with throttle and catch pan (with AC compressor regulated from
the inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.5 Pressure test for vehicles with expansion valve and fluid reservoir (with AC compressor
regulated from the inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.6 Pressure test for vehicles with expansion valve, fluid reservoir and with regulating valve for
compressor of air conditioning system N280 (with AC compressor regulated from the
outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 Replace components of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1 Replace parts on the refrigerant circuit - General instructions . . . . . . . . . . . . . . . . . . . . . . 91
10.2 Components of the refrigerant circuit leaking or damaged - the refrigerant circuit is absolutely
empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.3 Components of the refrigerant circuit leaking or damaged - refrigerant is still in the refrigerant
circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.4 Replace AC compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.5 Replace AC reservoir/desiccator/restrictor/expansion valve . . . . . . . . . . . . . . . . . . . . . . . . 94
11 Tools and materials, which are available from the importer . . . . . . . . . . . . . . . . . . . . . . . . 96
11.1 Setting up tools and materials which are available from the importer . . . . . . . . . . . . . . . . 96
11.2 A/C service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.3 Flushing device for the refrigerant circuits 6337/1 or follow-up models (manufacturer Behr)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.4 Flushing device for the refrigerant circuits 6336/1 or follow-up models (manufacturer
Waeco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.5 Leak detector V.A.G 1796 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.6 Leak detection system VAS 6196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.7 Leak detection system VAS 6201A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.8 Adapter case of motor car set VAS 6338/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.9 Release tools VAS 6127/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.10 Socket T10364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12 Tools and materials, which are commercially available . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.1 Setting up tools and materials which are available from a dealer . . . . . . . . . . . . . . . . . . . . 101
12.2 Filling hoses . . . . . . . . .Protected . . . . .by. copyright.
. . . . . .Copying
. . . .for. .private
. . . or
. .commercial
. . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. . . .is. not
. .permitted
. . . . 102
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
12.3 Bottle connecting piece forwith pressure bottle
respect to the . . of
correctness . .information
. . . . . in
. .this
. .document.
. . . . . Copyright
. . . . . by . .ŠKODA
. . . . AUTO
. . . A.
. .S.�
. . 102
12.4 Valve caps with replacement gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.5 Pressure gauge with pressure reducer for nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
12.6 Quick-coupling adapter for service connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
12.7 Tools, which you make yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

ii Contents
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Air conditioning system with refrigerant R134a - Edition 05.2017

00 – Technical data
1 General notes on the air conditioning
system
(SRL001078; Edition 05.2017)
⇒ “1.1 Important instructions”, page 1
⇒ “1.2 Further documentation and information means”,
page 2
⇒ “1.3 Principles of the air-conditioning technology”, page 2
⇒ “1.4 Advantages of the air conditioning system - comfort”, page
4
⇒ “1.5 Operation of the air conditioning system”, page 4
⇒ “1.6 Refrigerant R134a”, page 5
⇒ “1.7 Vapour pressure table for refrigerant R134a”, page 6
⇒ “1.8 Properties of refrigerant R134a”, page 7
⇒ “1.9 Evidence of leaks”, page 8
⇒ “1.10 Refrigerant machine oil”, page 9
⇒ “1.11 General occupational safety”, page 9
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “1.12 Using pressure tank”, page 11
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

⇒ “1.13 Safety precautions when working with extraction and fill‐

ing systems”, page 12
⇒ “1.14 Safety measures when working on vehicles with air con‐
ditioning system and when using refrigerant R 134a”, page 13
⇒ “1.15 Basics for working on the refrigerant circuit ”, page 13

1.1 Important instructions

This workshop manual provides basic knowledge to foremen and
mechanics, in order to carry out professional work on air condi‐
tioning systems for vehicles.
In order to carry out professional work on air conditioning systems
for vehicles, you must have worked through the content of this
Workshop Manual or completed a training course on the air con‐
ditioning system including general knowledge (possibly with a
corresponding final test) and you must be able to implement these
elements in practice.
Only these workers are recognised as qualified to pursue the ac‐
tivities on air conditioning systems for vehicles.

Note

♦ This workshop manual can also serve as training documen‐

tation.
♦ This Workshop Manual should be kept at the work place and
it must be submitted at the request of the responsible super‐
visory authority, if required.
♦ Alternative or additional regulations may be valid in certain
countries.

1. General notes on the air conditioning system 1

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Air conditioning system with refrigerant R134a - Edition 05.2017

Caution

Non-approved tools or materials (e.g. stop leak additive) can

cause damage/deterioration to the system.
Only tools and materials approved by the manufacturer may
be used.
There is no guarantee if non-approved tools or materials were
used.

1.2 Further documentation and information

means
♦ Workshop manual for type related repair work ⇒ Heating, Air
Conditioning; Rep. gr. 87
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
♦ Self-study programmes, e.g. ⇒ Self-study programme No.
10 ; air conditioning system in the vehicle or ⇒ Self-study pro‐
gramme No. 25 ; Octavia - Climatronic
♦ Video programmes for occupational training
♦ ⇒ Electronic Catalogue of Original Parts “ETKA”
♦ ⇒ Catalogue of factory equipment and special tools

1.3 Principles of the air-conditioning tech‐

nology
⇒ “1.3.1 Physical principles”, page 2
⇒ “1.3.2 Heat always flows from a warmer substance to a colder
substance”, page 3
⇒ “1.3.3 Pressure and boiling point”, page 3

1.3.1 Physical principles

The four known aggregate phases of water also exist for the re‐
frigerants of the air conditioning system.
1- gaseous (not visible)
2- vaporous
3- liquid Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4- solid

2 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

If water is heated in a container (heat absorption) rising water

vapour is visible. If the vapour is heated even more through heat
absorption, the visible vapour becomes invisible gas. The proce‐
dure is reversible. If the heat content is extracted from the gas‐
eous water, this results first of all in vapour, from this the vapour
turns into water and then into ice.
A - Heat absorption
B - Heat dissipation

1.3.2 Heat always flows from a warmer sub‐

stance to a colder substance
Each substance consists of a mass of moving molecules. The fast
moving molecules of a warmer substance give up a part of their
energy to the molecules which are slower and have less heat.
This slows down the molecular movement of the warmer sub‐
stance and the molecular movement of the colder substance is
accelerated. This happens until the molecules of both substances
move with the same speed. Then they have the same tempera‐
ture and no further heat exchange takes place.

1.3.3 Pressure and boiling point

The boiling point of a liquid given in the tables always refers to
the atmospheric pressure of 1 bar. If the pressure of a liquid
changes, so does its boiling point.
It is known, for example, that water boils at lower temperatures
the lower the pressure.
Based on the vapour pressure curves for water and refrigerant
R134a it can be recognised, for example, that
Protected while maintaining
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
pressure, by lowering the temperature, theauthorised
unless vapour by turns
ŠKODA to liquid
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
(in the condenser), or that, for example, with
by reducing
respect to the the pressure,
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
the refrigerant turns from the liquid state into the vapour state
(evaporator).
Vapour pressure curve of water
A - liquid
B - gaseous
C - Vapour pressure curve of water
1 - Pressure of the liquid in bar (absolutely)
2 - Temperature in °C

1. General notes on the air conditioning system 3

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Air conditioning system with refrigerant R134a - Edition 05.2017

Vapour pressure curve of refrigerant R134a

A - liquid
B - gaseous
D - Vapour pressure curve of refrigerant R134a
1 - Pressure of the liquid in bar (absolutely)
2 - Temperature in °C

1.4 Advantages of the air conditioning sys‐

tem - comfort
One of the basic requirements for a concentrated and safe driving
is the feeling of comfort in the vehicle interior. This comfort is only
possible through the use of an air conditioning system, especially
in warm temperatures and at high humidity. Open windows, an
open sliding sunroof or a higher air flow rate certainly contribute
to the comfort, but there are disadvantages for the vehicle interior,
such as: additional noise, draught, exhaust, unfiltered infiltration
of pollen and dust (unpleasant for allergy sufferers).
Through a controlled air conditioning system, in combination with
a well-designed heating and ventilation system, the feeling of
well-being and comfort can be achieved by controlling the indoor
temperature, humidity and air movement, according to the exter‐
nal conditions. This is possible when the vehicle is stationary as
well as when driving.
Further important advantages of the air conditioning system are:
♦ The cleaning of the air injected into the interior (by the wet fins
of the evaporator, for example, dust and pollen are washed
out and evacuated with the condensation water).
Temperatures in a medium-class car, eg: after a short driving
time, outside temperature 30 ° C in the shade and vehicle under
the sun:
with air condition‐ without air condi‐
ing system tioning system
Head room 23 °C 42 °C
Chest 24 °C 40 °C
Footwell 30 °C 35 °C

1.5 Operation of the air conditioning system

The temperature in the passenger compartment is influenced by
radiant heat through the window and by the contact heat emitted
by metallic parts. In order to provide agreeable temperatures for
the passengers on very hot days, some of the ambient heat must
be evacuated.
As it isProtected
a wellbyknown
copyright. fact
Copyingthat heatorspreads
for private commercial towards colder
purposes, in part tem‐is not permitted
or in whole,
peratures, an aggregate
unless authorised that A.
by ŠKODA AUTO generates
S. ŠKODA AUTO lower
A. S.temperatures
does not guarantee or has
accept any liability
been fitted to the
with respect vehicle,
to the i.e.
correctness the evaporator.
of information Refrigerant
in this document. is con‐
Copyright by ŠKODA AUTO A. S.�
tinuously evaporated in this evaporator. The heat required for this
operation is drawn from the air flowing through the evaporator.
The refrigerant gas together with the absorbed heat is pumped
out of the evaporator by the AC compressor. The AC compres‐
sor's compression work increases the heat content and the tem‐
perature of the refrigerant. It is now considerably higher than the
ambient air temperature.

4 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

The high-temperature refrigerant and its heat content flow to the

condenser. There, because of the temperature difference be‐
tween the refrigerant and the ambient air, the refrigerant releases
heat into the ambient air via the condenser and liquefies.
The refrigerant is also a heat conveyor. As it will be re-used, it is
again pumped to the evaporator.
For this reason, the basic principle of all air conditioning systems
is a circuit for refrigerants. Differences arise in the composition of
the aggregates.

1.6 Refrigerant R134a

⇒ “1.6.1 Physical data of the refrigerant R134a”, page 5
⇒ “1.6.2 Trade names and designations of the refrigerant R134a”,
page 5
⇒ “1.6.3 Critical point”, page 5
⇒ “1.6.4 Environmental aspects of the refrigerant R134a”,
page 6

1.6.1 Physical data of the refrigerant R134a

The evaporation and condensation process is the procedure used
for all air conditioning systems in vehicles. Thus it works with a
lightly boiling substance, which is described as a refrigerant.
The refrigerant used is Tetrafluorethan R134a, which boils at
-26.5°C under a pressure of 1 bar.
Chemical formula CH2F-CF3 or CF3-CH2F
Chemical designation Tetrafluorethan
Boiling point at 1 bar -26.5 °C
Solidification point -101.6 °C
Critical temperature 100.6 °C
Critical pressure 39.56 bar (absolutely)
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1.6.2 Trade names and designations of the
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refrigerant R134a
The refrigerant R134a is currently available under the following
trade names:
♦ H-FKW 134a
♦ SUVA 134a
♦ KLEA 134a

Note

♦ In other countries, other trade names may also be common.

♦ Among the wide range of different refrigerants, only this re‐
frigerant should be used for automobiles. The designation
“Frigen” or “Freon” are trade names. They also apply to re‐
frigerants that are not intended to be used for automobiles.

1.6.3 Critical point

The critical point (critical temperature and critical pressure)
means that there is no divide over the same interface between
the surface of the liquid and the gas.
A substance is always gaseous when it is above its critical point.

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At temperatures below the critical point, all types of refrigerants

in pressure tanks have a liquid and a gas phase, which means
that a gas blanket is present above the liquid.
As long as gas is still present in the tank aside from liquid, the
pressure depends upon the ambient temperature
⇒ “1.7 Vapour pressure table for refrigerant R134a”, page 6 .

1.6.4 Environmental aspects of the refrigerant

R134a
♦ R134a is a fluorinated hydrocarbon (PFC) and contains no
chlorine.
♦ R134a has a lower atmospheric lifetime than the refrigerant
R12.
♦ R134a does not attack the ozone layer.
♦ The contribution of R134a to the greenhouse effect is by a
factor of 10 less than the effect of the refrigerant R12.

1.7 Vapour pressure table for refrigerant

R134a
The vapour pressure table is decisive for each refrigerant used in
the literature for refrigeration technicians. From this table can be
read which vapour pressure above the liquid column in the vessel
pushes when the temperature of the reservoir is known.
As for any refrigerant a characteristic vapour pressure table is
known, knowledge of the refrigerant concerned can be obtained
by pressure and temperature measurement.
Temperature in °C Pressure in bar (overpressure)
R134a
-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00Copying for private or commercial purposes, in part or in whole, is not permitted
Protected by copyright.
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-5 with respect to 1.43
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

0 1.92
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6.70
35 7.83
40 9.10
45 10.54
50 12.11
55 13.83
60 15.72
65 17.79

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Temperature in °C Pressure in bar (overpressure)

R134a
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34

1.8 Properties of refrigerant R134a

⇒ “1.8.1 Colour”, page 7
⇒ “1.8.2 Vapour pressure”, page 7
⇒ “1.8.3 Air displacement as a result of gaseous refrigerant”, page
7
⇒ “1.8.4 Behaviour with metals”, page 7
⇒ “1.8.5 Behaviour with plastics”, page 7
⇒ “1.8.6 Critical temperature/critical pressure”, page 8
⇒ “1.8.7 Water content”, page 8
⇒ “1.8.8 Flammability”, page 8
⇒ “1.8.9 Filling factor”, page 8

1.8.1 Colour
As vapour and liquid, the refrigerant is as colourless as water, and
as gas it is invisible. Only the boundary layer between gas and
liquid is visible (fluid level in the standpipe of the filling cylinder or
bubbles in an inspection glass). In an inspection glass, the liquid
of the refrigerant R134a may appear coloured (milky). This opac‐
ity arises from partially dissolved refrigerant oil and does not
indicate an error.

1.8.2 Vapour pressure

In a fully filled and closed reservoir, the vapour refrigerant that
evaporates on the surface is of the same volume which again
liquifies when the vapour particles fuse. This balanced status is
created under pressure and is frequently called vapour pressure.
The vapour pressure is temperature dependent
⇒ “1.7 Vapour pressure table for refrigerant R134a”, page 6

1.8.3 Air displacement as a result of gaseous

refrigerant
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Refrigerant gas is heavier than airauthorised
unless and therefore
by ŠKODA AUTOdisperses along
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the floor. It gathers in depressions where
with respect it displaces
to the correctness ofthe available
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air.

1.8.4 Behaviour with metals

In pure condition the refrigerant R134a is chemically stable and
does not corrode iron and aluminium. Contaminations of the re‐
frigerant, e.g. with chlorine compounds, may result in certain
metals and plastics being corroded. This may lead to choking,
leaks or other deposits on the AC compressor piston.

1.8.5 Behaviour with plastics

Refrigerant is a solvent for certain plastics. These dissolved plas‐
tics may be eliminated during cooling in the expansion valve. This
may result in blockage of the valve. Therefore only use original
spare parts!

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1.8.6 Critical temperature/critical pressure

Up to a gas pressure of 3.95 MPa (39.5 bar) overpressure (this
corresponds to a temperature of 101°C) refrigerant R134a re‐
mains chemically stable, above this temperature the refrigerant
decomposes see ⇒ “1.8.8 Flammability”, page 8 .

1.8.7 Water content

Water is only soluble in very small quantities in the liquid refrig‐
erant. As opposed to this refrigerant vapour and water vapour mix
in any proportion.
Water possibly present in the system is conveyed through the
refrigerant circuit as drops, once the desiccator in the fluid reser‐
voir has become saturated. The function of the desiccator is no
longer guaranteed. This water flows to the nozzle of the expan‐
sion valve where it turns to ice. This reduces the efficiency of the
cooling system.

Note

Water destroys the air conditioning system, as acids are produced

under high pressures and temperatures in combination with other
contaminations.

1.8.8 Flammability
Refrigerant is non-flammable. Conversely, it has a fire-retardant/
fire-extinguishing effect. Refrigerant decomposes when brought
into contact with flames or red-hot surfaces. UV light also splits
the refrigerant (generated during electrical welding). This results
in toxic fission products (hydrogen fluoride and traces of carbonyl
fluoride and fluorine), which give adequate advance warning as
they irritate the mucous membranes.

1.8.9 Filling factor

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The reservoir must also include vapour space in addition to the
fluid space. As the temperature rises the fluid expands. The space
filled with vapour becomes smaller. At a given moment there will
only be fluid left in the reservoir. After this, only a minor temper‐
ature increase is required to generate very high pressures in the
reservoir as the fluid can no longer expand because there is no
more space. The resulting forces are great enough to burst the
reservoir. In order to ensure a reservoir is not over-filled, the pres‐
sure gas regulations stipulate how many kilos of refrigerant may
be filled per litre of inside volume of the reservoir. This “filling fac‐
tor” multiplied by the inside volume indicates the authorised filling
content. For the refrigerant R134a, it is 1.15°kg/l.

1.9 Evidence of leaks

The refrigerant circuit may start leaking because of external dam‐
age. Because of the small amount of leaked refrigerant, evidence
of minor leaks can be detected for example with an electronic leak
detector or leak detection additive which is filled into the refriger‐
ant circuit. Leaks with less than 5 grams of refrigerant loss per
year can be detected with the electronic leak detector.
For the different refrigerants, leak detectors are used which are
designed for the composition of the relevant refrigerant. For ex‐
ample, leak detectors for refrigerant R12 are not suitable for
R134a, the refrigerant R134a has no chlorine atoms, this is why
these leak detectors do not respond.

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1.10 Refrigerant machine oil

Refrigerator oil mixes (about 20 - 40 %, depending on the refrig‐
erant AC compressor type and refrigerant volume) with the re‐
frigerant, constantly circulates in the circuit and lubricates the
moving parts.
In combination with R134a air conditioning systems, special syn‐
thetic refrigerator oils, such as poly-alkyl-glycol (PAG) oil, is used.
This is necessary because, for example, mineral oil does not mix
with R134a. In addition, the materials of the R134a air condition‐
ing system are attacked if the mixture under pressure and high
temperatures flows through the refrigerant circuit or the lubricat‐
ing film in the AC compressor tears. The use of non-approved oils
results in the failure of the air conditioning system, therefore, only
approved oils may be filled in, see ⇒ Electronic Catalogue of
Original Parts “ETKA” .

Note

♦ Do not store refrigerator oil when it is open, because it is very

hygroscopic (water retentive).
♦ Always keep the oil reservoir closed.
♦ Do not use any used refrigerator oil. Because of its chemical
properties, refrigerator oil must not be disposed of with engine
oil or gearbox
Protectedoil. Dispose
by copyright. of as
Copying for used oilcommercial
private or of unknown origin
purposes, in part (see
or in whole, is not permitted
waste, Environmental Protection,
unless authorised by ŠKODA AUTO A. S. EUŠKODARegulation on refriger‐
AUTO A. S. does not guarantee or accept any liability
ants 2037/2000).
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

⇒ “1.10.1 Properties of the refrigerant oil”, page 9

1.10.1 Properties of the refrigerant oil

The main properties have high dissolving power with refrigerant,
good lubricating properties, acid-free and very low in water con‐
tent.
The poly-alkylene-glycol (PAG) oils which are suitable for the re‐
frigerant R134a are strongly hygroscopic (water retentive) and
cannot be mixed with other oils. Therefore, to ensure protection
against penetrating humidity immediately close opened cans. Re‐
frigerant oil ages when exposed to humidity and acids; it becomes
dark, viscous and corrodes metals.

1.11 General occupational safety

♦ Under current regulations and laws as well as in compliance
with the regulations of the Workers' Association.
♦ Observe occupational safety and job-related operating in‐
structions ⇒ Environmental Protection, Article 17 EU Regu‐
lation 2037/2000 . These must be hung out at the work place
for refrigerant.

1. General notes on the air conditioning system 9

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Air conditioning system with refrigerant R134a - Edition 05.2017

⇒ “1.11.1 Product features”, page 10

⇒ “1.11.2 Using refrigerant R 134a”, page 10
⇒ “1.11.3 Wear safety goggles”, page 10
⇒ “1.11.4 Wear protective gloves and apron”, page 10
⇒ “1.11.5 Do not breath in refrigerant vapours”, page 11
⇒ “1.11.6 Smoking ban”, page 11
⇒ “1.11.7 Welding and soldering”, page 11
⇒ “1.11.8 Pungent odour”, page 11
⇒ “1.11.9 First Aid”, page 11

1.11.1 Product features

Refrigerant which is used in the air conditioning systems for ve‐
hicles, belongs to the new generation of refrigerants which is
based on chlorine-free hydrofluorocarbon (HFC, R134a).
In regards to their physical behavior, this relates to under pres‐
sure liquefied refrigerant. They are subject to the pressure tank
regulation and must only be filled into approved and marked pres‐
sure gas tanks.
For safe and proper use, certain conditions which apply must be
respected.

1.11.2 Using refrigerant R 134a

WARNING

There is a risk through icing.

The refrigerant can leak as fluid or as vapour.
Do not open the reservoir in which the refrigerant is.

If the refrigerant reservoirs are opened, the contents can leak as

fluid or as vapour. This procedure is more intense the higher the
pressure is inside the reservoir.
How high the pressure is depends on two conditions:
• What type of refrigerant is filled in the reservoir. The following
applies: the lower the boiling point, the higher the pressure.
• How high the temperature is. The following applies: the higher
the temperature, the higher the pressure.

1.11.3 Wear safety goggles

Wear safety goggles. It prevents that refrigerant gets into the eyes
and possibly severe damage caused by frostbite.

1.11.4 Wear protective gloves and apron

Refrigerants dissolve fats and oils pretty well. When in contact
with the skin, therefore remove the protective fat film. However,
degreased skin is sensitive to cold and disease germs.
Do not spill liquid refrigerant onto the skin. The heat to vapourise
extracts the refrigerant from the surrounding area. Thus, very low
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
temperatures can be achieved. This unlessresults
authorisedin
bylocal
ŠKODAfrostbites
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
(boiling point of R134a ambient pressure atto-26.5°C).
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1.11.5 Do not breath in refrigerant vapours

Note

In higher concentrations, escaping refrigerant vapours mix with

the surrounding air and replace the atmospheric oxygen neces‐
sary to breathe.

