Skoda 2012 Citigo Instruction manual

Workshop Manual
Citigo 2012 ➤ , Fabia 2000 ➤ ,
Fabia II 2007 ➤ , Fabia II 2009 ➤ ,
Fabia II 2011 ➤ , Fabia III 2015 ➤ ,
Octavia 1997 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Octavia III 2013 ➤ ,
Octavia III 2014 ➤ , Rapid 2011 ➤ ,
Rapid NH 2013 ➤ , Roomster 2006 ➤ ,
Superb 2002 ➤ , Superb II 2008 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤
Air conditioning system with refrigerant R134a
Edition 10.2014
Service
Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
Service
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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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Pressures and temperatures in the refrigerant circuit and its arrangement . . . . . . . . . . . . 24
2.4 Switch and sender on the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5 Electrical components which are not fitted on the 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
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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 catch pan and throttle/fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.7 Leak detection system VAS 6201A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.8 Adapter case of motor car set VAS 6338/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.9 Case of release tools VAS 6127/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.10 Socket insert T10364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12 Tools and materials, which are commercially available . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12.1 Setting up tools and materials which are available from a dealer . . . . . . . . . . . . . . . . . . . . 100
12.2 Filling hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.3 Bottle connecting piece for pressure bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.4 Valve caps with replacement gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.5 Pressure gauge with pressure reducer for nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.6 Quick-coupling adapter for service connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.7 Tools, which you make yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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Air conditioning system with refrigerant R134a - Edition 10.2014
ii Contents
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00 – Technical data
1 General notes on the air conditioning
system
(SRL000755; Edition 10.2014)
⇒ “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 oil”, page 9
⇒ “1.11 General occupational safety”, page 9
⇒ “1.12 Using pressure tank”, page 11
⇒ “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 14
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.
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1. General notes on the air conditioning system 1
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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.
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
♦ ⇒ 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
4 - solid
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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 while maintaining
pressure, by lowering the temperature, the vapour turns to liquid
(in the condenser), or that, for example, by reducing the pressure,
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
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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. Of course, opening
the windows, sunroof or allowing a greater flow of air through the
vehicle can contribute to well-being of occupants, but this also
has disadvantages in the vehicle interior, e.g.: additional noise,
draughts. exhaust fumes, unfiltered entry of pollen (unpleasant
for persons with allergies).
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 mid-range car, e.g.: after a short period driving,
an outdoor temperature of 30 °C in the shade and the vehicle
under direct sunlight:
with air condition‐
ing system without air condi‐ 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 is a well known fact that heat spreads towards colder tem‐
peratures, an aggregate that generates lower temperatures has
been fitted to the vehicle, i.e. the evaporator. Liquid refrigerant is
continuously evaporated in this aggregate. The heat required for
this operation is drawn from the air flowing through the evapora‐
tor.
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‐
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perature of the refrigerant. It is now considerably higher than the
ambient air temperature.
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 6
⇒ “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)
1.6.2 Trade names and designations of the
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.
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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.
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 1.00
-5 1.43
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
Citigo 2012 ➤ , Fabia 2000 ➤ , Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fab ...
Air conditioning system with refrigerant R134a - Edition 10.2014
6 Rep. gr.00 - Technical data
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