1.11.6 Smoking ban

Refrigerants may decompose in cigarette ash. The resulting sub‐
stances are toxic and should not be inhaled.

1.11.7 Welding and soldering

Note

Damaged or leaky components of the air conditioning system

must not be repaired by welding or soldering, however they must
be replaced.

Before welding and soldering on vehicles (in the vicinity of com‐

ponents of the air conditioning system) the refrigerant must be
drained off and the residues must be removed by blowing through
with compressed air and nitrogen.
The products of decomposition resulting from the refrigerant
through the effect of the heat are not only toxic, but are also highly
corrosive, so that pipes and components can be attacked. It is
essentially hydrogen fluoride.

1.11.8 Pungent odour

If the smell is pungent, then the mentioned products of decom‐
position have already formed. It must be avoided by all means to
breathe in these substances, otherwise damage to the respiratory
tract, lungs and other organs, could be the consequence.

1.11.9 First Aid

• On contact with eyes or mucous membranes, immediately
rinse extensively with running water and seek the attention of
an ophthalmologist.
• In case of contact with the skin, immediately remove conta‐
minated clothing and rinse the skin with plenty of water.
• During inhalation of refrigerant vapours at a higher concen‐
tration, bring those affected immediately to fresh air. Request
a physician. In case of respiratory disorder, give oxygen. If the
person concerned breathes only limitedly or not at all, tilt the
head backwards and give artificial respiration.

1.12 Using pressure tank

Secure bottles which are standing against falling, secure bottles
which are lying down against rolling away!
Do not throw the reservoir!
• When the reservoirs fall, they can become severely deformed
causing them to tear open. The refrigerant evaporates abrupt‐
ly, thus releasing considerable forces. Bottle parts which go
flying can cause serious injuries.
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1. General notes on the air conditioning system 11

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• If improperly transported, the bottle valve can break off. To

protect the bottle valves, the bottles may only be transported
with the protective cap screwed on.
Do not place near radiators!
• Increased temperatures can occur next to the radiators. High‐
er temperatures also mean higher pressures, whereby the
permissible pressure for the reservoir can be exceeded.
Do not heat above 50°C
• In order to exclude a danger, the “pressure tank regulation”
stipulates that the reservoirs must not be heated above 50°C.
• Under no circumstances heat on an open flame. Through the
local overheating, structural changes can occur in the reser‐
voir material which reduce the pressure load of the reservoir.
Moreover, there is the danger of refrigerant decomposition by
local overheating.
Close and seal empty containers.
• In any case, empty refrigerant reservoirs must be sealed to
prevent any humidity from penetrating. Humidity leads to cor‐
rosion of reservoirs made of steel. This weakens the wall of
the reservoir. In addition, the rust particles which get into the
refrigeration plants from the reservoirs cause malfunctions.

1.13 Safety precautions when working with

extraction and filling systems

Caution

Operating instructions must be part of each extraction and fill‐

ing system, where the work procedure, the safety instructions
as well as the regulations are listed.
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Prior to working with the extraction
unless authorised byand filling
ŠKODA AUTOsystem, acquaint
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yourself with the safety instructions as well as the regulations
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

contained in the operating instructions and comply with them.

The operating instructions must always be readily available to
the staff, foremen and monitoring bodies.

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1.14 Safety measures when working on ve‐

hicles with air conditioning system and
when using refrigerant R 134a

WARNING

It is recommended to hold an eye bath flask within reach. If

liquid refrigerant gets into the eyes rinse the eyes out with water
for approximately 15 minutes.
Subsequently apply eye drops and immediately contact a
physician, even if the eyes are not painful. The physician must
be informed that the frostbites were caused by refrigerant
R134a.
If in spite of these safety measures refrigerant comes into con‐
tact with other body parts, rinse immediately with water for at
least 15 minutes.
Work on the air conditioning refrigerant circuit must only be
carried out in well-ventilated areas. Existing workshop suction
systems must be switched on.
Refrigerant must not be stored in lower areas (e.g. cellars) or
related exits or window openings.
During paint repairs, the temperature of the objects placed in
the drying oven or in its pre-heating zone must not exceed max.
80 °C (because heating causes a strong overpressure in the
system that may result in the opening of the pressure relief
valve).
Welding and soldering see
⇒ “1.11.7 Welding and soldering”, page 11 .
Never fill the containers completely with liquid refrigerant. With
sufficient expansion space (gas blanket) the container will
burst as the temperature rises with catastrophic consequences
⇒ “1.8 Properties of refrigerant R134a”, page 7 .
Refrigerant containers (e.g. filling cylinders at the A/C Service
position) must never be heated considerably or be exposed to
direct sunlight see ⇒ “1.12 Using pressure tank”, page 11 .
Under no circumstances should refrigerant be filled into sys‐
tems and reservoirs in which there is air (evacuate systems
and reservoirs before filling with refrigerant).

1.15 Basics for working on the refrigerant cir‐

cuit
⇒ “1.15.1 General”, page 13
⇒ “1.15.2 Removing contaminants from the refrigerant circuit ”,
page 14
⇒ “1.15.3 Additional work on vehicles with AC compressor without
magnetic coupling ”, page 15
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ “1.15.4 O-rings”, page
with15
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

⇒ “1.15.5 Work procedure before operating the air conditioning

system after a repair”, page 15

1.15.1 General
♦ Keep the work area and all tools clean.

1. General notes on the air conditioning system 13

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♦ Wear work clothes, protective goggles and gloves when han‐

dling refrigerant and nitrogen.
♦ Switch on all available exhaust systems in the workshop.
♦ Only use an A/C service station to empty the refrigerant circuit;
only then may you open the screwed connections and replace
defective components.
♦ Seal off opened aggregates and hoses immediately with caps
to protect them against humidity and dirt.
♦ Only use tools and materials intended for refrigerant R134a.
♦ Protect the refrigerant oil from humidity by closing opened
cans.

Note

♦ After completing repair works, screw on screw caps on all the

suction-, filler valves and service connections (with gaskets).
♦ Before operating the air conditioning system, observe the ve‐
hicle-specific filling contents.
♦ Do not top up with refrigerant, drain existing refrigerant and
refill the system.

1.15.2 Removing contaminants from the refrig‐

erant circuit
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Flush the refrigerant circuit with R134a (if necessary blow
through), if:
– Humidity or dirt has penetrated into the refrigerant circuit (e.g.
after an accident).
– The refrigerant oil is dark and viscous.
– After replacing an A/C compressor, there is too much refrig‐
erant oil in the refrigerant circuit.
– The air conditioning compressor must be replaced because of
internal damage (e.g. it is too laud, jammed or no output).

Note

Remove contaminants from the refrigerant circuit

⇒ “7 Removing contaminants from the refrigerant circuit”,
page 52 .

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1.15.3 Additional work on vehicles with AC

compressor without magnetic coupling

Note

♦ The engine must only be started if the refrigerant circuit is cor‐

rectly assembled (A/C compressor operates).
♦ If possible, only start the engine if the refrigerant circuit is filled.
♦ The engine must on no account be started if vacuum is present
in the refrigerant circuit (in case of evacuating with an A/C
service station). This would result in mechanical damage of
the A/C compressor.
♦ If the engine runs with an empty refrigerant circuit (no vacuum
must be present in the circuit), an increase in its revolutions
must be absolutely avoided. There must be at least a quarter
of the refrigerant oil volume prescribed for this refrigerant cir‐
cuit present in the AC compressor and the engine may be run
for max. 10 minutes.
♦ So that the AC compressor suffers no damage when the re‐
frigerant circuit is empty, it is fitted with a secured oil supply.
This means that approx. 40 to 50 cm3 of refrigerant oil is left
in the AC compressor.

1.15.4 O-rings
These O-rings seal off the connection points between the indi‐
vidual components of the refrigerant circuit.
Only use O-rings that are resistant to refrigerant R134a and re‐
lated refrigerant oils. Original spare parts offer this guarantee.
Black and coloured O-rings are fitted.
O-rings:
♦ Only use once, replace.
♦ Pay attention to correct diameter -a- and -b-.
♦ Moisten with refrigerant oil before inserting.

1.15.5 Work procedure before operating the air

conditioning system after a repair
– Turn the A/C compressor on the clutch or the belt pulley of the
magnetic coupling about 10 revolutions by hand.
– Start the engine with the air conditioning system deactivated
( air conditioner magnetic coupling - N25- and regulating valve
for compressor of air conditioning system - N280- are not ac‐
tivated).
– After the idling speed has stabilised, switch on the AC com‐
pressor and operate it for at least 10 minutes at idle speed and
at maximum refrigerating capacity.

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2 General instructions for refrigerant

circuit
⇒ “2.1 Components of the refrigerant circuit”, page 16
⇒ “2.2 Extractor, filler and measurement valves for quick cou‐
plings of the AC service station on the refrigerant circuit”,
page 21
⇒ “2.3 Pressures and temperatures in the refrigerant circuit and
its arrangement”, page 24
⇒ “2.4 Switch and sender on the refrigerant circuit”, page 28
⇒ “2.5 Electrical components which are not fitted on the refrigerant
circuit”, page 29
⇒ “2.6 The inspection and measurement work can be performed
using the pressure gauge”, page 30
⇒ “2.7 Air conditioning service and recycling equipment ”,
page 31
⇒ “2.8 Repair and maintenance instructions for refrigerant circuit”,
page 31

2.1 Components of the refrigerant circuit

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ “2.1.1 Distribution of the components of the refrigerant
unless authorised by circuit
ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
and their influence on the high- and low-pressure side”,
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

page 17
⇒ “2.1.2 AC compressor”, page 18
⇒ “2.1.3 Condenser”, page 19
⇒ “2.1.4 Fluid reservoir with desiccator cartridge”, page 19
⇒ “2.1.5 Evaporator”, page 20
⇒ “2.1.6 Choke”, page 20
⇒ “2.1.7 Expansion valve”, page 21
⇒ “2.1.8 O-rings”, page 21
⇒ “2.1.9 Pipes and hoses of the refrigerant circuit”, page 21
⇒ “2.1.10 Pressure relief valve”, page 21

Caution

Non-approved tools or materials (e.g. stop leak additive) can

cause damage/deterioration to the system.
Only tools and materials approved by the manufacturer may
be used.
There is no guarantee if non-approved tools or materials were
used.

• All the components of the refrigerant circuit, which are sent in

for quality monitoring, must always be closed (use original
screw caps of the original part).
• Replace damaged or leaky components of the refrigerant cir‐
cuit.

16 Rep. gr.00 - Technical data

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2.1.1 Distribution of the components of the re‐

frigerant circuit and their influence on
the high- and low-pressure side
On the high-pressure side, the condenser as well as the fluid res‐
ervoir are present and as a separation from the HP liquid side and
the LP liquid side, the throttle or the expansion valve is present.
The high pressure arises from the fact that the throttle valve or
the expansion forms a constriction and the refrigerant dams, this
leads to a pressure and temperature increase.
Too much high pressure arises if too much refrigerant or refrig‐
erant oil is added, the condenser is contaminated, the radiator fan
is defective, a blockage is present in the system or if there is
moisture in the refrigerant circuit (icing of the restrictor or expan‐
sion valve).
On the low-pressure side are located, the evaporator, the tem‐
perature sensor - evaporator and as a separation from the HP gas
side and the LP gas side, the AC compressor.
A pressure drop in the system can occur through refrigerant loss,
through the throttle or expansion valve (constriction not given),
the AC compressor which is defective or the evaporator which is
iced up.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. General instructions for refrigerant circuit 17

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2.1.2 AC compressor
The AC compressor sucks refrigerant gas from the evaporator,
compresses it and transfers it to the condenser.
The AC compressor contains refrigerant oil, which can be mixed
with R134a refrigerant at all temperatures.
The identification plate indicates which refrigerant is suitable for
the AC compressor.
Different versions of A/C compressors with various parameters
are fitted according to the engine and vehicle type.
The total volume of refrigerant oil is contained in the spare part
AC compressor.
AC compressor with magnetic coupling:
♦ When the air conditioning system is switched on an electro‐
magnetic coupling, which is mounted on the AC compressor,
generates the shaft grip between the V-ribbed belt pulley and
the AC compressor crankshaft.

Note

So that the AC compressor suffers no damage when the refrig‐

erant circuit is empty, the air conditioner magnetic coupling - N25-
is switched off and the regulating valve for compressor of air
conditioning system - N280- is no longer activated.

AC compressor without magnetic coupling:

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Observe safety measures on vehicles with an AC compressor
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
without magnetic coupling
⇒ “1.15.3 Additional work on vehicles with AC compressor without
magnetic coupling ”, page 15 .

♦ Overload protection installed on the belt pulley or in the drive

unit of the AC compressor is triggered if the AC compressor is
difficult to move and thereby protects the belt drive against
overload.
♦ Externally controlled A/C compressors with variable displace‐
ment of piston. The displacement of the AC compressor is
controlled via an externally driven regulating valve with PWM
signal on the suction side in accordance with the required
cooling output.
♦ The AC compressor continues operating with a minimum pow‐
er supply requirement even when the air conditioning system
is off.

18 Rep. gr.00 - Technical data

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Belt protection for blocked A/C compressor (AC compressors

without magnetic coupling)
The AC compressor operates continuously via a driver clutch
-1- and -2- in the belt drive, whether or not the air conditioning
system is switched on.
If the AC compressor blocks, the rubber elements -2- will shear
off or the driver disc -1- will become deformed depending on the
compressor temperature (it depends on the temperature).
In any case the belt pulley of the AC compressor can rotate while
the driver disc/A/C compressor shaft is at a standstill.
Replace the AC compressor.

Note

The design of the driver clutch may differ depending on the com‐
pressor.

2.1.3 Condenser
The condenser dissipates heat from the compressed refrigerant
gas into the ambient air.
During this process the refrigerant gas condenses and liquefies.

2.1.4 Fluid reservoir with desiccator cartridge

The fluid reservoir with desiccator gathers the liquid drops and
conveys them to the throttle or expansion valve in a constant flow.
Humidity, that has penetrated into the refrigerant circuit during
assembly, is caught by a desiccator bag integrated in the fluid
reservoir.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. General instructions for refrigerant circuit 19

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The new generation of fluid reservoirs -6- has a desiccator car‐

tridge -5- and a strainer too, and is directly attached to the
condenser.

Note

♦ Replace the fluid reservoir (if possible only the desiccator) if

the refrigerant circuit was opened for a longer period of time
(beyond the normal repair time) and humidity penetrated or if
it is required because a specific complaint was made
⇒ “8 Complaints”, page 66 .
♦ Only remove the screw plug (desiccator housing) shortly be‐
fore the installation.
♦ The desiccator bag, which is located in a unclosed fluid res‐
ervoir (housing), will be saturated with humidity and become
unusable after a short period of time.
♦ If necessary, observe the arrow for the direction of flow when
installing.

2.1.5 Evaporator
The liquid refrigerant evaporates in the evaporator. The heat re‐
quired for this operation is drawn from the air flowing through the
evaporator fins.
The air cools down the evaporator. The refrigerant evaporates
and is sucked in with the absorbed heat as gas by the AC com‐
pressor.
The externally regulated AC compressor allows a variable air out‐
let temperature of 1 to 11°C.

2.1.6 Choke
The throttle forms a constriction. This constriction throttles the
flow, thus dividing the refrigerant circuit into a high-pressure side
and a low-pressure side.
Upstream of the throttle the refrigerant is warm while under high
pressure. Downstream of the throttle the refrigerant
Protected is cold
by copyright. Copying whileor commercial purposes, in part or in whole, is not permitted
for private
under low pressure. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Before the constriction there is a strainer for dirt protection, after
the constriction there is a strainer to vaporize the refrigerant be‐
fore it reaches the evaporator.

Note

♦ -Arrow A- on the throttle points to the evaporator.

♦ Replace the throttle after each opening of the refrigerant cir‐
cuit.

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2.1.7 Expansion valve

The expansion valve atomizes incoming refrigerant and controls
the flow in accordance with the different pressures in such a way
that, depending on the heat transport, the vapour only becomes
gaseous at the outlet of the evaporator.

2.1.8 O-rings
Everything on this chapter, see ⇒ “1.15.4 O-rings”, page 15 .

2.1.9 Pipes and hoses of the refrigerant circuit

The mixture of refrigerant oil and refrigerant R134a corrodes cer‐
tain metals (e.g. copper) and alloys and dissolves certain hose
materials.
Therefore only original spare parts may be used.

Note

Observe the prescribed torques on screw connections and use

the provided release tools when disconnecting the quick cou‐
plings.

2.1.10 Pressure relief valve

The pressure relief valve is located on the AC compressor and
opens in the event of overpressure. The refrigerant does not flow
out completely.
If the valve was opened the adjoining area is also covered in oil.
Opening pressure: 4 ±0.4 MPa (40±4 bar)
Closing pressure: at least 3.1 MPa (31 bar)

Note

If the pressure relief valve was opened, determine the cause of

the overpressure in the system and eliminate it.

2.2 Extractor, filler and measurement valves

for quick couplings of the AC service
station
Protected on the
by copyright. refrigerant
Copying circuit
for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

WARNING

Before removing the extractor and filler valves, the refrigerant

must be drained off with the aid of the A/C service station.
If the refrigerant circuit is not opened within 10 minutes after
draining it off, pressure can arise in the refrigerant circuit due
to the post-evaporation. Drain the refrigerant once again.

2. General instructions for refrigerant circuit 21

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• Only use valves and connections that are resistant to refrig‐

erant R134a and related refrigerant oils.
• Different connections (outside diameter) for the high-pressure
and low-pressure side guarantee that the quick-coupling
adapters are not interchanged.
• After disconnecting the quick-coupling adapter tighten the
caps to prevent any dirt from penetrating.
Special tools and workshop equipment required
♦ Socket - T10364-

Arrangement in the vehicle, see ⇒ Heating, Air Conditioning; Rep.

gr. 87 .
⇒ “2.2.1 Extractor, filler and measurement connections with
Schrader valve”, page 22
⇒ “2.2.2 Extractor, filler and measurement connections with ac‐
tant head valve”, page 23

2.2.1 Extractor, filler and measurement con‐

nections with Schrader valve

Note

♦ Carefully screw in the handwheel of the service coupling after

connecting the A/C service station and only until the valve is
definitely open in the service connection (observe the pres‐
sure gauge, do not over-press the valve).
♦ Carefully tighten the valve and observe the specified tighten‐
ing torque.
♦ Observe the correct version of the valve core -2- and the cor‐
rect assignment of the screw cap -4- see ⇒ Electronic Cata‐
logue of Original Parts “ETKA” .
♦ Use the adapter from the socket insert - T10364- for removal
and installation.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

22 Rep. gr.00 - Technical data

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High-pressure side
1 - Service coupling in the refrigerant line
2 - Extractor, filler and measurement valve
3 - Sealing ring
4 - Cap

Low-pressure side
1 - Service coupling in the refrigerant line
2 - Extractor and measurement valve
3 - Sealing ring
4 - Cap
Tightening torques
Component Tightening torque
Valve core with thread M8 x 1.0 2.2 ± 0.2 Nm
mm, Pos. -2-

2.2.2 Extractor, filler and measurement con‐

nections with actant head valve

Note

♦ Carefully screw in the handwheel of the service coupling after

connecting the A/C service station and only until
Protected the valve
by copyright. is for private or commercial purposes, in part or in whole, is not permitted
Copying
definitely open in the service connectionunless
(observe the
authorised pres‐AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by ŠKODA
sure gauge, do not over-press the valve). with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Observe the correct version of the valve core -2- and the cor‐
rect assignment of the screw cap -4- see ⇒ Electronic Cata‐
logue of Original Parts “ETKA” .
♦ Carefully tighten the valve and observe the specified tighten‐
ing torque.
♦ Use the adapter from the socket insert - T10364- for removal
and installation.

Low-pressure side
1 - Base with outside thread and groove for O-ring
2 - O-ring 7,6 mm; 1,8 mm
3 - Valve with inside thread M8 x 1 for cap
4 - Seal
5 - Cap

2. General instructions for refrigerant circuit 23

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Air conditioning system with refrigerant R134a - Edition 05.2017

High-pressure side
1 - Base with inside thread
2 - O-ring 10,8 mm; 1,8 mm
3 - Valve with groove for O-ring and inside thread M8 x 1 for cap
4 - Seal
5 - Cap
Tightening torques
Component Tightening torque
Valve with nut, Pos. -3- 9 ± 1 Nm

2.3 Pressures and temperatures in the re‐

frigerant circuit and its arrangement

Caution

When working on the refrigerant circuit, observe the generally

applicable safety instructions and the pressure tank regulation
⇒ “1 General notes on the air conditioning system”, page 1 .

The pressures and temperatures in the refrigerant circuit are de‐

pendent on current operating conditions (e.g. engine speed, ra‐
diator fan stage 1, 2 or 3, engine temperature, AC compressor on
or off) as well as on the effect of the environmental characteristics
(e.g. ambient temperature, humidity, required cooling capacity).
On vehicles with the regulating valve for compressor of air con‐
ditioning system - N280- , the pressure on the low-pressure side
is changed by the actuation of the valve.
Air conditioning compressors which do not regulate their own
power output are switched off by the relevant control unit via the
regulating valve for compressor of air conditioning system - N280-
at an evaporator temperature below 0 °C.
This is why the indicated values in the following table are only
reference points. They are set after approx. 20 min and at an en‐
gine speed of 1500 to 2000 rpm and an ambient temperature of
20 °C.
At 20 °C and if the engine is stationary, a pressure of 4.7 bar
arises in the refrigerant circuit
⇒ “1.7 Vapour pressure table for refrigerant R134a”, page 6 .

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The pressure is given
unless authorised in different
by ŠKODA AUTO A. S.units, 1 MPa
ŠKODA AUTO A. S.equals 10 bar or accept any liability
does not guarantee
overpressure or 145
with respect psi. Oneof bar
to the correctness absolute
information pressure
in this document. plusby0ŠKODA
Copyright bar AUTO A. S.�
overpressure corresponds approximately to the ambient pressure
(atmospheric pressure).

⇒ “2.3.1 Pressures, temperatures and arrangement of the refrig‐

erant circuit with expansion valve”, page 25 .
⇒ “2.3.2 Pressures, temperatures and arrangement of the refrig‐
erant circuit with throttle”, page 26 .

24 Rep. gr.00 - Technical data

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2.3.1 Pressures, temperatures and arrangement of the refrigerant circuit with ex‐
pansion valve
Component Aggregate state of re‐ Pressure (bar over‐ Temperature in Celsius
frigerant pressure)
Evaporator -13-, from inlet Vapour approx. 1.2 bar1) approx. -7 °C 2)
to outlet
Expansion valve -12- Liquid, released in va‐ approx. 14 bar approx. +55 °C (high pressure
pour side), reduced to -7 °C (low pres‐
sure side)
High pressure switch / Liquid approx. 14 bar approx. +55 °C
high pressure sender -6-
Service connection - high Liquid approx. 14 bar approx. +55 °C
pressure side -10- and flu‐
id reservoir -9-
Condenser -8- from gas (at the inlet) approx. 14 bar from approx. +65 °C (at the inlet)
via vapour to liquid (at to approx. +55 °C (at the outlet)
the outlet)
Pressure relief valve -5- gas approx. 14 bar approx. +65 °C
and air conditioning com‐
pressor - high pressure
side
Air conditioning compres‐ gas approx. 1.2 bar1) approx. -1 °C 2)
sor - low pressure side
Service connection - low gas approx. 1.2 bar1) approx. -1 °C 2)
pressure side -14-
1) In refrigerant circuits with regulated AC compressor, the pres‐
sure is maintained at approx. 2 bar absolute pressure (corre‐
sponds to approx. 1 bar overpressure) despiteCopying
Protected by copyright. the varying heat
for private or commercial purposes, in part or in whole, is not permitted
transfer and different engine speeds. ThisbyisŠKODA
unless authorised only AUTO
validA.within
S. ŠKODA the
AUTO A. S. does not guarantee or accept any liability
performance range of the AC compressor; in the event the per‐
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

formance range of the AC compressor is exceeded, the pressure

rises
⇒ “9 Check the pressure in the refrigerant circuit (with the A/C
service station)”, page 71 .
2)In refrigerant circuits with regulated AC compressor, the tem‐
perature is maintained within the performance range of the AC
compressor despite the varying heat transfer and different engine
speeds. This is only valid within the performance range of the AC
compressor. If the performance ranges of the AC compressor are
exceeded, the temperature rises
⇒ “9 Check the pressure in the refrigerant circuit (with the A/C
service station)”, page 71 .

HP = High-pressure side
LP = Low-pressure side

2. General instructions for refrigerant circuit 25

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Air conditioning system with refrigerant R134a - Edition 05.2017

1 - Regulating valve for com‐

pressor of air conditioning sys‐
tem - N280-
2 - AC compressor
3 - Belt pulley
❑ with anti-lock device
4 - Oil drain plug
5 - Pressure relief valve
6 - High-pressure sender -
G65-
7 - Connection with valve
8 - Condenser
9 - Fluid reservoir with desic‐
cator cartridge
10 - Extractor, filler and meas‐
urement valve
❑ High-pressure side
11 - Screw cap
12 - Expansion valve
13 - Evaporator
14 - Extractor and measure‐
ment valve
❑ Low-pressure side Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
15 - Screw cap with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

16 - Damper
❑ for damping of pressure
fluctuations
❑ only fitted on certain
models

2.3.2 Pressures, temperatures and arrangement of the refrigerant circuit with

throttle
Component Aggregate state of re‐ Pressure (bar over‐ Temperature in Celsius
frigerant pressure)
Air conditioning compres‐ gas up to 20 bar up to +70 °C
sor - high pressure side
Condenser -7- from gas via vapour to up to 20 bar up to +70 °C
liquid
Throttle -11- from liquid to vapour High pressure side High pressure side up to +60 °C,
up to 20 bar, low low pressure side warmer than -4
pressure side great‐ °C
er than 1.0 bar
Evaporator -12- from vapour to gas greater than 1.0 bar warmer than -4 °C
Catch pan -15- gas
Air conditioning compres‐ gas
sor - low pressure side
The “regulating” AC compressor maintains the pressures on the
low pressure side at approx. 2 bar (corresponds to approx. 1 bar
overpressure) even at different engine speeds. This is only valid
within the performance range of the AC compressor. If the per‐

26 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

formance ranges of the AC compressor are exceeded

⇒ “9 Check the pressure in the refrigerant circuit (with the A/C
service station)”, page 71 .

HP = High-pressure side
LP = Low-pressure side

1 - AC compressor
2 - Air conditioning system
magnetic coupling - N25-
3 - Oil drain plug
4 - Pressure relief valve
5 - Connection with valve
6 - Air conditioner pressure
switch - F129-
7 - Condenser
8 - Screwed connection in the
refrigerant line
9 - Screw cap
10 - Extractor and filler valve
❑ High-pressure side
11 - Choke
12 - Evaporator
13 - Extractor and filler valve
❑ Low-pressure side
14 - Screw cap
15 - Catch pan with desiccator
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. General instructions for refrigerant circuit 27

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2.4 Switch and sender on the refrigerant cir‐

cuit
⇒ “2.4.1 Outside temperature switch F38 ”, page 28
⇒ “2.4.2 Air conditioner pressure switch F129 ”, page 28
⇒ “2.4.3 High-pressure sensor G65 ”, page 28
⇒ “2.4.4 Regulating valve for compressor of air conditioning sys‐
tem N280 ”, page 29

2.4.1 Outside temperature switch - F38-

Switches off the magnetic coupling at a temperature of 2°C and
switches it on again at 5°C (evaporator icing protection).

2.4.2 Air conditioner pressure switch - F129-

This pressure switch has 3 functions:
1- Switches the radiator fan to the next speed in the event of a
pressure rise [approx. 1.6 MPa (16 bar) overpressure] in the
refrigerant circuit.
2- Disconnects the air conditioning system in the event of ex‐
cessive pressure (approx. 3.2 MPa/32 bar overpressure) -
insufficient engine cooling -.
3- Disconnects the air conditioning system if the pressure is
too low (0.2 MPa/2 bar overpressure) (e.g. during loss of
refrigerant).

2.4.3 High-pressure sensor - G65-

Note

The high pressure sender - G65- (specifically designed for vehi‐

cles) can be installed instead of the pressure switch for the air
conditioning system - F129- .

The high-pressure sender - G65- determines the pressure in the

refrigerant circuit and transmits the values to the Air conditioning
system control unit - J301- or to the Climatronic control unit -
J255- .
The following are shifted via these control units:
♦ The radiator fan - V7- switches to the next speed in the event
of a pressure rise in the refrigerant circuit
♦ Reduction of the A/C compressor output if the pressure is too
high, 3.2 MPa
Protected by (32 bar),
copyright. e.g.fortoo
Copying little
private engine purposes,
or commercial coolingin part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Reduction of the AC compressor output if the pressure is too
low, 0.2 MPa (2 bar), e.g. after loss of refrigerant

28 Rep. gr.00 - Technical data

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2.4.4 Regulating valve for compressor of air

conditioning system - N280-
The regulating valve is installed in the AC compressor. It is actu‐
ated by the control and display unit for air conditioner Climatronic
- E87- or the Climatronic control unit - J255- (if necessary specif‐
ically designed for vehicles via a databus and an additional control
unit). The pressure on the low-pressure side is influenced by the
regulating valve and thus the temperature in the evaporator is
regulated.

Note

The regulating valve for compressor of air conditioning system -

N280- is a component of the AC compressor and cannot be
replaced separately.

2.5 Electrical components which are not fit‐

ted on the refrigerant circuit
⇒ “2.5.1 Radiator fan control unit J293 ”, page 29
⇒ “2.5.2 Evaporator vent temperature sender G263 or evaporator
temperature sensor G308 ”, page 29

2.5.1 Radiator fan control unit - J293-

This control unit switches the magnetic coupling and thus the AC
compressor on and off. It turns on the coolant fans and calculates
the pressure in the refrigerant circuit on vehicles with high-pres‐
sure sender - G65- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.

2.5.2 Evaporator vent temperature sender -

G263- or evaporator temperature sen‐
sor - G308-
The evaporator vent temperature sender - G263- determines the
temperature behind the evaporator. This value passes on to the
air conditioning system control unit and serves as a reference
signal for the regulation of the AC compressor. Thus, icing of the
evaporator is avoided.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. General instructions for refrigerant circuit 29

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Air conditioning system with refrigerant R134a - Edition 05.2017

2.6 The inspection and measurement work

can be performed using the pressure
gauge
Readout on the pressure gauge
1- Temperature scale for refrigerant R134a CF3–CH2F or
CH2F–CF3
2- Pressure scale
The pressure gauges can have one or more temperature scales
in addition to the pressure scale. The values of the scale for
R134a are assigned to the relevant vapour pressure table.
As various refrigerants build up different vapour pressures at the
same temperature, every temperature scale is marked for the
corresponding refrigerant.
⇒ “2.6.1 Pressure gauges allow to carry out the following inspec‐
tion and measurement work”, page 30

2.6.1 Pressure gauges allow to carry out the

following inspection and measurement
Protected bywork
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Pressure
withand temperature
respect to the correctnessmeasurement
of information in this on the refrigerant
document. circuit
Copyright by ŠKODA AUTO A. S.�

♦ The high-pressure manometer measures the pressure and the

temperature, which spreads evenly from the outlet of the AC
compressor via the condenser up to the constriction (throttle
or expansion valve) when the AC compressor is switched on.
♦ The low-pressure manometer measures the pressure and the
temperature, which spreads evenly from the constriction
(throttle or expansion valve) via the evaporator up to the inlet
of the AC compressor.

Note

The interdependence described on the pressure gauges, be‐

tween pressure and temperature, only exists where liquid or
vapour is contained in the refrigerant circuit, however not gas. In
the gaseous condition, the temperature is around 10 °C to 30 °C
higher than the pressure gauge indicates.

Evidence of refrigerants in a closed reservoir

In a closed reservoir or in the refrigerant circuit, the refrigerant
R134a is present if the temperature reading of the pressure gauge
corresponds to the temperature of the refrigerant (liquid is at am‐
bient temperature).
A closed reservoir or a switched off refrigerant circuit is empty if
the temperature reading of the pressure gauge lies below the
temperature of the refrigerant.

Note

The interdependence described on the pressure gauges, be‐

tween pressure and temperature, does no longer exist if no liquid
is contained and the pressure only builds up through gas.

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2.7 Air conditioning service and recycling

equipment
Currently various manufacturers offer on the market air condi‐
tioning service equipment for extracting, cleaning and filling the
refrigerant in air conditioning systems for vehicles.
Certain A/C service stations can also be used for flushing the re‐
frigerant circuit (if necessary with a suitable additional system and
various adapters).
Allocating the extraction and filling systems in groups

Note

♦ The air conditioning service and recycling equipment used in

the vehicle workshops are extraction and filling systems
(group “3”) which do not need a permission and must be only
operated by knowledgeable personnel. The systems must be
operated and maintained according to the manufacturer's doc‐
umentation.
♦ The extraction and filling systems of the group “1” and “2” are
used in the vehicle workshops.

The extraction and filling systems of the group “3”:

Portable extraction and filling systems to fill the pressure gas
tanks which are firmly connected to the system.
The refrigerant or refrigerant/oil mixture is filled into pressure gas
tanks which are permanently connected to the portable systems.
In this case, according to the “pressure tank regulation”, the pres‐
sure gas tanks are equal to the pressure tanks.

Note

There is no need for a permission nor the need to have the filling
systems examined by the expert, because the gas is filled into
pressure gas tanks which are equivalent to pressure tanks. (A
permit, which is subject to the audit requirement, is in turn re‐
quired for the system in order to fill up the pressure gas tanks with
what is present in these pressure tanks and to pass them on to
others). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2.8 Repair and maintenance instructions for
refrigerant circuit

WARNING

When working on the refrigerant circuit, observe the generally

applicable safety instructions and the pressure tank regulation.

2. General instructions for refrigerant circuit 31

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Caution

Non-approved tools or materials (e.g. stop leak additive) can

cause damage/deterioration to the system.
Only tools and materials approved by the manufacturer may
be used.
There is no guarantee if non-approved tools or materials were
used.

Special tools and accessories

In order to implement a proper and professional repair of an air
conditioning system:
• Special tools and materials are required.
• The basic instructions belonging to the leak detector must be
observed.
• If general knowledge is required.

Note

Draining the refrigerant into the environment is not permitted.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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3 Legal texts and legal regulations

⇒ “3.1 Laws and regulations”, page 33
⇒ “3.2 Verification procedure of refrigerant”, page 34

3.1 Laws and regulations

The effects of the climate change can now be observed world‐
wide. The climate protection is therefore one of the most impor‐
tant tasks of mankind. This task presents huge challenges for all
the parties concerned.
The global climate protection goals are defined, among other
things, in the so-called Kyoto Protocol. In this protocol are inclu‐
ded carbon dioxide reduction targets as well as targets for reduc‐
ing fluorinated greenhouse gases such as for the refrigerant
R134a due to the high greenhouse potential.
Numerous relevant laws were adopted for the motor industry for
example at the European level:
♦ Regulation (EC) No. 1005/2009 (replaces the regulation (EC)
No. 2037/2000)
♦ Regulation (EC) No. 842/2006
♦ Regulation (EC) No. 706/2007
♦ Regulation (EC) No. 307/2008
♦ Directive 2006/40/EC
Different or additional laws and directives apply in other countries
and on other continents.
All persons who carry out maintenance and repair work on air
conditioning systems for vehicles must have attended a training
course or a training program and must have general knowledge
(proof of expertise). Outside the European Community, different
or additional provisions may apply.
In general the following applies:
Operation, maintenance, take out of operation, guarantee of re‐
turn
♦ During the operation, when carrying out repair work and when
taking products out of operation that contain refrigerants, con‐
trary to the state of the art, it is prohibited to let those agents
escape into the atmosphere which are contained in these
products.
♦ Therefore it is recommended to keep records on the initial
quantity for the operation and maintenance work so that a
proof of use can be submitted at the request of the responsible
authority, if required. A record sheet must no longer be kept in
the EC on the basis of a Regulation of the European Parlia‐
ment in the year 2005. Other regulations maybe valid in coun‐
tries that do not belong to the EC.
♦ Distributors of agents and preparations referred to in the
above-mentioned regulations are required to withdraw these
agents and preparations after use or to ensure the withdrawal
by a third party designated by them.
♦ Maintenance work on products and those products which are
taken out of operation containing refrigerants, referred to in the
mentioned regulations as well as the withdrawal of the agents
and preparation referred to in these regulations must only be
carried out by persons who have the required expertise and
technical equipment.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Crimes
unless and misdemeanors
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Legal texts and legal regulations 33

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♦ The following is illegal in respects to the regulations and laws

mentioned above: if someone acts with intent or negligently
during operation, commissioning, or when putting products out
of service which contain the mentioned refrigerants, contrary
to the state of the art or if someone intentionally or negligently
violates the above-mentioned applicable laws and regulations.
Disposing of the refrigerant and the refrigerator oil
Statutory regulations for handling and disposing of refrigerants
and refrigerant oils must be stipulated in the Emissions Protection
Act, Recycling Management and Waste Management Act.
Refrigerant
The provided refrigerants to be disposed of must be filled into
marked recycling containers in compliance with the permissible
filling quantity and returned to the manufacturer responsible for
their disposal in accordance with the Environmental Protection
Legislations (different or additional directives may apply in certain
countries).
Refrigerant machine oil
Used refrigerator oils of systems with halogenised hydrocarbons
must be disposed of in the same way as waste requiring special
supervision. A mixture with other oils or agents is not allowed. The
refrigerant machine oil must be disposed of as oil of unknown
origin. The appropriate storage and disposal must be carried out
in accordance with the specific country guidelines.

3.2 Verification procedure ofŠKODA

unless authorised by refrigerant
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Proof must be given regarding the consumption of a specific
quantity of refrigerants per year in accordance with the Environ‐
mental Statistics Act.
Therefore, vehicle workshops can expect to give information
about the consumption of refrigerants to the respective regional
authorities concerned. Therefore it is always recommended to
keep a record sheet.

Note

♦ A record sheet for the amount of refrigerant which is converted

in the vehicle workshop, must no longer be kept in the EC on
the basis of a Regulation of the European Parliament in the
year 2005. At present, a record sheet is only necessary for a
consumption of 50 kg or more per year (see, for example, the
regulation (EC) No 1005/2009).
♦ Since the regional authorities may require information on the
consumption of refrigerants above a certain volume (currently
above a consumption of 20 kg per year), it is recommended to
always keep an appropriate record sheet.
♦ Other regulations maybe valid in countries that do not belong
to the EC.

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4 Refrigerant circuit
⇒ “4.1 Important repair instructions for air conditioning systems”,
page 35

4.1 Important repair instructions for air con‐

ditioning systems
• Never mix different refrigerants.
• The refrigerant oils specially developed for refrigerant circuits
with R134a and R12 must not be mixed.
• A/C Service stations, which come in contact with the refriger‐
ant, must only be used for the provided refrigerant.
• The components of the refrigerant circuit for refrigerant R134a
are marked with green stickers or are arranged in such a way
that they cannot be switched with components for refrigerant
R12 (e.g. other threads).
• There is a sign in the engine compartment on the lock carrier
or in the plenum chamber, which is intended to draw the at‐
tention to the refrigerant used.

Note

Observe the information contained in the chapters “safety instruc‐

tions”
⇒ “1.14 Safety measures when working on vehicles with air con‐
ditioning system and when using refrigerant R 134a”, page 13 and
“basics for working on the refrigerant circuit”
⇒ “1.15 Basics for working on the refrigerant circuit ”, page 13
when working on the refrigerant circuit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4. Refrigerant circuit 35
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5 Working with the A/C service station

For currently available AC Service stations, see ⇒ Catalogue of
factory equipment .

Caution

If it is suspected that chemical agents (special additives) have

been filled into the vehicle refrigerant circuit for sealing any
leaks, the A/C Service station does not connect and the refrig‐
erant cannot be drained.
Chemical agents (special additives) used for sealing leaks
form deposits in the refrigerant circuit which impair the function
of the air conditioning system and lead to a failure of the air
conditioning system (and the A/C Service station).
The customer must be informed that there are agents present
in his air conditioning system which were not approved by Ško‐
da. This air conditioning system cannot be emptied or repaired
by them.

Note

♦ The Škoda company does not use chemicals to seal leaks on

refrigerant circuits.
♦ Chemical agents (special additives) used for sealing leaks on
the refrigerant circuit usually react to the ambient air and the
humidity contained within the air. They lead to functional prob‐
lems of the valves and other components with which they
come into contact through deposits in the refrigerant circuit
(and the A/C Service station). These deposits can no longer
be completely removed from the components.
♦ In most cases, chemical agents used for sealing leaks in the
refrigerant circuit cannot be detected from the outside. The
necessary sticker, which must be affixed for identification, is
often not present. Therefore be careful with a vehicle, whose
past you are not familiar with.
♦ In the accessory trade containers are offered in which these
chemical agents (for
Protected by sealing
copyright. leaks)
Copying should
for private be deposited.
or commercial purposes, inSince
part or in whole, is not permitted
the companyunlessŠkoda
authorisedrejects
by ŠKODAthe AUTOuseA. S.of these
ŠKODA agents,
AUTO nonotstate‐
A. S. does guarantee or accept any liability
ment aboutwith therespect
effectiveness and the deposition rate of these
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

filters can be made at this point.

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⇒ “5.1 Important instructions for working with the A/C Service

station”, page 37
⇒ “5.2 Connecting the A/C service station to the refrigerant circuit
for measuring and testing”, page 38
⇒ “5.3 Empty the refrigerant circuit with the A/C service station.”,
page 38
⇒ “5.4 Evacuate the refrigerant circuit with the A/C service sta‐
tion.”, page 39
⇒ “5.5 Fill the refrigerant circuit with the A/C service station.”, page
40
⇒ “5.6 Operate the air conditioning system after filling”,
page 40
⇒ “5.7 Fill refrigerant into the reservoir (filling cylinder or reservoir
bottle) of the A/C service station”, page 40
⇒ “5.8 Draining the A/C service station”, page 41

5.1 Important instructions for working with

the A/C Service station
For operating the A/C service stations (currently available A/C
service positions see ⇒ Catalogue of factory equipment ) the fol‐
lowing must be observed:
– The installed filters and desiccators must be replaced at the
latest after reaching the operating time specified in the related
operating instructions.
– If the A/C service station is also used for the flushing of the
refrigerant circuit, the installed filters and desiccators must be
replaced within short periods of time.
– Only fill in refrigerant oils which are approved for the refrigerant
circuit specifically designed for vehicles.
– If there is any doubt about the composition of the refrigerant,
the refrigerant which was suctioned out of the refrigerant cir‐
cuit must not be re-used even after it has been cleaned in the
A/C service station.
• In this case the A/C service station must be drained
⇒ page 41 , if necessary the system must be cleaned, the
filters and the desiccators as well as the filled-in refrigerant oil
must be replaced.
• Contaminated refrigerant
Protected by copyright. canorbe
Copying for private returned
commercial to the
purposes, supplier
in part of the
or in whole, is not permitted
refrigerant,
unless authorisede.g. in the
by ŠKODA Federal
AUTO Republic
A. S. ŠKODA AUTO A. S.ofdoes
Germany,
not guarantee inorso-
accept any liability
called recycling bottles for preparation or ecological disposal
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

(different or additional directives may apply in certain coun‐

tries).
The commercially available A/C service stations can be sub-divi‐
ded into 2 groups:
♦ A/C service stations which clean drained refrigerant for re-use
(so-called extraction and recycling stations).
♦ A/C service stations which fill drained refrigerant into recycling
bottles (in order to then treat it commercially), these systems
are known as extraction systems.

5. Working with the A/C service station 37

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Air conditioning system with refrigerant R134a - Edition 05.2017

5.2 Connecting the A/C service station to

the refrigerant circuit for measuring and
testing

Note

♦ Depending on the type of the selected A/C service station,

variations can occur in the work procedure.
♦ The work procedure must always be carried out as described
in the operating instructions of the selected A/C service sta‐
tion.

So that neither air nor humidity can pass through the filling hoses
into the refrigerant circuit, they must be connected according to
the following work procedure:
– Switch off ignition.
– Connect the A/C service station to the voltage supply.
– Unscrew the screw caps from the service connections or the
connections with valve,
Protected see refrigerant
by copyright. circuit
Copying for private specifically
or commercial purposes,de‐
in part or in whole, is not permitted
signed for vehicles ⇒ Heating,
unless authorised by ŠKODA Air Conditioning;
AUTO A. S. ŠKODA AUTORep.A. S.gr.
does87 .
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– If necessary, evacuate the filling hoses.
– Connect the filling hoses of the A/C service station with quick
couplings to the service connections of the refrigerant circuit.

WARNING

Do not open the valves on the low or high pressure side with
the engine running. Otherwise, the A/C compressor or the A/
C service station can be destroyed due to the short-circuit be‐
tween the high and low pressure side of the refrigerant circuit,
when the air conditioning system is switched on.

– Screw in the handwheel of the quick-coupling adapters so far

until the valves of the service connections are safely opened
(observe the pressure gauge, do not over-press the valve).

5.3 Empty the refrigerant circuit with the A/

C service station.
• The refrigerant circuit must be drained if parts of the refrigerant
circuit are removed, in case there is any doubt about the vol‐
ume of refrigerant in the circuit or when required according to
the safety measures.
• Depending on the type of the selected A/C service station,
variations can occur in the work procedure.
• The work procedure must always be carried out as described
in the operating instructions of the selected A/C service sta‐
tion.
Draining off:
– Connect the A/C service station to the service connections
according to the relevant operating instructions (see refriger‐
ant circuit specifically designed for vehicles) and operate it.

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Note

♦ It is always possible that some refrigerant oil will be extracted

from the refrigerant circuit with the refrigerant. In order to en‐
sure the lubrication of the AC compressor, the refrigerant oil
volume in the circuit must be topped up with fresh oil ⇒ Heat‐
ing, Air Conditioning; Rep. gr. 87 .
♦ On vehicles with an AC compressor without magnetic coupling
(with regulating valve for compressor of air conditioning sys‐
tem - N280- ) the engine should run with an empty refrigerant
circuit for a relatively short period of time (max. 10 minutes),
thus a high engine speed must be avoided (the AC compres‐
sor keeps on running), see
⇒ “1.15.3 Additional work on vehicles with AC compressor
without magnetic coupling ”, page 15 .
♦ On vehicles with an AC compressor with magnetic coupling,
the air conditioner pressure switch - F129- or the high pressure
sender - G65- switches off the magnetic coupling as soon as
the refrigerant is in the refrigerant circuit.
♦ The engine must only be started if the refrigerant circuit is cor‐
rectly assembled.

5.4 Evacuate the refrigerant circuit with the

A/C service station.
• Before the refrigerant circuit is filled with refrigerant, it must be
evacuated. In addition, humidity is drawn from the circuit.
• Depending on the type of the selected A/C service station,
variations can occur in the work procedure.
• The work procedure must always be carried out as described
in the operating instructions of the selected A/C service sta‐
tion.

Caution

♦ When evacuating and if vacuum is present in the refriger‐

ant circuit, the engine must not be started.
♦ If the engine is started when vacuum is present in the re‐
frigerant circuit, the A/C compressor can be damaged.

Evacuating:
– Connect the A/C service station to the service connections
according to the relevant operating instructions (see refriger‐
ant circuit specifically designed for vehicles) and operate it.
If the vacuum in the system does not remain when evacuating
(see instructions), the following must be done:
– Pour 100 g of refrigerant into the refrigerant circuit, use a leak
detector to detect leaks and eliminate them.
– Evacuate the refrigerant circuit once again.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

Only if the vacuum stays steady, the refrigerant circuit can be fil‐
led.

5. Working with the A/C service station 39

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5.5 Fill the refrigerant circuit with the A/C

service station.
• Depending on the type of the selected A/C service station,
variations can occur in the work procedure.
• The work procedure must always be carried out as described
in the operating instructions of the selected A/C service sta‐
tion.
• The volume of refrigerant oil that was drained off must again
be added to the circuit when filling.

5.6 Operate the air conditioning system af‐

ter filling

Note

If the AC compressor was removed, the free wheel must be turned

by hand approx. 10 turns on the V-ribbed belt pulley before it is
first put into service. This prevents that no damage occurs after
switching on the air conditioning system for the first time as a re‐
sult of fluid hammer in the AC compressor (if oil is present in the
cylinder of the AC compressor, it is pressed out when turning).

– Start the engine with the AC compressor switched off (version

with magnetic coupling).
– Set the AC compressor to the lowest possible performance;
operating mode “Econ” or A/C off (version without magnetic
coupling with regulating valve).
– Wait until the idling speed has stabilised.
– Switch on the AC compressor and operate the system for at
least 2 minutes at idle speed.
– If necessary, check the pressures in the refrigerant circuit with
the A/C service station.
– Switch off the engine.
– Release the handwheel on the quick-coupling adapter.
– Remove the
Protected by filling hoses
copyright. Copying from theor refrigerant
for private circuit.
commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Screwwith
onrespect
the protective caps once again.
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5.7 Fill refrigerant into the reservoir (filling

cylinder or reservoir bottle) of the A/C
service station
• The work procedure must always be carried out as described
in the operating instructions of the A/C service station.
• A certain amount of refrigerant is recommended for filling into
each air conditioning system. In order to ensure that neither
too much nor too little refrigerant is filled in, the reservoir for
the refrigerant is standing on a scale.

WARNING

Do not overfill. A completely filled reservoir (filling cylinder or

reservoir bottle) could burst if the temperature rises, resulting
in catastrophic consequences ⇒ “1.8.9 Filling factor”, page 8 .

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5.8 Draining the A/C service station

Note

♦ If it is necessary to drain the A/C service station (e.g. because

contaminated refrigerant was drained off), always replace all
the filters and desiccators (shortly before installing, remove
the filters and desiccators from the airtight sealed transport
packaging in order to keep the increase of humidity as low as
possible).
♦ Refrigerant bottles which are filled with contaminated and
used refrigerant are known under the designation “recycling
bottles”.
♦ Always evacuate recycling bottles before filling with refrigerant
for the first time (refrigerant bottles, in which there is air, must
not be filled with refrigerant).
♦ Different types of refrigerants must not be mixed with each
other (refrigerant mixtures can no longer be recycled yet they
must be disposed of). If there is any doubt about the compo‐
sition of the bottle content, the refrigerant operator must be
advised.

Caution

♦ When filling up recycling bottles (pressure gas tanks) the

existing regulations, technical rules and laws must be ob‐
served.
♦ In any case, avoid overfilling the recycling bottles (overfil‐
led recycling bottles have a too low gas blanket in order to
absorb the liquid expansion caused by the effect of the
heat). There is a risk of bursting.
♦ For your own safety, only use recycling bottles with a
safety valve fitted.
♦ Recycling bottles must be weighed on a calibrated scale
when filling up. The maximum authorised filling capacity
is 75 % (filling factor 0.75) of the filling weight given on the
recycling bottle (it cannot be excluded that besides the re‐
frigerant, refrigerant oil is also filled into the recycling
bottle).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5. Working with the A/C service station 41

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6 Leak detection on the refrigerant cir‐

cuit
⇒ “6.1 Looking for leaks in the refrigerant circuit - important in‐
structions”, page 42
⇒ “6.2 Leak detection on the refrigerant circuit with compressed
air or nitrogen”, page 43
⇒ “6.3 Detecting leaks on the refrigerant circuit with the leak de‐
tector VAG1796 ”, page 45
⇒ “6.4 Detecting leaks on the refrigerant circuit with the leak de‐
tector VAS 6196 or VAS 6201A ”, page 45

6.1 Looking for leaks in the refrigerant circuit

- important instructions

Note

♦ On the open market, numerous procedures are offered for leak

detection on the refrigerant circuit. These procedures do not
always produce accurate results. In case they are not carried
out according to the instructions, it can happen that compo‐
nents of the refrigerant circuit appear to be leaking even
though they are leak tight. In addition, during certain proce‐
dures, components of the refrigerant circuit can be damaged
or initially damaged.
♦ If leaks are found on some components, they must not be re‐
paired but replaced with original parts.
♦ If a major leak is suspected, do not fill the refrigerant circuit
with the refrigerant R134a, see
⇒ “6.2 Leak detection on the refrigerant circuit with com‐
pressed air or nitrogen”, page 43 .

Caution

♦ Chemical agents must not be used to seal leaks on a re‐

frigerant circuit.
♦ If it is suspected that chemical agents have been filled into
the vehicle refrigerant circuit to seal leaks, do not connect
the AC service station and do not drain the refrigerant.
♦ Chemical agents used for sealing leaks form deposits in
the refrigerant circuit which impair the function of the air
conditioning system and lead to a failure of the air condi‐
tioning system (and the A/C service station).
♦ The Škoda company does not use chemicals to seal leaks
on refrigerant circuits.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

42
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rep. gr.00 - Technical data
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Air conditioning system with refrigerant R134a - Edition 05.2017

Note

♦ Chemical agents (special additives) used for sealing leaks on

the refrigerant circuit usually react to the ambient air and the
humidity contained within the air. They lead to functional prob‐
lems of the valves and other components with which they
come into contact through deposits in the refrigerant circuit
(and the A/C Service station). These deposits can no longer
be completely removed from the components.
♦ In most cases, chemical agents used for sealing leaks in the
refrigerant circuit cannot be detected from the outside. The
necessary sticker, which must be affixed for identification, is
often not present. Therefore be careful with a vehicle, whose
past you are not familiar with.
♦ In the accessory trade containers are offered in which these
chemical agents (for sealing leaks) should be deposited. Since
the company Škoda rejects the use of these agents, no state‐
ment about the effectiveness and the deposition rate of these
filters can be made at this point.

6.2 Leak detection on the refrigerant circuit

with compressed air or nitrogen
A major leak can be determined, for example, if a pressure of
maximum 15 bar builds up in the refrigerant circuit with clean and
dried compressed air or with nitrogen.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

6. Leak detection on the refrigerant circuit 43

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Air conditioning system with refrigerant R134a - Edition 05.2017

Note

♦ If a major leak is suspected, do not fill the refrigerant circuit

with the refrigerant R134a.
♦ If the leak is large enough, noise can be heard at the leak point
which is produced by the escaping air or gas.
♦ The compressed air or the nitrogen enters via the service con‐
nection.
♦ The quick-coupling adapter for the service connections can be
connected to the workshop compressed air system for exam‐
ple with a changed filling hose -A- (e.g. with a thread 5/8"-18
UNF, depending on the thread at the quick-coupling adapter)
and with a suitable adapter -B-.
♦ Compressed air test - in addition use a combination fine-filter
unit for the compressed-air system, oil, dirt and water separa‐
tor (as is common for painting systems). It must be installed
between the compressed-air system and the filling hose -A-.
♦ Nitrogen check - by means of a pressure gauge battery with
pressure reducer forunless
nitrogen (maximum reduced pressure: 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
bar) -1- via a filling hose -2- (e.g.
with respect with a thread
to the correctness 5/8"-18
of information in this UNF)
document. Copyright by ŠKODA AUTO A. S.�
to the service connection (on which a quick-coupling adapter
for service connections has been connected) at the closed re‐
frigerant circuit-3-.

– Slowly increase the pressure in the refrigerant circuit to max.

15 bar.

WARNING

♦ The maximum permissible working pressure is 15 bar.

♦ For leak detection with nitrogen, only work with pressure
reducer for nitrogen bottles.
♦ Nitrogen may leak uncontrollably from the bottle.

– It is possible to determine the leak point by the noise which

occurs at the point where the gas (nitrogen) escapes or by
applying a coat of soapy water to the leak point.
– Eliminate the leak.

Note

There must be no pressure in the refrigerant circuit before con‐

necting to the A/C service station. The nitrogen and the com‐
pressed air must not enter the service bottle with the refrigerant
R134a.

– After eliminating the leakage, connect an A/C service station

and check the refrigerant circuit for tightness by performing a
vacuum test.
– If a minor leak is suspected (according to the vacuum test),
subsequently carry out a leak check using the leak detector -
VAG1796-
⇒ “6.3 Detecting leaks on the refrigerant circuit with the leak
detector VAG1796 ”, page 45 , if necessary the leak detec‐
tion system - VAS 6196-
⇒ “6.4 Detecting leaks on the refrigerant circuit with the leak
detector VAS 6196 or VAS 6201A ”, page 45 .

44 Rep. gr.00 - Technical data

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– The refrigerant circuit can only be filled once the leak check
has been performed successfully.

6.3 Detecting leaks on the refrigerant circuit

with the leak detector - VAG1796-
Minor leaks can be detected for example with an electronic leak
detector or with an UV lamp.

Note

♦ Refrigerant gas quickly floats away with the movement of the

air. Therefore avoid any draught during leak detection.
♦ If the refrigerant circuit is absolutely empty, fill in approx. 100
grams of refrigerant.

Leak detection:
– Operate the leak detector according to the relevant operating
instructions.
– Always hold the test prod below the suspected leakage.
If the knocking noises increase or a whining tone occurs as a re‐
sult of the design, the leak point has been found (see operating
instructions belonging to the leak detector).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6.4 Detecting leaks on the refrigerant circuit
with the leak detector - VAS 6196- or -
VAS 6201A-
Minor leaks can be made visible with the fluorescent leak detec‐
tion additive - VAS 6196/1- which is added to the refrigerant
circuit.

6. Leak detection on the refrigerant circuit 45

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Note

♦ Depending on the size and the area of the leak, it might take
several days until enough refrigerant oil escapes with the ad‐
ditive and the leak point becomes visible.
♦ In case of leaks on the evaporator, the additive is perhaps
washed up by the condensation water and escapes through
the condensation water drain. On most vehicles the evapora‐
tor is not accessible without extensive preliminary work, there‐
fore if a test is carried out e.g. on the condensation water drain,
leaks can be detected on the evaporator. To do so, the leak
detection additive should be present in the refrigerant circuit
for a lengthy period (several days).
♦ Refrigerant gas quickly floats away with the movement of the
air. Therefore avoid any draught during leak detection.
♦ The leak detection additive can remain in the refrigerant cir‐
cuit.

Before commencing work, the information on how to operate the

leak detection system can be obtained from the relevant operating
instructions.
Leak detection system -VAS 6196-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Leak detection system -VAS 6201A-

1- Hand pump - VAS6201/1-
2- Cartridge - VAS 6201/2-
3- Cleaning agent - VAS 6201/3-
4- UV leak detection lamp - VAS 6201/4-
5- UV absorbing goggles - VAS 6201/6-
6- Sticker - VAS 6201/7-
7- Small tube - VAS 6201/8-
8- Protective gloves - VAS 6201/9-
– Empty the refrigerant circuit with the aid of the A/C service
station.

Note

If a larger leak is already found during the evacuation, locate it as

described in
⇒ “6.2 Leak detection on the refrigerant circuit with compressed
air or nitrogen”, page 43 .

46 Rep. gr.00 - Technical data

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There is 15.4 ml of leak detection additive in the cartridge -A- (one

unit -B- is equivalent to 2.5 ml).

– Assemble the hand pump -1- with the cartridge -2-.

Pour in leak detection additive when the refrigerant circuit is emp‐
ty

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with–respect
Whento the the refrigerant
correctness circuit
of information in thisis empty,
document. the leak
Copyright detection
by ŠKODA AUTO A. addi‐
S.�
tive can be filled into the circuit through an opened connection.
– Open an easily accessible connection point on the refrigerant
circuit.
– Cover the area around the connection point with foil or ab‐
sorbent paper.
– Hold the small tube upwards.
– Screw in the toggle of the hand pump sufficiently until the leak
detection additive flows out of the small tube.
– Fill 2.5 ±0.5 ml (millilitre = cm3) of leak detection additive into
the refrigerant circuit.

Note

If a leakage additive has already been installed in a refrigerant

circuit during an earlier repair, the following must be observed:
only fill in new leakage additive if the refrigeration oil is replaced.
If only part of the refrigerator oil was replaced, only a relative
amount of leak detection additive must be replenished. If, for ex‐
ample, 100 ml of refrigerator oil was replaced on a vehicle with a
250 ml-capacity, only replenish with 1 ml (cm3) of leak detection
additive.

– Replace the O-rings on all opened connection points.

– Assemble the refrigerant circuit.

6. Leak detection on the refrigerant circuit 47

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– Attach a sticker near the service connectors with a note that

leak detection additive has been added to this refrigerant cir‐
cuit.
– Drain and re-fill the refrigerant circuit with the aid of the A/C
service station.
– Start up the air conditioning system.

Note

The air conditioning system must be operated for at least 60 mi‐

nutes so that the added additive is distributed throughout the
refrigerant circuit (the AC compressor must run). Depending on
the size of the leak, the leak point will already become visible
within this period of time.

– Search for the leak on the refrigerant circuit using the UV leak
detection lamp - VAS 6201/4- ⇒ page 50 .
Pour in leak detection additive when the refrigerant circuit is full.

Note

♦ If a leakage additive has already been installed in a refrigerant

circuit during an earlier repair, the following must be observed:
only fill in new leakage additive if the refrigeration oil is re‐
placed. If only part of the refrigerator oil was replaced, only a
relative amount of leak detection additive must be replenished.
If, for example, 100 ml of refrigerator oil was replaced on a
vehicle with a 250 ml-capacity, only replenish with 1 ml (cm3)
of leak detection additive.
♦ A small amount of leak detection additive remains in the serv‐
ice connection. Carefully remove the remaining amount so
that it is not mistaken for a leak point during a subsequent leak
detection.

– Switch off ignition.

– Remove the screw cap from the service connection on the low-
pressure side of the refrigerant circuit.

Note

Make sure that the hose of the hand pump is completely filled with
leak detection additive.

– Fit the quick coupling onto the service connection of the low-
pressure side and open the service coupling by screwing in
the handwheel. Hold the hose upwards and screw in the toggle
of the hand pump sufficiently until the leak detection additive
begins to flow out at the small tube.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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– Cover the area around the service connection on the vehicle

with foil or absorbent paper.
– Fill 2.5 ±0.5 ml (millilitre = cm3) of leak detection additive into
the refrigerant circuit by screwing in the toggle of the hand
pump.
– Close the service coupling and remove it from the service
connection.
– Remove the residues of the leak detection additive from the
service connection, e.g. using absorbent paper.
– Close the service connector with the screw cap.
– If necessary, clean the surrounding area of the service con‐
nection with the cleaning agent.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

6. Leak detection on the refrigerant circuit 49

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Air conditioning system with refrigerant R134a - Edition 05.2017

– Attach a sticker near the service connectors with a note that

leak detection additive has been added to this refrigerant cir‐
cuit.
– Start up the air conditioning system.

Note

The air conditioning system must be operated for at least 60 mi‐

nutes so that the added additive is distributed throughout the
refrigerant circuit (the AC compressor must run). Depending on
the size of the leak, the leak point will already become visible
within this period of time.

– Search for the leak on the refrigerant circuit using the UV leak
detection lamp - VAS 6201/4- ⇒ page 50 .
Search for leaks on the refrigerant circuit using the UV leak de‐
tection lamp - VAS 6201/4-

WARNING

Do not stare into the UV lamp.

Do not point the UV lamp towards anybody.

Note

♦ The air conditioning system must be operated for at least 60

minutes so that the added additive is distributed throughout
the refrigerant circuit (the AC compressor must run). Depend‐
ing on the size of the leak, the leak point will already become
visible within this period of time.
♦ In case of leaks on the evaporator, the additive may be washed
away with the condensation water and flows out via the con‐
densation water drain. On most vehicles the evaporator is not
accessible without extensive preliminary work, therefore if a
test is carried out e.g. on the condensation water drain, this
could provide an indication of a leaking evaporator. For this
purpose, it is necessary that the additive has already been in
the refrigerant circuit for a longer period of time.
♦ The protective goggles serve to protect the eyes as well as
increase the luminosity of the additive when exposed to UV
light.
♦ Depending on the accessibility of various components of the
refrigerant circuit, it may be necessary to remove certain com‐
ponents of the vehicle (e.g. the bumper or the air filter).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

50 Rep. gr.00 - Technical data

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– Park the vehicle in a darker area of the workshop (in daylight

or in case of strong lighting, the effect of the UV light is re‐
duced).
– Check the accessibility of the various components of the re‐
frigerant circuit and remove the parts in the surrounding area
of the refrigerant circuit, which obstruct the view of the com‐
ponents of the refrigerant circuit (e.g. the cover for the noise
insulation and the bumper).
– Always wear the safety goggles in order to protect your eyes.
– Connect the UV lamp to a 12-volt battery (vehicle battery). Pay
attention to the correct polarity of the connections.
– Switch on the UV lamp and inspect the components of the
refrigerant circuit. Points where refrigerant, refrigerator oil and
thus leak detection additive leaks out, will glow under UV light
(fluorescent).

Note

The leak detection additive can remain in the refrigerant circuit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

6. Leak detection on the refrigerant circuit 51

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7 Removing contaminants from the re‐

frigerant circuit
⇒ “7.1 Cleaning the refrigerant circuit with compressed air and
nitrogen”, page 52
⇒ “7.2 Cleaning refrigerant circuit with refrigerant R134a (flush)”,
page 54
⇒ “7.3 Principle circuit diagrams for different rinsing cycles”, page
58
⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61

7.1 Cleaning the refrigerant circuit with compressed air and nitrogen
In order to remove impurities as well as aged refrigerant oil in a
clean refrigerant-saving and environmentally friendly manner,
without demanding installation, the refrigerant circuit is flushed
out with refrigerant R134a or is blown through with compressed
air and nitrogen.

Note

Blowing through the refrigerant circuit with compressed air and

nitrogen requires considerably more work than flushing with re‐
frigerant R134a. When flushing with refrigerant R134a, the clean‐
ing of the components is better and more effective, one should
therefore always flush if there is a problem.

The refrigerant circuit or the individual components must be blown through first with compressed air and then
with nitrogen, if:
♦ it is not possible to flush the refrigerant circuit with the refrigerant R134a.
♦ dirt or other impurities has/have entered into the circuit.
♦ When evacuating a tight refrigerant circuit the vacuum gauge is not constant (there is humidity in the re‐
frigerant circuit and builds up pressure)
♦ If the refrigerant circuit has been left open for longer than normally required for repairs (e.g. following an
accident).
♦ If pressure and temperature measurements indicate that there is humidity in the refrigerant circuit
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ There is any doubt about
with respectthe
to theoil volumeof information
correctness in the refrigerant circuit.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
in this document. Copyright by ŠKODA AUTO A. S.�

♦ the A/C compressor needed to be replaced because of internal damage (in this case it is preferable to flush
with refrigerant R134a ⇒ “7.2 Cleaning refrigerant circuit with refrigerant R134a (flush)”, page 54 ).
♦ required after replacing one of the components of the Workshop Manual.

Blowing through the refrigerant circuit

WARNING

♦ Nitrogen may leak uncontrollably from the bottle.

♦ Only work with reduction valve for nitrogen cylinders (max‐
imum working pressure: 15 bar).
♦ The gas mixture emanating from the components must be
exhausted via a suitable exhaust system.

52 Rep. gr.00 - Technical data

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Note

♦ To ensure neither oil nor moisture is transferred from the com‐

pressed-air system into the refrigerant circuit, the compressed
air must be led through a compressed-air cleaning system for
cleaning and drying. For this use a filter and dryer for com‐
pressed air (scope of delivery as tool for paint work).
♦ The maximum working pressure when blowing through must
not be greater than 15 bar, (if necessary also use a pressure
reducer for compressed air).
♦ Use a suitable adapter to connect the pressure hose to the
refrigerant circuit.
♦ The adapters must not damage the components of the refrig‐
erant circuit.
♦ Remove the fluid reservoir with desiccator before blowing
through the condenser (if possible).
♦ The evaporator must be blown through via the low-pressure
line connection (large diameter) once the expansion valve or
the throttle has been removed.
♦ Check expansion valve; replace if corroded or contaminated.
♦ If there are dark, sticky deposits in the components that cannot
be removed with compressed air, replace these components.
♦ Thin, light grey deposits on the inside do not hinder the oper‐
ation of the components.
♦ Compressed air and nitrogen cannot be blown through the A/
C compressor and the expansion valve or the throttle.
♦ Always blow through the components against the flow direc‐
tion of the refrigerant.

Work procedure
– Connect the changed filling hose with suitable adapters to the workshop compressed air system and con‐
nect the component to be blown through.

– Switch on the exhaust system and vacuum impurities and refrigerant oil with the suction hose.

– First blow through old refrigerant oil and dirt with compressed air.

– Blow through components with compressed air until no more dirt and refrigerant oil is expelled (e.g. check
with absorbent paper or a white cloth).

– Connect the reduction valve with the nitrogen pressure hose to the nitrogen cylinder and “dehumidify” the
individual components with nitrogen using the nitrogen pressure hose and the relevant adapters (exhaust
system must be on).

– Replace the AC compressor, unscrew the drain plug from the removed AC compressor as needed and
drain the remaining refrigerant oil. In order to speed up the evacuation of the refrigerant oil, turn the AC
compressor with the clutch disk of the magnetic coupling by hand (disposal of used oil
⇒ “3 Legal texts and legal
unless regulations”,
authorised pageA. S.33 ). Subsequently
ŠKODA fillguarantee
AUTO A. S. does not the volume
or acceptof
anynew
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA AUTO refrigerant oil, which
liability
corresponds to the refrigerant oilcorrectness
with respect to the volumeofin the original
information part AC
in this document. compressor,
Copyright by ŠKODA AUTO intoA.the
S.� removed AC com‐
pressor ⇒ Heating, Air Conditioning; Rep. gr. 87 .

7. Removing contaminants from the refrigerant circuit 53

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Note

♦ Draining off the oil from the A/C compressor is only possible
through the filling opening, the A/C compressor must therefore
be removed.
♦ Once no more refrigerant oil runs out of the A/C compressor;
turn on the A/C compressor by hand and drain off residual oil.

Replace the fluid reservoir with desiccator cartridge whenever the

refrigerant circuit has been blown through and keep it closed as
long as possible to prevent insofar as possible any humidity from
penetrating into the desiccator cartridge.

7.2 Cleaning refrigerant circuit with refrigerant R134a (flush)

• In order to remove impurities (e.g. abrasion from defective A/
C compressor) as well as used refrigerant oil in a clean refrig‐
erant-saving and environmentally friendly manner, without de‐
manding installation, the refrigerant circuit is flushed out with
refrigerant R134a or is blown through with compressed air and
nitrogen.
The refrigerant circuit must be flushed with refrigerant R134a, if:
♦ Dirt or other contaminations in the refrigerant circuit are present.
♦ When evacuating a tight refrigerant circuit the vacuum gauge is not constant (there is humidity in the re‐
frigerant circuit and builds up pressure)
♦ If the refrigerant circuit has been left open for longer than normally required for repairs (e.g. following an
accident).
♦ If pressure and temperature measurements indicate that there is humidity in the refrigerant circuit
♦ There is a doubt about the oil volume in the refrigerant circuit.
♦ The air conditioning compressor needed to be replaced because of internal damage (e.g. noise or no
output)
♦ Required for the respective vehicle after replacing one of the components of the workshop manual

Special tools and workshop equipment required

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ A/C service station with rinsing device -unless
VASauthorised
6456A- or -VAS
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
6380A- . For these A/C service stations, the auxiliary function
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

“flush refrigerant circuit with coolant R134a” is available and

the necessary flushing device for coolant circuits
♦ Adapter set for passenger vehicles - VAS 6338/1-
Preliminary work
– Drain refrigerant circuit.

– Remove AC compressor ⇒ Heating, Air Conditioning; Rep. gr. 87 .

– Remove catch pan/fluid reservoir with desiccator or only desiccator (specifically designed for vehicles) ⇒
Heating, Air Conditioning; Rep. gr. 87 and reconnect together with cable. To do so, use the adapter and
the filling hose -VAS 6338/31- from the adapter case of the motor car set.

– Vehicles with expansion valve - remove expansion valve and install the adapter from the adapter case of
the motor car set - VAS 6338/1- ⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61 .

– Vehicles with throttle - remove throttle and always connect the refrigerant lines together.

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Vehicles with expansion valve without adapter:

Drill out the expansion valve

Note

♦ If no suitable adapter for the expansion valve, see

⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61 ,
can be found in the adapter case of the motor car set - VAS
6338/1- , the removed expansion valve can be drilled out and
in this way it can be used instead of the adapter (in most cases
the old expansion valve is replaced after the flushing of the
refrigerant circuit and thus it is no longer needed).
♦ During drilling operation, make absolutely sure that the sealing
surfaces on the expansion valve are not damaged. The cool‐
ing medium could then leak when flushing.
♦ Before drilling out, remove the control element and drill out the
expansion valve with a suitable drill (drill diameter e.g. 6 mm).
♦ The expansion valve is available in different versions with var‐
ious designs. For the version -A- e.g. components -B-, -C- and
-D- must be removed. Disconnect the component -E- (control
element) from the component -D-. After this, use a suitable drill
(diameter 6 mm) to drill out the expansion valve in range -F-.
♦ Remove components -H-, -I- and -K-, pressure rod on the ver‐
sion -G- and after this, use a suitable drill (diameter 6 mm) to
drill out range -L-.
♦ Clean the drilled out expansion valve from machining residues
(swarf).
♦ Re-install components -B-, -C- and -D- on version -A- or com‐
ponent -H- on version -G-.

Refrigerant
– Check volume of refrigerant in the A/C service station, there must be at least 7 kg of refrigerant R134a.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– 30 min before
unless thebyfirst
authorised ŠKODA purging
AUTO A. process
S. ŠKODA AUTO or switching
A. S. does noton the heating
guarantee forliability
or accept any
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
the middle refrigerant bottle located
in the A/C service station (pressure in the middle refrigerant bottle increases) and before the first suctioning
procedure switch off the heating again during the purging process.

– Empty the container for the used oil of the A/C service station.

– Connect the intake hose (high-pressure side) of the A/C service station to the low-pressure line which leads
to the AC compressor with the aid of an adapter (cable with the larger diameter).

– Connect return-flow hose (low-pressure side or suction side) of the A/C service station to the outlet of the
flushing device for the refrigerant circuits.

– Connect the inlet of the flushing device on the high pressure line to the AC compressor with the aid of an
adapter (cable with smaller diameter).

7. Removing contaminants from the refrigerant circuit 55

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Note

♦ Adapter for setting up the rinsing cycles (specifically designed

for vehicles)
⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61 .
♦ The components are always flushed through against the flow
direction of the refrigerant when the air conditioning is in op‐
eration.
♦ When flushing, impurities get out of the refrigerant circuit into
the flushing device and are retained in the filters and desicca‐
tors installed there. Depending on the impurities, these com‐
ponents must be changed within short periods of time
according to the operating instructions of the A/C service sta‐
tion or the flushing device for refrigerant circuits.
♦ Depending on the type and intensity of the contamination of
the flushed refrigerant circuit, the filter in the flushing device
for refrigerant circuits must be replaced no later than after 5 to
10 flushing cycles (vehicles flushed thoroughly). If a heavily
contaminated refrigerant circuit is flushed (the refrigerant oil
from the refrigerant circuit is black and viscous or there is a lot
of swarf in the refrigerant circuit), the filter must be replaced
after only flushing the one refrigerant circuit. If the refrigerant
circuit is very dirty, it is also purposeful to once again flush the
refrigerant circuit after changing the filter.
♦ Depending on the type of the contamination, dirt deposits itself
(used refrigerant oil and abrasion from the AC compressor) on
the inspection glass or the inspection glasses of the flushing
device for refrigerant circuits. Clean the inspection glass or the
inspection glasses after flushing and flush the refrigerant cir‐
cuit once again using a purging process for inspection.
♦ The liquid refrigerant cannot be led through the expansion
valve and the desiccator bag of certain fluid reservoirs with the
required speed. These components must therefore be re‐
moved and replaced by adapters.

– Switch on the A/C service station and flush the refrigerant cir‐
cuit (a flushing cycle with three purging processes lasts ap‐
prox. 1 to 1.5 hours).

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ The flushing of a refrigerant circuit must be performed accord‐
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
ing to the operating instructions of the A/C service station.
♦ Depending on the version of the A/C service station, the con‐
tainer for the used oil contains approx. 125 cm3 of used
refrigerant oil. If a system with a greater refrigerant oil volume
must be flushed, it may be required to empty the used oil res‐
ervoir after the first purging process of a flushing cycle.
♦ When flushing (up to minor residues can be neglected) the
total refrigerant oil is washed out of the refrigerant circuit.

– Observe the refrigerant which flows back out of the refrigerant

circuit. Only when the refrigerant flows clear and completely
colourless through the inspection glasses of the flushing de‐
vice, the refrigerant circuit is clean.

56 Rep. gr.00 - Technical data

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The procedure of the purging process (the procedure is determined automatically according to the program
of the A/C service station)
♦ After switching on, the rinsing cycle is first of all evacuated and while doing so the refrigerant circuit is tested
for leaks (depending on the version of the A/C service station, manually moving forward is perhaps required
see ⇒ operating instructions of the A/C service station ).
♦ In the evacuated rinsing cycle, the corresponding specific volume of coolant (e.g. 4 kg) is filled in via the
high-pressure side of the A/C service station (against the normal flow direction of the air conditioning and
therefore on the low-pressure side of the refrigerant circuit of the vehicle). Depending on the version of the
A/C service station, enough refrigerant is filled in until the rinsing cycle is completely filled with liquid re‐
frigerant. This is determined in such a way that for a given period of time no more refrigerant can flow
through.
♦ After topping up with the determined volume of refrigerant, for example, the heating of the flushing device
for refrigerant circuits is switched on depending on the version of the A/C service station and the flushing
device for refrigerant circuits (only if the refrigerant is drained off in gaseous condition from the flushing
device for refrigerant circuits).
♦ After the refrigerant was drained off, the heating of the flushing device (if present) for the refrigerant circuits
is switched off, the refrigerant circuit is again briefly evacuated depending on the version and after the
evacuation, the refrigerant oil suctioned out of the refrigerant circuit is expelled out of the A/C service station.
♦ The procedure, fill with refrigerant, drain off (and evacuate) is repeated twice (altogether it is performed
three times).
After completing the purging processes:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Check the inspection glass or the inspection
unless authorised byglasses
ŠKODA AUTOof theA. S.flushing
ŠKODA AUTO device. If dirty,
A. S. does clean
not guarantee the purging
or accept any liability proc‐
ess in accordance with the operating instructions of the flushing device and once again perform a check of
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

the purging process (it lasts only one purging process, about 30 minutes).

– Remove the connections to the A/C service station from the refrigerant circuit of the vehicle (there must
not be any overpressure present in the refrigerant circuit, if necessary briefly evacuate the refrigerant circuit
once again).

– Replace throttle and catch pan/fluid reservoir with desiccator or only desiccator (specifically designed for
vehicles).

– Vehicles with expansion valve - Check expansion valve, replace if dirty or corroded.

– Depending on the fault:

• Replace the AC compressor, unscrew the drain plug from the removed AC compressor as needed and
drain the remaining refrigerant oil. In order to speed up the evacuation of the refrigerant oil, turn the AC
compressor with the clutch disk of the magnetic coupling by hand (disposal of used oil
⇒ “3 Legal texts and legal regulations”, page 33 ). Subsequently fill the volume of new refrigerant oil, which
corresponds to the refrigerant oil volume in the original part AC compressor, into the removed AC com‐
pressor ⇒ Heating, Air Conditioning; Rep. gr. 87 .

Note

In the original part AC compressor there is a certain determined

refrigerant oil volume.

– Completely assemble again the refrigerant circuit, evacuate

and fill.
– Set the air conditioning again to operate and perform a func‐
tional test.

7. Removing contaminants from the refrigerant circuit 57

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7.3 Principle circuit diagrams for different

rinsing cycles

Note

♦ The arrows in the following figures point towards the flow di‐
rection of the refrigerant when flushing (the refrigerant flows
out against the flow direction in the air conditioning when
flushing, therefore the high-pressure side of the A/C service
station is connected to the low-pressure connection of the re‐
frigerant circuit to the AC compressor).
♦ Adapter for setting up the rinsing cycles (specifically designed
for vehicles)
⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61 .

Refrigerant circuit with expansion valve and fluid reservoir

Note

The expansion valve is removed and is replaced by an adapter. The fluid reservoir must be removed depending
on the vehicle and the line connections to the fluid reservoir must connect with each other using two adapters
and a filling hose.

1 - A/C service station

❑ With electronics and a
program for flushing or
with a flushing device.
❑ If an A/C service station
without a program for
flushing Protected
is used,bythe pro‐Copying for private or commercial purposes, in part or in whole, is not permitted
copyright.
cedure must be per‐by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
formed manually (evac‐
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

uate, flush three times,

at least 4 kg each time
and drain the refrigerant
again).
2 - Refrigerant hoses on the A/
C service station
❑ From the high-pressure
side of the A/C service
station (usually red in
colour) to the connec‐
tion for the low-pressure
side of the AC compres‐
sor (larger diameter).
3 - Adapter to connection for
the low-pressure side
❑ Different versions de‐
pending on the vehicle.
❑ From the adapter case
of the motor car set -
VAS 6338/1- .
4 - Connection of the low-pres‐
sure side on the refrigerant cir‐
cuit to the A/C compressor
❑ Different versions de‐
pending on the vehicle.

58 Rep. gr.00 - Technical data

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5 - Adapter for the installed expansion valve

❑ Different versions depending on the vehicle.
❑ From the adapter case of the motor car set -VAS 6338/1- .
6 - Evaporator
7 - Connection to the fluid reservoir
❑ Different versions depending on the vehicle.
❑ Not available on vehicles with a desiccator cartridge in the fluid reservoir at the condenser or with a fluid
reservoir installed in the condenser.
8 - Adapter for bridging the removed fluid reservoir
❑ Not required on all vehicles (see the above-mentioned point).
❑ Different versions depending on the vehicle.
❑ From the adapter case of the motor car set -VAS 6338/1- .
9 - Filling hose for refrigerant
❑ From the adapter case of the motor car set -VAS 6338/1- .
10 - Condenser
❑ If a fluid reservoir with desiccator cartridge is installed at the condenser, the desiccator cartridge must
be removed (close again after removing fluid reservoir at or in the condenser).
11 - Connection of the high-pressure side on the refrigerant circuit to the A/C compressor
❑ Different versions depending on the vehicle.
12 - Adapter to connection for the high-pressure side of the refrigerant circuit
❑ Different versions depending on the vehicle.
❑ From the adapter case of the motor car set -VAS 6338/1- .
13 - Filling hose of flushing device for the refrigerant circuits
❑ From connection to high-pressure side of the A/C compressor in the refrigerant circuit (smaller diameter)
to inlet of flushing device for the refrigerant circuits.
14 - Flushing device for the refrigerant circuits
❑ E.g. -VAS 6456A- .
❑ With filter, inspection glass, safety valve, heating, refrigerant reservoir etc. (depending on the version).
❑ Depending on the structure of the A/C service station and the flushing device for the refrigerant circuits,
a non-return valve can be installed on the outlet of the flushing device for the refrigerant circuits (in order
to ensure the correct flow direction of the refrigerant when flushing).
15 - Refrigerant hoses on the A/C service station
❑ From the low-pressure side of the A/C service station (usually blue in colour) to the outlet of the flushing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
device for the
with respect to therefrigerant circuits.in this document. Copyright by ŠKODA AUTO A. S.�
correctness of information

Refrigerant circuit with throttle and catch pan

Note

The throttle is removed and the refrigerant pipes are assembled again. The catch pan is also removed and the
line connections to the reservoir are connected together again. To do so, use the adapter and the filling hose
from the adapter case of the motor car set -VAS6338/31- , see
⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61 .

7. Removing contaminants from the refrigerant circuit 59

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1 - A/C service station

❑ with electronics and a
program for flushing or
with a flushing device
❑ If an A/C service station
without a program for
flushing is used, the pro‐
cedure must be per‐
formed manually (evac‐
uate, flush three times,
at least 4 kg each time
and drain the refrigerant
again).
2 - Refrigerant hoses on the A/
C service station
❑ From the high-pressure
side of the A/C service
station (usually red in
colour) to the connec‐
tion for the low-pressure
side of the AC compres‐
sor (larger diameter).
3 - Adapter to connection for
the low-pressure side
❑ different versions de‐
pending on the vehicle
❑ from the adapter case of
the motor car set -VAS
6338/1-
4 - Connection of the low-pres‐
sure side on the refrigerant cir‐
cuit to the A/C compressor
❑ different versions de‐
pending on the vehicle
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
5 - Connection to the catch pan unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
6 - Adapter for bridging the removed catch pan
❑ from the adapter case of the motor car set -VAS 6338/1-
7 - Filling hose for refrigerant
❑ from the adapter case of the motor car set -VAS 6338/1-
8 - Adapter for bridging the removed catch pan
❑ from the adapter case of the motor car set -VAS 6338/1-
9 - Connection to the catch pan
10 - Evaporator
11 - Fitting location of the throttle
❑ the throttle is removed
❑ Removing and installing the throttle ⇒ Heating, Air Conditioning; Rep. gr. 87
12 - Screwed connection in the refrigerant line
❑ screw together again after the removal of the throttle
13 - Condenser
14 - Connection of the high-pressure side on the refrigerant circuit to the A/C compressor
15 - Adapter to connection for the high-pressure side of the refrigerant circuit
❑ from the adapter case of the motor car set -VAS 6338/1-

60 Rep. gr.00 - Technical data

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16 - Filling hose of flushing device for the refrigerant circuits

❑ from the connection to the high-pressure side of the AC compressor on the refrigerant circuit (smaller
diameter) to inlet of flushing device for the refrigerant circuits
17 - Flushing device for the refrigerant circuits
❑ with filter, inspection glass, safety valve, heating, refrigerant reservoir etc. (depending on the version)
❑ Depending on the structure of the A/C service station and the flushing device for the refrigerant circuits,
a non-return valve can be installed on the outlet of the flushing device for the refrigerant circuits (in order
to ensure the correct flow direction of the refrigerant when flushing).
18 - Refrigerant hoses on the A/C service station
❑ From the low-pressure side of the A/C service station (usually blue in colour) to the outlet of the flushing
device for the refrigerant circuits.

7.4 Adapter for setting up the rinsing cycles

♦ The table below lists various adapters which are necessary for
connecting the A/C service station to the refrigerant circuit,
flushing and bridging the removed fluid reservoir or catch pan
and the expansion valve (specifically designed for vehicles).
♦ If a flushed refrigerant circuit is not reassembled immediately
after flushing, leave the adapters on the connections and close
the connections on the adapters with the screw caps (from the
adapter case of the motor car set - VAS 6338/1- ).

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
The work procedures of the installation work for condensers, des‐
iccators, strainers, expansion valves etc. are described in the
Workshop Manual ⇒ Heating, Air Conditioning; Rep. gr. 87 .

Fabia; Fabia II; Fabia III; Roomster, Rapid

Vehicle Adapters for the connections Condenser with integrated res‐ Miscellaneous
to the AC compressor ervoir with desiccator
Fabia; Fa‐ ♦ High-pressure side (ex‐ – Before flushing remove the – Replace expansion valve
bia II; Fabia cept 6Q0 820 808) adapt‐ desiccator cartridge, on the with adapter -
III; Room‐ er -VAS6338/3- condensers “Modine” also VAS6338/34- , -
ster; Rapid the strainer and the contain‐ VAS6338/39- or a reworked
♦ High-pressure side - A/C er. (drilled out) expansion
compressors 6Q0 820 valve, see
808 - adapter - – After the flushing, install a ⇒ “7.2 Cleaning refrigerant
VAS6338/2- new desiccator cartridge circuit with refrigerant
♦ Low-pressure side - and a strainer (condensers R134a (flush)”, page 54 .
adapter -VAS6338/12- Modine).
– Check expansion valve af‐
ter flushing (corrosion, dirt),
replace if necessary.

7. Removing contaminants from the refrigerant circuit 61

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Citigo
Vehicle Adapters for the connections Condenser with integrated res‐ Miscellaneous
to the AC compressor ervoir with desiccator
Citigo ♦ Adapter -VAS6338/3- – Flush circuit with reservoir – Replace expansion valve
high-pressure side with desiccator. with adapter -
VAS6338/36- , -
♦ Adapter -VAS6338/12- – Install a new reservoir with VAS6338/34- or a reworked
low-pressure side desiccator after flushing. (drilled out) expansion
valve, see
⇒ “7.2 Cleaning refrigerant
circuit with refrigerant
R134a (flush)”, page 54 .

– Check expansion valve af‐

ter flushing (corrosion, dirt),
replace if necessary.

Octavia I
Vehicle Adapters for the connections Adapter for bridging the reser‐ Miscellaneous
to the AC compressor voir with desiccator
Octavia I ♦ Adapter -VAS6338/2- – Remove reservoir with des‐ – Replace expansion valve
high-pressure side iccator. with adapter -VAS6338/19-
♦ 2 times adapter - or a reworked (drilled out)
♦ Adapter -VAS6338/7- VAS6338/2- expansion valve, see
low-pressure side ⇒ “7.2 Cleaning refrigerant
♦ connect with hose - circuit with refrigerant
VAS6338/31- R134a (flush)”, page 54 .
– Install a new reservoir with
desiccator after flushing. – Check expansion valve af‐
ter flushing (corrosion, dirt),
replace if necessary.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

62 Rep. gr.00 - Technical data

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Octavia II
Vehicle Adapters for the connections Condenser with reservoir with Miscellaneous
to the AC compressor desiccator
Octavia II ♦ Adapter -VAS6338/3- – Condensers “DENSO” with – Replace expansion valve
high-pressure side firmly integrated reservoir with adapter -VAS6338/18-
with desiccator - two proce‐ or a reworked (drilled out)
♦ Adapter -VAS6338/12- dures are possible: expansion valve, see
low-pressure side ♦ First procedure - remove ⇒ “7.2 Cleaning refrigerant
condenser and connect the circuit with refrigerant
connections with adapter - R134a (flush)”, page 54 .
VAS6338/4- , -VAS6338/3-
and connecting hose - – Check expansion valve af‐
VAS6338/31- . The adapter ter flushing (corrosion, dirt),
-VAS6338/3- must be re‐ replace if necessary.
worked by making (milling)
an additional hole 1).
♦ Second procedure - un‐
screw screw cap from res‐
ervoir with desiccator, care‐
fully remove the desiccator
cartridge and then the
strainer below the desicca‐
tor cartridge using a wire
with hook. Screw in the
screw cap again and flush
the circuit with condenser.
Install a new condenser
with reservoir with desicca‐
tor after flushing.
– Condensers “SHOWA” with
replaceable reservoir with
desiccator:
♦ Flush circuit with reservoir
with desiccator.
♦ Replace reservoir with des‐
iccator after flushing.
–unless
Condensers
Protected by copyright.“Modine” withor commercial purposes, in part or in whole, is not permitted
Copying for private
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
firmly integrated reservoir
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
with desiccator:
♦ Remove desiccator bag
and strainer from the reser‐
voir. Screw in the screw cap
again and flush the circuit
with condenser. After the
flushing, install a new des‐
iccator cartridge and a
strainer.

7. Removing contaminants from the refrigerant circuit 63

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Octavia III
Vehicle Adapters for the connections Adapter for bridging the reser‐ Miscellaneous
to the AC compressor voir with desiccator
Octavia III ♦ Adapter -VAS6338/3- – Remove desiccator bag – Replace expansion valve
high-pressure side and strainer from the reser‐ with adapter -VAS6338/38-
voir. Screw in the screw cap or a reworked (drilled out)
♦ Adapter -VAS6338/12- again and flush the circuit expansion valve, see
low-pressure side with condenser. After the ⇒ “7.2 Cleaning refrigerant
flushing, install a new des‐ circuit with refrigerant
iccator cartridge and a R134a (flush)”, page 54 .
strainer.
– Check expansion valve af‐
ter flushing (corrosion, dirt),
replace if necessary.

1) Rework adapter -VAS6338/3- :

– In order to connect the adapter -VAS6338/3- at the connection
to the condenser, it must be reworked by making (milling) an
additional hole -A- according to the figure (the dimensions in
the figure are given in mm).

Note

♦ Use an upright drilling machine for drilling, if necessary use a

hand-held power drill in a stand and tension the adapter in a
vice.
♦ For better guidance of the drill, predrill the bore with a smaller
drill ∅3 mm.

Superb
Vehicle Adapters for the connections Adapter for bridging the reser‐ Miscellaneous
to the AC compressor voir with desiccator
Superb ♦ Adapter -VAS6338/2- – Remove reservoir with des‐ – Remove throttle and reas‐
high-pressure side iccator. semble coolant pipe.
♦ 2 times adapter -
♦ Adapter -VAS6338/12- VAS6338/10- – Install a new throttle after
low-pressure side flushing.
♦ connect with hose -
VAS6338/31-
– Install a new reservoir with
desiccator after flushing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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Superb II; Superb III; Yeti; Kodiaq; Karoq

Vehicle Adapters for the connections Condenser with reservoir with Miscellaneous
to the AC compressor desiccator
Superb II; ♦ Adapter -VAS6338/3- – Condensers “SHOWA” with – Replace expansion valve
Superb III; high-pressure side replaceable reservoir with with adapter -
Yeti; Ko‐ desiccator: VAS6338/18- , -
diaq; Karoq ♦ Adapter -VAS6338/12- ♦ Flush circuit with reservoir VAS6338/38- or a reworked
low-pressure side with desiccator. (drilled out) expansion
valve, see
♦ Replace reservoir with des‐ ⇒ “7.2 Cleaning refrigerant
iccator after flushing. circuit with refrigerant
– Condensers “Modine” with R134a (flush)”, page 54 .
firmly integrated reservoir
with desiccator: – Check expansion valve af‐
♦ Remove desiccator bag ter flushing (corrosion, dirt),
and strainer from the reser‐ replace if necessary.
voir. Screw in the screw cap
again and flush the circuit
with condenser. After the
flushing, install a new des‐
iccator cartridge and a
strainer.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

7. Removing contaminants from the refrigerant circuit 65

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8 Complaints
⇒ “8.1 Possible complaints”, page 66
⇒ “8.2 Temperature test of cooling capacity”, page 67
⇒ “8.3 Odour from the heating and air conditioning unit”,
page 68

8.1 Possible complaints

Note

For all complaints marked with an *

⇒ “9 Check the pressure in the refrigerant circuit (with the A/C
service station)”, page 71 .

♦ The cooling system has failed completely.*

♦ Insufficient cooling capacity for all vehicle speeds or engine
speeds.*
♦ No cooling or insufficient cooling after a few kilometres of driv‐
ing.*
♦ The AC compressor, the air conditioner magnetic coupling -
N25- or the regulating valve for compressor of air conditioning
system - N280- are switched off, due to a too high or too low
pressure, by a low pressure switch for air conditioning system
- F73- , , the high pressure switch for magnetic coupling -
F118- , the air conditioner pressure switch - F129- or from the
Climatronic control and display unit for air conditioner - E87- ,
or the Climatronic control unit - J255- .*
♦ No or a strong decrease of fresh air supply after a few kilo‐
metres of driving (evaporator iced up).*
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Odour from the heating and air conditioning
with respect to theunit
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ “8.3 Odour from the heating and air conditioning unit”, page
68
In addition, the following complaints may still arise:
The air conditioning compressor makes noises
– Tighten the fixing screws for the AC compressor and the AC
compressor bracket with a torque wrench.
– Check the routing of the coolant pipes, they must not be flush
with other components and must be installed free of tension
(align if necessary).
Immediately after switching on the air conditioning system and/or
when cornering or braking, noises occur (refrigerant hammering):
– Drain refrigerant circuit, evacuate and fill again (too much re‐
frigerant in the circuit).

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Note

♦ This complaint may also arise if there is too much refrigerant

oil in the circuit (when changing the AC compressor, for ex‐
ample, the quantity of refrigerant oil was not modified) . For
this complaint, the refrigerant circuit must be flushed with re‐
frigerant R134a.
♦ The refrigerant oil must be drained out of the AC compressor
via the oil drain plug. In order to facilitate this, the V-ribbed belt
pulley or the clutch disc of the magnetic coupling must be
turned by hand on the AC compressor. Then, the refrigerant
circuit must be filled with refrigerant oil to its total filling capacity
according to the vehicle-specific workshop manual ⇒ Heating,
Air Conditioning; Rep. gr. 87 (70 grams straight into the AC
compressor).

On an air conditioning system which otherwise functions perfect‐

ly, water sprays out of the vents (the dash panel or in the footwell):
– Check the perfect laying of the condensation water drain, it
must not be crimped or bent.
– Check the condensation water drain valve, it must not stick
with wax or underbody sealant and must properly open and
close.
– Check the plenum chamber cover, it must not be damaged
and must be installed correctly (no water may flow into the
evaporator).
– Check the water drainage openings of the plenum chamber,
they must not be blocked (e.g. through leaves).

8.2 Temperature test of cooling capacity

– Measure the ambient temperature.
– Close the front flap, windows and sliding roof.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Open all dash panel vents. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Position the air distribution to person flow.

– Insert the measuring tip of the temperature probe -2- in the
middle -1- of the dash panel vents in the indicated area (vehi‐
cle-specific) -3-, in such a way that it is located at least 20 mm
behind the vent lamellae.
– Start engine.
– Switch on the air conditioning system and set to maximum re‐
frigerating capacity, see
⇒ “9.1 Test requirements before the pressure test”,
page 71 .
– Increase and maintain engine speed at 2000 rpm.

Note

Start of time measurement (5 min).

Evaluate

8. Complaints 67
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After 5 minutes, the temperature of the air flow from the vents
must be within the tolerance (see diagram) depending on the am‐
bient temperature.
A - Temperature of the air flow from the vents
B - Ambient temperature
C - Permissible tolerance range

Note

When measuring, the ⇒ Vehicle diagnostic tester, function - cool‐

ing capacity of the air conditioning system (Climatronic) or in the
measured value block - temperature in the vent outlets, can also
be used (not valid for manual air-conditioning unit).

8.3 Odour from the heating and air condi‐

tioning unit
⇒ “8.3.1 Possible odours coming from the heating and air condi‐
tioning unit”, page 68
⇒ “8.3.2 Spray evaporator with compressed air pistol VAG 1538
with spray nozzle”, page 69
⇒ “8.3.3 Ultrasonic air conditioning system cleaning device VAS
6189B ”, page 69

8.3.1 Possible odours coming from the heat‐

ing and air conditioning unit
♦ Fishy odour
– Due to leak tightness at the cooling system of the engine or
the heat exchanger in the heating and air conditioning unit.

Note

If a weak fishy odour can be detected when the temperature is

set to “cold” or a stronger odour occurs when the temperature is
set to “warm”, check the heat exchanger for leak tightness.

♦ Odours after the clutch is burnt

♦ Evaporations from footmats, subsequently fitted protective
seat covers etc.
♦ Foul, mouldy odour
– Due to accumulation and deposit of leaves, tree needles, etc.
in the plenum chamber.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Note unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Clean plenum chamber.

– Use water which cannot drain out the plenum chamber.

Note

Check water drainage openings in plenum chamber.

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♦ Odour from the heating and air conditioning unit

Note

Odours which can occur in the heating and air conditioning unit,
can be detected in the fresh as well as re-circulating air mode.

– Due to excessive condensation water in the heating and air

conditioning unit.

Note

Check condensation water drain ⇒ Heating, Air conditioning;

Rep. gr. 87 .

– Caused by old or heavily soiled dust and pollen filters.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Check dust and pollenunless
filter and replace if necessary ⇒ Heating,
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Air Conditioning; Rep. gr. 80 or ⇒ Rep. gr. 87 .

– Due to deposits on the fins of the evaporator.

Note

♦ Numerous methods for cleaning the heating and air condition‐

ing unit, which differ in their use and effect, are offered on the
market.
♦ Cleaning the evaporator, see
⇒ “8.3.2 Spray evaporator with compressed air pistol VAG
1538 with spray nozzle”, page 69 where necessary
⇒ “8.3.3 Ultrasonic air conditioning system cleaning device
VAS 6189B ”, page 69
♦ When cleaning, proceed according to the enclosed instruction.

Currently offered equipment to clean the evaporator ⇒ Workshop

Equipment catalogue .

8.3.2 Spray evaporator with compressed air

pistol - VAG 1538- with spray nozzle
The evaporator is sprayed directly with Contra Sept with the spray
nozzle. AeroClean neutralises microbes and bacteria directly in
the evaporator.
To enable access to the evaporator, various spray nozzles are
required, e.g.: -VAG 1538/8- or -VAG 1538/9- .
A purifier is enclosed for evaporator D 600 100 A2 with the guide
for the corresponding vehicle.
Current devices and spray nozzles ⇒ Workshop Equipment cata‐
logue .

8.3.3 Ultrasonic air conditioning system

cleaning device - VAS 6189B-
– The ultrasonic air conditioning system cleaning device - VAS
6189B- is placed in the footwell on the front passenger side

8. Complaints 69
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and atomises the Aeroclean agent. AeroClean neutralises mi‐

crobes and bacteria in the heating and air conditioning unit.
Operating instructions come with the device.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

70 Rep. gr.00 - Technical data

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9 Check the pressure in the refrigerant

circuit (with the A/C service station)
⇒ “9.1 Test requirements before the pressure test”, page 71
⇒ “9.2 Check pressures”, page 72
⇒ “9.3 Continuation of the test depending on the arrangement of
the refrigerant circuit”, page 74
⇒ “9.4 Pressure test for vehicles with throttle and catch pan (with
AC compressor regulated from the inside)”, page 74
⇒ “9.5 Pressure test for vehicles with expansion valve and fluid
reservoir (with AC compressor regulated from the inside)”,
page 78
⇒ “9.6 Pressure test for vehicles with expansion valve, fluid res‐
ervoir and with regulating valve for compressor of air conditioning
system N280 (with AC compressor regulated from the outside)”,
page 83

9.1 Test requirements before the pressure

test
• The radiator and condenser are clean (if necessary clean).
• The heat-protection insulation on the expansion valve is O.K.
and is correctly installed. See vehicle-specific Workshop Man‐
ual ⇒ Heating, Air Conditioning; Rep. gr. 87 .
• The V-ribbed belts for AC compressor and AC generator are
O.K. and are correctly tensioned.
• All the air guides, covers and seals are O.K. and are correctly
installed.
• No fault has been detected on the electrical system, the vac‐
uum system and the air guide with the fault finding ⇒ Vehicle
diagnostic tester, ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations and ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
• The self-diagnosis of the air conditioning system (e.g. with the
⇒ Vehicle diagnostic tester) does not detect any fault, no
switch-off condition of the AC compressor is displayed in the
measured value block (only for vehicles with air conditioning
system self-diagnosis).
• The air flow rate through the dust and pollen filter is not im‐
paired by contamination. See vehicle-specific Workshop Man‐
ual ⇒ Heating, Air Conditioning.; Rep. gr. 87 ⇒ Rep. gr. 87
• The heating and air conditioning unit does not draw any sec‐
ondary air at the highest fresh air blower speed.
• The air guide flaps in the heating and air conditioning unit, in
the heating and in the evaporator reach their final setting. See
vehicle-specific Workshop Manual ⇒ Heating, Air Condition‐
ing; Rep. gr. 87 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• The fresh air intake ducts under the front flap and in the pas‐
senger compartment as well as the related water drain valves
are O.K. see vehicle-specific workshop manual⇒ Heating, Air
Conditioning; Rep. gr. 87 .
• The engine is at operating temperature.
• The vehicle is not exposed to the sun's rays.
• The ambient temperature is higher than 15°C.
• All the dash panel vents are opened.

9. Check the pressure in the refrigerant circuit (with the A/C service station) 71
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Air conditioning system with refrigerant R134a - Edition 05.2017

• While the engine is running and with the air conditioning sys‐
tem set to maximum cooling capacity:
Set maximum cooling capacity of the air conditioning system
Setting on the control and display unit for air conditioner Clima‐
tronic - E87- :
– Pre-select operating mode “auto” (AC compressor switched
on).
– Set temperature pre-selection “LO” for driver and passenger
side.
Setting on the manual heater control, air conditioner Climatic:
– “AC” and re-circulating button pressed.
– Temperature rotary switch is positioned on stop “cold”.
– Rotary switch for fresh air blower - V2- on position “4”.
• If the radiator fan (if the fans run) runs -V7- (min. in stage 1).

Note

On certain versions, the fan is only switched on after the pressure

in the refrigerant circuit has exceeded a given value.

• The AC compressor is indeed driven ( air conditioner magnetic

coupling - N25- is closed, it is possible that the existing belt
protection in the AC compressor belt pulley is not damaged).

9.2 Check pressures

– Switch off ignition.
– Connect A/C service station
⇒ “5 Working with the A/C service station”, page 36
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Read the pressures on the pressure gauges, they can show
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
two results:
♦ The pressure in the refrigerant circuit is lower than given in the
table.
♦ The pressure in the refrigerant circuit corresponds to what is
given in the table or is higher.
Ambient temperature (in Celsius) Pressure in the refrigerant
circuit in bar overpressure
+15 °C 3.9
+20 °C 4.7
+25 °C 5.6
+30 °C 6.7
+35 °C 7.8
+40 °C 9.1
+45 °C 10.5

72 Rep. gr.00 - Technical data

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Note

♦ The temperature of the components of the refrigerant circuit

should be equal to the ambient temperature (if individual com‐
ponents of the refrigerant circuit are warmer or colder, the
pressure deviates from the values in the table).
♦ At absolute pressure, 0 bar corresponds to an absolute vac‐
uum. The normal ambient pressure (overpressure) corre‐
sponds to 1 bar absolute pressure. On the scales of most
pressure gauges, 0 bar corresponds to an absolute pressure
of one bar (recognizable by the indication -1 bar below 0).
♦ On vehicles with high pressure sender - G65- , on which the
measured pressure is displayed in the measured value block,
the measured pressure should correspond to the values in the
table.

The measured pressure in the refrigerant circuit is lower than the

pressure indicated in the table:
Too little refrigerant in the circuit.
– Detecting leaks on the refrigerant circuit
⇒ “6 Leak detection on the refrigerant circuit”, page 42 .
– Check pressure relief valve
⇒ “2.1.10 Pressure relief valve”, page 21 .
If the pressure relief valve is drained:
– Check the radiator fan actuation.
– Check coolant pipes and refrigerant hoses for cross-sectional
constrictions, for too small bending radii.
– Check coolant pipes and coolant hoses for external damage.
– If no fault is found, clean refrigerant circuit
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 .
The pressure in the refrigerant circuit corresponds to what is given
in the table or is higher:
– Start engine.
– Set air conditioning system to maximum refrigerating capacity
⇒ page 72 . by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

On vehicles with regulating valve for compressor of air condition‐

ing system - N280- , the control current can be read in the
measured value block ⇒ Vehicle diagnostic tester

If the AC compressor is not driven while the engine is running or

the regulating valve is not actuated (compressor specific):
– The cause, for example, can be determined and eliminated by
querying the event memory of the air conditioning system
⇒ Vehicle diagnostic tester
– Test the voltage supply for the air conditioner magnetic cou‐
pling - N25- if it is O.K., repair magnetic coupling.
– Check the actuation of the regulating valve for compressor of
air conditioning system - N280- ⇒ Vehicle diagnostic tester

9. Check the pressure in the refrigerant circuit (with the A/C service station) 73
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Note

The regulating valve for compressor of air conditioning system -

N280- is actuated by the control and display unit for air conditioner
Climatronic - E87- or by the Climatronic control unit - J255- ⇒ Ve‐
hicle diagnostic tester

– Continuation of the test depending on the arrangement of the

refrigerant circuit
⇒ “9.3 Continuation of the test depending on the arrangement
of the refrigerant circuit”, page 74 .

9.3 Continuation of the test depending on

the arrangement of the refrigerant circuit
♦ Pressure test for vehicles with throttle and catch pan (with AC
compressor regulated from the inside)
⇒ “9.4 Pressure test for vehicles with throttle and catch pan
(with AC compressor regulated from the inside)”, page 74 .
♦ Pressure test for vehicles with expansion valve and fluid res‐
ervoir (with AC compressor regulated from the inside)
⇒ “9.5 Pressure test for vehicles with expansion valve and fluid
reservoir (with AC compressor regulated from the inside)”,
page 78 .
♦ Pressure test for vehicles with expansion valve, fluid reservoir
and with regulating valve for compressor of air conditioning
system - N280- (with AC compressor regulated from the out‐
side)
⇒ “9.6 Pressure test for vehicles with expansion valve, fluid
reservoir and with regulating valve for compressor of air con‐
ditioning system N280 (with AC compressor regulated from
the outside)”, page 83 .

9.4 Pressure test for vehicles with throttle

and catch pan (with AC compressor
regulated from the inside)

Note

♦ Connect A/C service station

⇒ “5 Working with the A/C service station”, page 36
♦ Observe test requirements
⇒ “9.1 TestProtected
requirements
by copyright. before the
Copying for pressure
private test”,
or commercial page
purposes, 71or. in whole, is not permitted
in part
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Bring the engine speed to 2000 rpm.
– Observe the pressure gauge of the A/C service station.

Note

Switching pressures of the pressure switch for the air conditioning

system - F129- on the refrigerant circuit ⇒ Heating, Air Condi‐
tioning; Rep. gr. 87 .

Specified values
High-pressure side:
From the output pressure (when connecting the pressure gauge)
rising up to maximum 20 bar overpressure.

74 Rep. gr.00 - Technical data

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Low-pressure side:
From the output pressure (when connecting the pressure gauge)
dropping to diagram value.
A - High pressure (measured on the service connection) in bar
overpressure.
B - Low pressure (measured on the connection with valve on the
AC compressor or on the catch pan) in bar overpressure.
C - Permissible tolerance range.
D - Low pressure (measured on the connection with the valve for
the low pressure switch or on the service connection) in bar over‐
pressure.
E - Permissible tolerance range.

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure remains constant or in‐ Too little refrigerant in the cir‐ – Search for leaks with the
creases only slightly (above the pres‐ cuit. leak detector, eliminate.
sure while engine is not running),
– Newly filling the refrigerant
• Low pressure drops quickly to diagram circuit.
value or lower,
• The required cooling capacity is not
reached.

• High pressure is normal,

• Low pressure corresponds to the dia‐
gram value,
• The required cooling capacity is not
reached.

• High pressure is normal,

• Low pressure is too low (see diagram),
• The required cooling capacity is not
reached.

Note

If no fault is found for this complaint, clean the refrigerant circuit

⇒ “7 Removing contaminants from the refrigerant circuit”,
page 52 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

9. Check the pressure in the refrigerant circuit (with the A/C service station) 75
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Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure increases only slightly AC compressor defective. – Clean the refrigerant circuit
above the pressure while engine is not ⇒ “7 Removing contami‐
running, nants from the refrigerant
circuit”, page 52 .
• Low pressure drops only slightly,
• The required cooling capacity is not – Replace AC compressor.
reached.

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure increases above the Constriction or blockage in the – Feel the temperature gradi‐
specified value, refrigerant circuit. ent of the refrigerant circuit
with the hand.
• Low pressure drops quickly to diagram
value or lower, • A temperature gradient is
• The required cooling capacity is not noticed on a component:
reached. – In case a hose line or a pipe
is bent or constricted, re‐
place this component.

– In case of a blockage, clean

the refrigerant circuit
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 .

• If no fault is found:
– Clean the refrigerant circuit
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 .
• High pressure and low pressure is nor‐ Humidity in the refrigerant cir‐ – Check catch pan (with des‐
mal at first, after a certain period of time: cuit. iccator) and throttle and re‐
Protected by copyright. Copying for private orplace
commercialif necessary,
purposes, in partthen
or in whole, is not permitted
– the high pressure increases above the unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. the
evacuate refrigerant
S. does not guaranteecir‐
or accept any liability
specified value, cuit for at least 3 hours (see
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

notes).
– the low pressure drops to diagram value
or lower, – Clean the refrigerant circuit
⇒ “7 Removing contami‐
– the required cooling capacity is no lon‐ nants from the refrigerant
ger reached. circuit”, page 52 .
• High pressure and low pressure is nor‐
mal at first.
• After a longer operating time, the low
pressure drops remarkably low (evapo‐
rator ices up).

76 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

Note

♦ If problems arise due to humidity in the refrigerant circuit only

after a longer operating time or only occasionally (the low
pressure drops below the specified value and the evaporator
ices up), it is adequate to replace the desiccator (the volume
of refrigerant oil must be adapted
⇒ “10.5 Replace AC reservoir/desiccator/restrictor/expansion
valve”, page 94 ). Subsequently the refrigerant circuit must
be evacuated for at least 3 hours.
♦ First of all, it is not required to clean the refrigerant circuit for
this complaint (to flush with refrigerant R134a or to blow
through with compressed air and nitrogen), as normally only
a small amount of humidity is present in the system which can
be removed through a longer period of evacuation.

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure is normal or too high, Too much refrigerant in the cir‐ – Drain the refrigerant from
cuit. the refrigerant circuit.
• Low pressure is too high (see diagram),
• the AC compressor makes noises (es‐ • The volume of refrigerant
pecially after switching it on), suctioned out corresponds
approximately to the speci‐
• The required cooling capacity is not fied filling capacity:
reached.
– Replace AC compressor.

• The volume of refrigerant

suctioned out is considera‐
bly more than the specified
filling capacity:
– Newly filling the refrigerant
circuit.

– Repeat check.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure and low pressure is nor‐ Too much refrigerant oil in the – Drain the refrigerant from
mal, refrigerant circuit. the refrigerant circuit.
• The required cooling capacity is not – Clean the refrigerant circuit
reached. ⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 .
• High pressure and low pressure is nor‐ – Newly filling the refrigerant
mal, circuit.
• the AC compressor makes noises (es‐ – Repeat check.
pecially after switching it on),
• the required cooling capacity is
reached.

9. Check the pressure in the refrigerant circuit (with the A/C service station) 77
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Air conditioning system with refrigerant R134a - Edition 05.2017

Note

♦ Over-filling with refrigerant oil can occur if, for example, the AC
compressor has been replaced without matching the volume
of refrigerant oil.
♦ In case too much refrigerant oil is present in the refrigerant
circuit, the AC compressor must be emptied and the catch pan
with desiccator must be replaced. After the refrigerant circuit
has been cleaned
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 , fill the correct volume of refrigerant oil into the circuit.

9.5 Pressure test for vehicles with expan‐

sion valve and fluid reservoir (with AC
compressor regulated from the inside)

Note

♦ Connect A/C service station

⇒ “5 Working with the A/C service station”, page 36
♦ Observe test requirements
⇒ “9.1 Test requirements before the pressure test”, page 71 .

– Bring the engine speed to 2000 rpm.

– Observe the pressure gauge of the A/C service station.

Note

♦ Switching pressures of the pressure switch for the air condi‐

tioning system - F129- on the refrigerant circuit ⇒ Heating, Air
Conditioning; Rep. gr. 87 .
♦ The pressures must be measured on the service connections,
the fitting location of these connections is specifically designed
for vehicles.

Specified values
High-pressure side:
From the output pressure (when connecting the pressure gauge)
rising up to maximum 20 bar overpressure.
Low-pressure side:
From the output pressure (when connecting the pressure gauge)
dropping to diagram value.
A - High pressure in bar overpressure. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
B - Low pressure in bar overpressure. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

C - Permissible tolerance range.

78 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure remains constant or in‐ Too little refrigerant in the cir‐ – Drain the refrigerant from
creases only slightly (above the pres‐cuit or expansion valve defec‐ the refrigerant circuit.
sure while engine is not running), tive.
• The volume of refrigerant
• Low pressure drops quickly to diagram suctioned out corresponds
value or lower, approximately to the speci‐
• The required cooling capacity is not fied filling capacity:
reached. – Replace the expansion
valve.

– Newly filling the refrigerant

circuit.

– Repeat check.

• The volume of refrigerant

suctioned out is considera‐
bly less than the specified
filling capacity:
– Search for leaks with the
leak detector, eliminate.

– Newly filling the refrigerant

circuit.

– Repeat check.
• High pressure is normal,
• Low pressure corresponds to the dia‐
gram value,
• The required cooling capacity is not
reached.

Note

If no fault is found for this complaint, clean the refrigerant circuit

⇒ “7 Removing contaminants from the refrigerant circuit”,
page 52 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

79
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
9. Check the pressure in the refrigerant circuit (with the A/C service station)
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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure increases above the ♦ Constriction or blockage in – Feel the temperature gradi‐
specified value, the refrigerant circuit. ent of the refrigerant circuit
with the hand.
• Low pressure drops quickly to diagram ♦ Expansion valve defective.
value or lower, • A temperature gradient is
• The required cooling capacity is not noticed on a component:
reached. – In case a hose line or a pipe
is bent or constricted, re‐
place this component.

– In case of a blockage, clean

refrigerant circuit
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 , if neces‐
sary replace the expansion
valve.

• If no fault is found:
– Clean refrigerant circuit
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 , if neces‐
sary replace the expansion
valve.

– Repeat check.

Note

If the function is not in order after cleaning the refrigerant circuit,

the expansion valve must be replaced.

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure and low pressure is nor‐ ♦ Expansion valve defective. – Replace the fluid reservoir
mal at first, or only the desiccator (spe‐
♦ Humidity in the refrigerant cifically designed for vehi‐
• after a certain period of time the high circuit. cles) and evacuate the re‐
pressure rises above the specified value frigerant circuit for at least 3
if the low pressure drops to diagram val‐ hours (see notes).
ue or lower,
• the required cooling capacity is no lon‐ – Check the expansion valve
ger reached. for contamination or corro‐
sion and replace if neces‐
sary.

– Clean the refrigerant circuit

⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 .
• High pressure and low pressure is nor‐
mal at first.
• After a longer operating time, the low
pressure drops remarkably low (evapo‐
rator ices up).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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Air conditioning system with refrigerant R134a - Edition 05.2017

Note

♦ If problems arise due to humidity in the refrigerant circuit, only

after a longer operating time or only occasionally (the low
pressure drops below the specified value and the evaporator
ices up), it is adequate to replace the desiccator (the volume
of refrigerant oil must be adapted). Subsequently the refriger‐
ant circuit must be evacuated for at least 3 hours.
♦ First of all, it is not required to clean the refrigerant circuit for
this complaint (to flush with refrigerant R134a or to blow
through with compressed air and nitrogen), as normally only
a small amount of humidity is present in the system which can
be removed through a longer period of evacuation.

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure is normal or too high, ♦ Too much refrigerant in the – Drain the refrigerant from
circuit. the refrigerant circuit.
• Low pressure is too high (see diagram),
♦ Expansion valve or AC • The volume of refrigerant
• The required cooling capacity is not compressor defective.
reached, suctioned out corresponds
approximately to the speci‐
• the AC compressor makes noises (es‐ fied filling capacity:
pecially after switching it on).
– Replace the expansion
valve.

– does
Newly fillingorthe refrigerant
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. not guarantee accept any liability
with respect to the correctness of information in this document.circuit.
Copyright by ŠKODA AUTO A. S.�

– Repeat check.

• The volume of refrigerant

suctioned out is considera‐
bly more than the specified
filling capacity:
– Newly filling the refrigerant
circuit.
– Repeat check.

Note

If the function of the air conditioning system is not O.K. when re‐
peating the test, re-exchange expansion valve and clean refrig‐
erant circuit
⇒ “7 Removing contaminants from the refrigerant circuit”,
page 52 . Subsequently replace AC compressor and fluid reser‐
voir with desiccator or only desiccator (specifically designed for
vehicles).

9. Check the pressure in the refrigerant circuit (with the A/C service station) 81
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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure increases only slightly AC compressor defective. – Clean the refrigerant circuit
above the pressure while engine is not ⇒ “7 Removing contami‐
running, nants from the refrigerant
circuit”, page 52 .
• Low pressure drops only slightly,
• The required cooling capacity is not – Replace AC compressor
reached. and fluid reservoir with des‐
iccator or only desiccator
(specifically designed for
vehicles).

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure is normal, Expansion valve or AC com‐ – Replace the expansion
pressor defective. valve.
• Low pressure is too low (see diagram),
• the required cooling capacity is – Newly filling the refrigerant
reached. circuit.

– Repeat check.

Note

♦ If the function of the air conditioning system is not O.K. when

repeating the test, re-exchange expansion valve and clean
refrigerant circuit
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 . Subsequently replace AC compressor and fluid reservoir
with desiccator or only desiccator (specifically designed for
vehicles).
♦ If this fault occurs, it can happen that the evaporator ices up
although theProtected
volume of refrigerant
by copyright. Copying forin the orcircuit
private is O.K.
commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure and low pressure is nor‐ Too much refrigerant oil in the – Drain refrigerant circuit.
mal, refrigerant circuit.
– Clean the refrigerant circuit
• The required cooling capacity is not ⇒ “7 Removing contami‐
reached. nants from the refrigerant
circuit”, page 52 .
• High pressure and low pressure is nor‐ – Newly filling the refrigerant
mal, circuit.
• the AC compressor makes noises (es‐
pecially after switching it on),
• the required cooling capacity is
reached.

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Note

♦ Over-filling with refrigerant oil can occur if, for example, the AC
compressor has been replaced without matching the volume
of refrigerant oil.
♦ If too much refrigerant oil is present in the refrigerant circuit,
the AC compressor must be emptied and the fluid reservoir
with the desiccator or only the desiccator (specifically de‐
signed for vehicles) must be replaced. After the refrigerant
circuit has been cleaned
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 , fill the correct volume of refrigerant oil into the circuit.

9.6 Pressure test for vehicles with expan‐

sion valve, fluid reservoir and with reg‐
ulating valve for compressor of air
conditioning system - N280- (with AC
compressor regulated from the outside)

Note

♦ Connect A/C service station

⇒ “5 Working with the A/C service station”, page 36
♦ Observe test requirements
⇒ “9.1 Test requirements before the pressure test”, page 71 .

– Bring the engine speed to 2000 rpm.

– Observe the pressure gauge of the A/C service station.

Note

The pressures must be measured on the service connections, the

fitting location of these connections is specifically designed for
vehicles. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ “9.6.1 Specified values”, page 83

9.6.1 Specified values

High-pressure side:
From the output pressure (when connecting the pressure gauge)
rising up to maximum 20 bar overpressure.

9. Check the pressure in the refrigerant circuit (with the A/C service station) 83
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Air conditioning system with refrigerant R134a - Edition 05.2017

Low-pressure side:
From the output pressure (when connecting the pressure gauge)
dropping to diagram value.
A - Low pressure (measured on the service connection) in bar
absolute pressure.
B - The control current for the regulating valve for compressor of
air conditioning system -N280- in amps.
C - Permissible tolerance range (valid for A/C compressor load
between 10...90%)

Note

♦ The pressure on the high-pressure side can rise to maximum

29 bar under unfavourable conditions (very high ambient tem‐
peratures, high humidity) and the performance of the air con‐
ditioning system may not always suffice in order to reach the
given value.
♦ The control current -B- is indicated ⇒ Vehicle diagnostic tester
in the measured value block of the control and display unit for
air conditioner Climatronic - E87- or the Climatronic control
unit - J255- .
♦ The high pressure measured by the high pressure sender -
G65- is displayed in the measured
Protected value
by copyright. Copyingblock ⇒ Vehicle
for private or commercial purposes, in part or in whole, is not permitted
diagnostic tester. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ The low pressure settles in the tolerance range in line with the
control current for the regulating valve for compressor of air
conditioning system - N280- within the performance range of
the AC compressor.
♦ The specified working current for the regulating valve must be
greater than 0.3 A so that the regulating valve is easily actu‐
ated.
♦ On the setting “maximum refrigerating capacity” the control
current is regulated to approx. 0.65 A up to 0.8 A (specifically
designed for vehicles, displayed in the measured value block).

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure remains constant or in‐ ♦ The actuation of the regu‐ – Check the actuation of the
creases only slightly (above the pres‐ lating valve for compressor regulating valve for com‐
sure while engine is not running), of air conditioning system - pressor of air conditioning
N280- is incorrect. system - N280- .
• Low pressure drops quickly to diagram
value or lower, ♦ Too little refrigerant in the – Drain the refrigerant from
circuit. the refrigerant circuit.
• The required cooling capacity is not
reached. ♦ Expansion valve defective.
• The volume of refrigerant
suctioned out is considera‐
bly less than the specified
filling capacity:

• High pressure is normal, – Search for leaks with the

leak detector, eliminate.
• Low pressure corresponds to the dia‐
gram value, – Newly filling the refrigerant
• The required cooling capacity is not circuit.
reached.
– Repeat check.

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Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure is normal, • The volume of refrigerant
suctioned out corresponds
• Low pressure is too low (see diagram), approximately to the speci‐
• The required cooling capacity is not fied filling capacity:
reached. – Replace the expansion
valve.

– Newly filling the refrigerant

circuit.

– Repeat check.

Note

♦ If no fault is found for this complaint, clean the refrigerant cir‐

cuit
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 .
♦ Check the measured values of the evaporator vent tempera‐
ture sender - G263- and the actuation of the regulating valve
for compressor of air conditioning system - N280- . If the
measured value of the evaporator vent temperature sender -
G263- is incorrect, the evaporator can ice up and the cooling
capacity is not reached.
♦ If the function of the air conditioning system is not O.K. when
repeating the test after replacing the expansion valve (re-ex‐
change expansion valve), clean refrigerant circuit
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 . Subsequently replace AC compressor and fluid reservoir
with desiccator or only desiccator (specifically designed for
vehicles).
♦ If the expansion valve is defective (it is closed constantly or it
does not open up wide enough) the regulating valve for com‐
pressor of air conditioning system - N280- is actuated to
maximum performance and the low pressure drops to the di‐
agram value or lower (the AC compressor suctions the refrig‐
erant out of the low pressure side). As no refrigerant can flow
through the expansion valve, the cooling capacity is not
reached, perhaps the high pressure does not rise or only rises
slightly because no energy turnover exists.
♦ If this fault occurs, it can happen that the evaporator ices up
although the volume of refrigerant in the circuit is O.K.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure increases only slightly ♦ The actuation of the regu‐ – Check the actuation of the
above the pressure while engine is not lating valve for compressor regulating valve for com‐
running, of air conditioning system - pressor of air conditioning
N280- is incorrect. system - N280- .
• Low pressure drops only slightly,
♦ AC compressor defective. – Clean the refrigerant circuit
• The required cooling capacity is not
reached. ⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 .

– Replace AC compressor.

9. Check the pressure in the refrigerant circuit (with the A/C service station) 85
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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure increases above the ♦ The actuation of the regu‐ – Check the actuation of the
specified value, lating valve for compressor regulating valve for com‐
of air conditioning system - pressor of air conditioning
• Low pressure drops quickly to diagram N280- is incorrect. system - N280- .
value,
♦ Constriction or blockage in – Feel the temperature gradi‐
• The required cooling capacity is not the refrigerant circuit.
reached. ent of the refrigerant circuit
♦ Expansion valve defective. with the hand.

• A temperature gradient is
noticed on a component:
– In case a hose line or a pipe
is bent or constricted, re‐
place this component.

– In case of a blockage, clean

refrigerant circuit
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 , if neces‐
sary replace the expansion
valve.

• If no fault is found:
– Clean refrigerant circuit
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 , if neces‐
sary replace expansion
valve and fluid reservoir
with desiccator or only des‐
iccator (specifically de‐
signed for vehicles).

– Repeat check.

Note

♦ If this fault occurs, it can happen that the evaporator ices up

although the volume of refrigerant
unlessinauthorised
the circuit is O.K.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ If the expansion valve is defective (it is closed constantly or it
does not open up wide enough) the regulating valve for com‐
pressor of air conditioning system - N280- is actuated to
maximum performance and the low pressure drops to the di‐
agram value or lower (the AC compressor suctions the refrig‐
erant out of the low pressure side). As no refrigerant can flow
through the expansion valve, the cooling capacity is not
reached, perhaps the high pressure does not rise or only rises
slightly because no energy turnover exists.

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Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure and low pressure is nor‐ ♦ The actuation of the regu‐ – Check the actuation of the
mal at first, after a certain period of op‐ lating valve for compressor regulating valve for com‐
erating time: of air conditioning system - pressor of air conditioning
N280- is incorrect. system - N280- .
– the high pressure increases above the
specified value, ♦ Humidity in the refrigerant – Check expansion valve for
circuit. dirt or corrosion, replace if
– the low pressure drops to diagram value necessary.
or lower,
– Replace fluid reservoir with
– the required cooling capacity is no lon‐ desiccator or only desicca‐
ger reached. tor (specifically designed
for vehicles) see notes.
• High pressure and low pressure is nor‐ – Evacuate the refrigerant cir‐
mal at first, after a longer period of op‐ cuit for at least 3 hours.
erating time:
– Repeat the test after refill‐
– if the low pressure drops below the ing the circuit.
specified value (evaporator ices up).

Note

♦ If problems arise due to humidity in the refrigerant circuit only

after a longer operating time or only occasionally (the low
pressure drops below the specified value and the evaporator
ices up), it is adequate to replace the desiccator (the volume
of refrigerant oil must be adapted
⇒ “10.5 Replace AC reservoir/desiccator/restrictor/expansion
valve”, page 94 ). Subsequently the refrigerant circuit must
be evacuated for at least 3 hours.
♦ First of all, it is not required to clean the refrigerant circuit for
this complaint (to flush with refrigerant R134a or to blow
through with compressed air and nitrogen), as normally only
a small amount of humidity is present in the system which can
be removed through a longer period of evacuation.
♦ If this fault occurs, it can happen that the evaporator ices up
although the volume of refrigerant in the circuit is O.K.
♦ Due to a fault on the evaporator vent temperature sender -
G263- the refrigerant circuit can also ice up. For this complaint,
also observe the measured value of this sender ⇒ Vehicle di‐
agnostic tester

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

9. Check the pressure in the refrigerant circuit (with the A/C service station) 87
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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure is normal, ♦ The actuation of the regu‐ – Check the actuation of the
lating valve for compressor regulating valve for com‐
• Low pressure is too low (see diagram), of air conditioning system - pressor of air conditioning
• the required cooling capacity is N280- is incorrect. system - N280- .
reached. ♦ Expansion valve or AC – Clean the refrigerant circuit.
compressor defective. ⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 , if neces‐
sary replace expansion
valve and fluid reservoir
with desiccator or only des‐
iccator (specifically de‐
signed for vehicles) see
notes.

– Repeat the test after refill‐

ing the circuit.

– If the function is N.O.K., re‐

place A/C compressor.

Note

♦ In the event of a “High pressure normal, low pressure too low”

error, please note the following: This error may cause the
evaporator to freeze evenunless
though
Protected bythe amount
copyright. Copyingofforrefrigerant in purposes, in part or in whole, is not permitted
private or commercial
the circuit is OK. authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ If the fault occurs on the regulating valve for compressor of air

conditioning system - N280- (the regulating valve is not actu‐
ated and the AC compressor however keeps running) it is not
required to clean the refrigerant circuit (flush with refrigerant
R134a or blow through with compressed air and nitrogen). If
this fault occurs, it is sufficient to replace the AC compressor
(adapt the volume of refrigerant oil in the new AC compressor
⇒ “10.4 Replace AC compressor.”, page 93 ).
♦ If the expansion valve is defective (it is closed constantly or it
does not open up wide enough) the regulating valve for com‐
pressor of air conditioning system - N280- is actuated to
maximum performance and the low pressure drops to the di‐
agram value or lower (the AC compressor suctions the refrig‐
erant out of the low pressure side). As no refrigerant can flow
through the expansion valve, the cooling capacity is not
reached, perhaps the high pressure does not rise or only rises
slightly because no energy turnover exists.
♦ Due to a fault on the evaporator vent temperature sender -
G263- the refrigerant circuit can also ice up. Also observe the
measured value of this sender ⇒ Vehicle diagnostic tester

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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure is normal or too high, ♦ The actuation of the regu‐ – Check the actuation of the
lating valve for compressor regulating valve for com‐
• Low pressure is too high (see diagram), of air conditioning system - pressor of air conditioning
• the AC compressor makes noises (es‐ N280- is incorrect. system - N280- .
pecially after switching it on), ♦ Too much refrigerant in the – Drain the refrigerant from
• The required cooling capacity is not circuit. the refrigerant circuit.
reached. ♦ Expansion valve defective.
• The volume of refrigerant
suctioned out is considera‐
bly more than the specified
filling capacity:
– Newly fill the refrigerant cir‐
cuit and repeat the test.

• The volume of refrigerant

suctioned out corresponds
approximately to the speci‐
fied filling capacity:
– Replace the expansion
valve.

– Newly fill the refrigerant cir‐

cuit and repeat the test.

– If the function is N.O.K.:

♦ Too much refrigerant oil in – Drain the refrigerant from
the refrigerant circuit. the refrigerant circuit.
♦ AC compressor defective. – Clean the refrigerant circuit.
⇒ “7 Removing contami‐
nants from the refrigerant
circuit”, page 52 , replace
fluid reservoir with desicca‐
tor or only desiccator (spe‐
cifically designed for vehi‐
cles).

– Newly fill the refrigerant cir‐

cuit and repeat the test.

– If the function is N.O.K., re‐

place A/C compressor.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Note

The cause of this fault may also be a surplus of refrigerant oil in

the circuit. Over-filling with refrigerant oil can occur if, for example,
the AC compressor has been replaced without matching the vol‐
ume of refrigerant oil.

9. Check the pressure in the refrigerant circuit (with the A/C service station) 89
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Air conditioning system with refrigerant R134a - Edition 05.2017

Possible deviation from the specified value Possible cause of fault Rectifying fault
• High pressure and low pressure is nor‐ ♦ The actuation of the regu‐ – Check the actuation of the
mal, lating valve for compressor regulating valve for com‐
of air conditioning system - pressor of air conditioning
• The required cooling capacity is not N280- is incorrect. system - N280- .
reached.
♦ Too much refrigerant oil in – Clean the refrigerant circuit.
the refrigerant circuit. ⇒ “7 Removing contami‐
♦ Expansion valve defective. nants from the refrigerant
circuit”, page 52 .

– Newly fill the refrigerant cir‐

cuit and repeat the test.
• High pressure and low pressure is nor‐ – If the function is N.O.K., re‐
mal, place expansion valve.
• the AC compressor makes noises (es‐
pecially after switching it on),
• The required cooling capacity is not
reached.

Note

♦ Over-filling with refrigerant oil can occur if, for example, the AC
compressor has been replaced without matching the volume
of refrigerant oil.
♦ If the expansion valve is defective (always open), the evapo‐
rator temperature is no longer regulated in such a way that
only gaseous refrigerant leaves the evaporator. Under certain
operating conditions, liquid drops can then be sucked into the
AC compressor, this then leads to noises (liquid cannot be
compressed).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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Air conditioning system with refrigerant R134a - Edition 05.2017

10 Replace components of the refriger‐

ant circuit
⇒ “10.1 Replace parts on the refrigerant circuit - General instruc‐
tions”, page 91
⇒ “10.2 Components of the refrigerant circuit leaking or damaged
- the refrigerant circuit is absolutely empty”, page 92
⇒ “10.3 Components of the refrigerant circuit leaking or damaged
- refrigerant is still in the refrigerant circuit”, page 93
⇒ “10.4 Replace AC compressor.”, page 93
⇒ “10.5 Replace AC reservoir/desiccator/restrictor/expansion
valve”, page 94

10.1 Replace parts on the refrigerant circuit -

General instructions
• All the components of the refrigerant circuit, which are sent in
for quality monitoring, must always be closed (use original
screw caps of the original part).
• The original parts (AC compressor, catch pan, evaporator,
condenser) were previously filled with nitrogen gas. This filling
of nitrogen gas escapes uniformly, more specifically, the pres‐
sure of the nitrogen filling is now so low that when opening for
the first time, it is no longer noticeable that gas escapes.
• On vehicles with an AC compressor without magnetic cou‐
pling, the engine must only be started if the refrigerant circuit
is correctly assembled, see
⇒ “1.15.3 Additional work on vehicles with AC compressor
without magnetic coupling ”, page 15 .
• So that the AC compressor with the regulating valve for com‐
pressor of air conditioning system - N280- suffers no damage
when the refrigerant circuit is empty, it is fitted with a secured
oil supply. This means that approx. 40 to 50 cm3 of refrigerant
oil is left in the AC compressor.
Two refrigerant circuit systems are installed:
♦ Refrigerant circuit with throttle and catch pan with integrated
desiccator (Superb l)
♦ Refrigerant circuit with expansion valve and fluid reservoir with
installed desiccator (all types except Superb l)
The catch pan / fluid reservoir / desiccator must not be replaced
under the following conditions:
♦ After an accident, but without any visible damage to the catch
pan / fluid reservoir, and if the refrigerant circuit was not
opened.
♦ The repair (replacement of defective components) is per‐
formed for a short period and no humidity has penetrated
(during the repair the components were immediately closed
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with screw caps after separatingwith
them in toorder
respect to avoid
the correctness any in this document. Copyright by ŠKODA AUTO A. S.�
of information
humidity from penetrating).

10. Replace components of the refrigerant circuit 91

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Air conditioning system with refrigerant R134a - Edition 05.2017

The catch pan / fluid reservoir / desiccator must be replaced under

the following conditions:

Note

♦ On vehicles with expansion valve the desiccator is arranged

as a separate component and thus the reservoir must not be
completely replaced yet, only the desiccator, see ⇒ Heating,
Air Conditioning; Rep. gr. 87 and ⇒ Electronic Catalogue of
Original Parts “ETKA” .
♦ The new generation of fluid reservoirs is directly installed on
the condenser and is therefore inseparably connected to it.

• The refrigerant circuit has been opened as of an undetermined

time (creeping leakage).
• The repair extends beyond the normal repair time and humid‐
ity has penetrated.
• The refrigerant circuit was blown through with compressed air
and nitrogen or was flushed with refrigerant R134a.
• The AC compressor has blocked (inner damage).
• The catch pan / fluid reservoir is damaged (accident).

10.2 Components of the refrigerant circuit

leaking or damaged - the refrigerant cir‐
cuit is absolutely empty

Note

♦ If it is only a minor leakage and the refrigerant has creepingly

escaped, the loss of the refrigerant oil and the penetration of
humidity have nearly no influence on the function of the air
conditioning system.
♦ Only carry out the work steps marked with an * for major leaks
(e.g. after an accident).

– Remove the defective component and replace it.

– Remove the A/C compressor. *
– If dirt penetrated into the AC compressor when the refrigerant
circuit was opened (e.g. during an accident), the AC compres‐
sor must be replaced.*
– Remove the oil drain plug from the AC compressor and drain
oil. In order to speed up the evacuation of the refrigerant oil,
turn the AC compressor with the clutch disk of the magnetic
coupling by hand (disposal of used oil
⇒ “3 Legal texts and legal regulations”, page 33 ).*
– Subsequently fill new refrigerant oil into the AC compressor (if
it is not replaced). The oil quantity and the oil type correspond
to the refrigerant oil volume in the new AC compressor, see ⇒
Heating, Air Conditioning; Rep. gr. 87 .*
– Flush the refrigerant circuit with the refrigerant R134a, if this
is not possible, blow through with compressed air and then
with nitrogen
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 .*
– Replace catch pan and throttle/fluid reservoir with desiccator
(or only desiccator, specifically designed for vehicles)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
92 Rep. gr.00 - Technical data
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⇒ “10.5 Replace AC reservoir/desiccator/restrictor/expansion

valve”, page 94 .
– Assemble the refrigerant circuit, evacuate and fill again.
– Check the function of the air conditioning system.

10.3 Components of the refrigerant circuit

leaking or damaged - refrigerant is still
in the refrigerant circuit
– Empty the refrigerant circuit with the aid of the A/C service
station.
– Remove defective component, blow through with compressed
air and while doing so collect any refrigerant oil which flows
out (disposal of used oil
⇒ “3 Legal texts and legal regulations”, page 33 ).
– The volume of refrigerant oil blown out must be filled into the
new component as fresh refrigerant oil volume, plus:
♦ for the evaporator - 20 cm3
♦ for the condenser, coolant pipes and refrigerant hoses - 10
cm3.
– Vehicles with throttle - replace restrictor.
– Assemble the refrigerant circuit, evacuate and fill again.
– Check the function of the air conditioning system.

10.4 Replace AC compressor.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
⇒ “10.4.1 When there is no need to eliminate impurities
with respect in the
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
refrigerant circuit e.g. for external damage after an accident”,
page 93
⇒ “10.4.2 An inner damage (e.g. noise or no performance)”, page
94

10.4.1 When there is no need to eliminate im‐

purities in the refrigerant circuit e.g. for
external damage after an accident
– Empty the refrigerant circuit with the aid of the A/C service
station.
– Remove the air conditioning compressor.
– Unscrew the oil drain plug from the removed AC compressor
and drain oil. In order to speed up the evacuation of the re‐
frigerant oil, turn the AC compressor with the clutch disk of the
magnetic coupling. Collect oil in a measuring vessel (disposal
of used oil ⇒ “3 Legal texts and legal regulations”, page 33 ).
– Drain oil out of the new A/C compressor using the same meth‐
od (attention - do not mix with the oil out of the removed A/C
compressor) and fill in again an amount of refrigerant oil which
corresponds to the oil quantity drained (the refrigerant oil
drained from the original part A/C compressor maybe used).
Example:
If 70 cm3 of refrigerant oil was drained out of the defective AC
compressor and 140 cm3 of refrigerant oil was drained out of the
original part AC compressor (a small amount of refrigerant oil re‐
mains in the AC compressor). In this case, fill in 70 cm3 of
refrigerant oil into the installed AC compressor.
– Vehicles with throttle - replace restrictor.

10. Replace components of the refrigerant circuit 93

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– Assemble the refrigerant circuit, evacuate and fill again.

– Check the function of the air conditioning system.

10.4.2 An inner damage (e.g. noise or no per‐

formance)
– Empty the refrigerant circuit with the aid of the A/C service
station.
– Remove the air conditioning compressor.
– Flush the refrigerant circuit with the refrigerant R134a, if this
is not possible, blow through with compressed air and then
with nitrogen ⇒ page 52 .
– Replace catch pan and throttle/fluid reservoir with desiccator
or only desiccator (specifically designed for vehicles).
– Assemble the refrigerant circuit, evacuate and fill again.
– Check the function of the air conditioning system.

10.5 Replace AC reservoir/desiccator/re‐

strictor/expansion valve
⇒ “10.5.1 Because of humidity which has penetrated (the refrig‐
erant circuit was opened over a longer period of time) (e.g. after
an accident) or inner damage on the A/C compressor”,
page 94
⇒ “10.5.2 Because of outer damage (e.g. caused by an accident),
no refrigerant has flown out and no humidity and no dirt has pe‐
netrated into the circuit”, page 95

10.5.1 Because of humidity which has penetra‐

ted (the refrigerant circuit was opened
over a longer period of time) (e.g. after
an accident) or inner damage on the A/
C compressor
– Empty the refrigerant circuit with the aid of the A/C service
station.
– Remove the air conditioning compressor.
– Eliminate fault cause.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Flush the refrigerant circuit with
unless the refrigerant
authorised by ŠKODA R134a,
AUTO A. S.ifŠKODA
this AUTO A. S. does not guarantee or accept any liability
is not possible, blow through with compressed
with respect air of
to the correctness and then in this document. Copyright by ŠKODA AUTO A. S.�
information
with nitrogen
⇒ “7 Removing contaminants from the refrigerant circuit”, page
52 .
– Check the expansion valve for contamination or corrosion and
replace if necessary; for vehicles with restrictor, replace re‐
strictor.
– Replace fluid reservoir with desiccator or only desiccator (de‐
pending on vehicle).
– If the AC compressor is not replaced:
♦ Unscrew the oil drain plug from the removed AC compressor
and drain oil. In order to speed up the evacuation of the re‐
frigerant oil, turn the AC compressor with the clutch disk of the
magnetic coupling by hand (disposal of used oil
⇒ “3 Legal texts and legal regulations”, page 33 ).
♦ Fill the volume of new refrigerant oil, which corresponds to the
refrigerant oil volume in the original part AC compressor, into

94 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

the removed AC compressor ⇒ Heating, Air Conditioning;

Rep. gr. 87 .
– If the AC compressor is replaced:
♦ A new original part A/C compressor is filled with a refrigerant
oil volume required for the complete refrigerant circuit.
– Assemble the refrigerant circuit, evacuate and fill again.
– Check the function of the air conditioning system.

10.5.2 Because of outer damage (e.g. caused

by an accident), no refrigerant has flown
out and no humidity and no dirt has pe‐
netrated into the circuit
– Empty the refrigerant circuit with the aid of the A/C service
station.
– Vehicles with throttle - replace restrictor.
– Remove fluid reservoir/catch pan and remove any heavy dirt.
– Weigh the removed and cleaned fluid reservoir/catch pan.
– Fill as much refrigerant oil into the new fluid reservoir/catch
pan until it has reached the weight of the removed reservoir.
– Assemble the refrigerant circuit, evacuate and fill again.
– Check the function of the air conditioning system.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

10. Replace components of the refrigerant circuit 95

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11 Tools and materials, which are avail‐

able from the importer
⇒ “11.1 Setting up tools and materials which are available from
the importer”, page 96
⇒ “11.2 A/C service station”, page 97
⇒ “11.3 Flushing device for the refrigerant circuits 6337/1 or fol‐
low-up models (manufacturer Behr)”, page 98
⇒ “11.4 Flushing device for the refrigerant circuits 6336/1 or fol‐
low-up models (manufacturer Waeco)”, page 98
⇒ “11.5 Leak detector V.A.G 1796 ”, page 98
⇒ “11.6 Leak detection system VAS 6196 ”, page 99
⇒ “11.7 Leak detection system VAS 6201A ”, page 99
⇒ “11.8 Adapter case of motor car set VAS 6338/1 ”, page 99
⇒ “11.9 Release tools VAS 6127/3 ”, page 99
⇒ “11.10 Socket T10364 ”, page 100

11.1 Setting up tools and materials which are available from the importer
This record serves as an overview of the test installations, A/C
service stations, tools and materials necessary for the professio‐
nal repair of the refrigerant circuit.

Caution

Non-approved tools or materials (e.g. stop leak additive) can

cause damage/deterioration to the components of the refrig‐
erant circuit or to the used service installations.
Only tools and materials approved by the manufacturer may
be used.
There is no guarantee if non-approved tools or materials were
used.

Overview Page
A/C service station, e.g. A/C service station with flushing device - VAS 6380A- or currently ⇒ “11.2 A/C serv‐
available service positions, see ⇒ Catalogue of factory equipment ice station”,
page 97
Flushing device for the refrigerant circuits - 6337/1- (currently available flushing devices ⇒ “11.3 Flushing
⇒ Catalogue of factory equipment ) device for the re‐
♦ Use on older A/C service stations for flushing the refrigerant circuit with refrigerant frigerant circuits
R134a. 6337/1 or follow-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted up models (man‐
♦ The reservoir volumeunless in the A/C
authorised service
by ŠKODA AUTO station is atAUTO
A. S. ŠKODA least
A. S.10 kgnotofguarantee
does refrigerant
or acceptR134a.
any liability ufacturer Behr)”,
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
page 98
Flushing device for the refrigerant circuits - 6336/1- (currently available flushing devices ⇒ “11.4 Flushing
⇒ Catalogue of factory equipment ) device for the re‐
♦ Use on older A/C service stations for flushing the refrigerant circuit with refrigerant frigerant circuits
R134a. 6336/1 or follow-
up models (man‐
♦ The reservoir volume in the A/C service station is at least 10 kg of refrigerant R134a. ufacturer Wae‐
co)”, page 98
Leak detector - V.A.G 1796- ⇒ “11.5 Leak de‐
tector V.A.G
1796 ”,
page 98

96 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

Overview Page
Leak detection system - VAS 6196- ⇒ “11.6 Leak de‐
tection system
VAS 6196 ”, page
99
Leak detection system - VAS 6201A- ⇒ “11.7 Leak de‐
tection system
VAS 6201A ”,
page 99
Leak detection additive, e. g. -VAS 6196/1- not shown
Adapter case of motor car set - VAS 6338/1- ⇒ “11.8 Adapter
♦ for connecting the A/C service station to the refrigerant circuit and bridging certain case of motor car
components when flushing with refrigerant R134a or blowing through with compressed set VAS 6338/1 ”,
air and nitrogen page 99

Ultrasonic air conditioning system cleaning device - VAS 6189B- not shown
♦ for eliminating unpleasant odours, caused by the air conditioning system (⇒ Catalogue
of factory equipment )

Release tools - VAS 6127/3- ⇒ “11.9 Release

♦ for separating the quick couplings from the refrigerant lines tools VAS 6127/3
”, page 99
Combination fine-filter unit for the compressed-air system, oil, dirt and water separator as not shown
is common for painting systems, see ⇒ Catalogue of factory equipment
O-rings ⇒ Electronic Catalogue of Original Parts “ETKA” not shown
Refrigerant oil ⇒ Electronic Catalogue of Original Parts “ETKA” not shown
Socket - T10364- ⇒ “11.10 Socket
♦ for removing and installing the extractor and filler valves of the air-conditioning system T10364 ”,
page 100

11.2 A/C service station

Except the stated A/C service station with flushing device - VAS
6380A- , other service stations and flushing devices can also be
used, which are approved by the company Škoda, see the current
⇒ Catalogue of factory equipment .
♦ Work procedures: testing, draining off (utilizing), delivering
(evacuating) and filling must be carried out according to the
enclosed operating instructions of the A/C service station.
♦ The installed filters and desiccators must be replaced at the
latest
Protected after reaching
by copyright. Copying for the operating
private or commercialtime specified
purposes, inwhole,
in part or in the related
is not permitted
operating
unless authorised byinstructions
ŠKODA AUTO A. and each
S. ŠKODA AUTOtime
A. S.after emptying
does not guarantee orthe
acceptA/C
any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
station (a new replacement filter must be available). Obtaina‐
ble from the device manufacturer, see ⇒ Operating instruc‐
tions .

11. Tools and materials, which are available from the importer 97
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11.3 Flushing device for the refrigerant cir‐

cuits - 6337/1- or follow-up models
(manufacturer Behr)

Note

♦ With filter -1- and two cylindrical inspection glasses.

♦ Depending on the type and intensity of the contamination of
the flushed refrigerant circuits, the filter in the flushing device
for refrigerant circuits must be replaced no later than after 2
flushing cycles. If a heavily contaminated refrigerant circuit is
flushed (the refrigerant oil from the refrigerant circuit is black
and viscous or there is a lot of swarf in the refrigerant circuit),
the filter must be replaced after only flushing the one refriger‐
ant circuit.

11.4 Flushing device for the refrigerant cir‐

cuits - 6336/1- or follow-up models
(manufacturer Waeco)

Note

♦ With filter -1- and one inspection glass.

♦ Depending on the type and intensity of the contamination of
the flushed refrigerant circuits, the filter in the flushing device
for refrigerant circuits must be replaced no later than after 2
flushing cycles. If a heavily contaminated refrigerant circuit is
flushed (the refrigerant oil from the refrigerant circuit is black
and viscous or there is a lot of swarf in the refrigerant circuit),
the filter must be replaced after byonly
Protected flushing
copyright. Copyingthe one orrefriger‐
for private commercial purposes, in part or in whole, is not permitted
ant circuit. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

11.5 Leak detector - V.A.G 1796-

Note

The work sequence for the leak detection must be carried out
according to the relevant operating instructions enclosed with the
device.

98 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

11.6 Leak detection system - VAS 6196-

Note

The work sequence for the leak detection must be carried out
according to the relevant operating instructions enclosed with the
device.

11.7 Leak detection system - VAS 6201A-

Note

The work sequence for the leak detection must be carried out
according to the relevant operating instructions enclosed with the
device.

11.8 Adapter case of motor car set - VAS

6338/1-

Note

Adapter for setting up the rinsing cycles (specifically designed for

vehicles), see
⇒ “7.4 Adapter for setting up the rinsing cycles”, page 61 .

11.9 Release tools - VAS 6127/3-

♦ green NW 8 for the high pressure line
♦ black NW 13 for the low pressure line

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

11. Tools and materials, which are available from the importer 99
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Air conditioning system with refrigerant R134a - Edition 05.2017

11.10 Socket - T10364-

Note

Description of use
⇒ “2.2 Extractor, filler and measurement valves for quick cou‐
plings of the AC service station on the refrigerant circuit”,
page 21 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

100 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

12 Tools and materials, which are com‐

mercially available
⇒ “12.1 Setting up tools and materials which are available from a
dealer”, page 101
⇒ “12.2 Filling hoses”, page 102
⇒ “12.3 Bottle connecting piece for pressure bottle”, page 102
⇒ “12.4 Valve caps with replacement gaskets ”, page 102
⇒ “12.5 Pressure gauge with pressure reducer for nitrogen”, page
103
⇒ “12.6 Quick-coupling adapter for service connections”,
page 103
⇒ “12.7 Tools, which you make yourself”, page 103

12.1 Setting up tools and materials which are available from a dealer

Caution

Non-approved tools or materials (e.g. stop leak additive) can

cause damage/deterioration to the components of the refrig‐
erant circuit or to the used service installations.
Only tools and materials approved by the manufacturer may
be used.
There is no guarantee if non-approved tools or materials were
used.

Overview Page
Filling hoses 5/8" - 18 UNF with valve opener ⇒ “12.2 Filling ho‐
ses”, page 102
Bottle connecting piece forunless
pressure
Protected by bottle for refrigerant and gasket ring with quick cou‐ ⇒ “12.3 Bottle
copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
permitted
pling connection or thread connection 5/8"
with respect to the - 18 UNF
correctness of information in this document. Copyright by ŠKODA AUTO A. connecting
S.� piece
for pressure bot‐
tle”, page 102
Valve caps 5/8" - 18 UNF ⇒ “12.4 Valve
caps with re‐
placement gas‐
kets ”, page 102
Pressure gauge with pressure reducer for nitrogen ⇒ “12.5 Pressure
gauge with pres‐
sure reducer for
nitrogen”,
page 103
2 pieces of quick-coupling adapters for service connections are included in the scope of ⇒ “12.6 Quick-
delivery of the A/C service station coupling adapter
for service con‐
nections”,
page 103
Open ring spanner; the spanner sizes correspond to the bolted connections at the coolant not shown
pipes
Valve opener for filling hoses not shown
Connecting nipple for conical surface seal 5/8" - 18 UNF not shown
Compressed air pistol with rubber mouthpiece not shown
Manual stop valve 5/8" - 18 UNF not shown
Recycling bottle for refrigerant R134a not shown

12. Tools and materials, which are commercially available 101

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Overview Page
Digital thermometer not shown
Protective gloves not shown
Protective goggles not shown
Refrigerant R134a with pressure bottle (content as needed) not shown
Nitrogen with pressure bottle not shown
Strap wrench (oil filter) as counterholder for V-ribbed belt pulley not shown

12.2 Filling hoses

Threads 5/8" - 18 UNF

Note

Filling hoses of different colours can be used, 1800 mm long.

12.3 Bottle connecting piece for pressure

bottle
For refrigerant with gasket ring, quick coupling connection or
thread connection 5/8" -18 UNF.

12.4 Valve caps with replacement gaskets

For threads 5/8" - 18 UNF.
Gaskets can also be used for filling hoses.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

102 Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 05.2017

12.5 Pressure gauge with pressure reducer

for nitrogen
Maximum reducing pressure: 15 bar.
1- Pressure gauge with pressure reducer
2- Pressure hose (inner diameter 5 mm, length 2 m) with hose
fittings
3- Nitrogen cylinder
4- Hose fitting

12.6 Quick-coupling adapter for service con‐

nections
♦ High-pressure side with nominal size 16 mm
♦ byLow-pressure
Protected side
copyright. Copying for with
private nominal
or commercial size 13
purposes, mm
in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

These quick couplings are included in the scope of delivery of the

A/C service station.

12.7 Tools, which you make yourself

Filling hose with connection for workshop compressed air system
A - Filling hose 5/8" - 18 UNF** (version with large inner diameter)
B - Connection for workshop compressed air system** (only op‐
erated with filter and desiccator for compressed air).
** Tools and materials, which are commercially available.

12. Tools and materials, which are commercially available 103

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