V871622 2019947

Technical Bulletin
Model(s)
All Models
(except Routan)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
1998 - 2017
All
All
All
All
Condition
87 16 22 October 24, 2015 2019947 Supersedes T.B. V871516 dated November 20, 2015 to include new model
years.
Air Conditioning, Cleaning of the Refrigerant Circuit (U.S. Only)
Debris can be dispersed throughout the refrigerant circuit after a/c component damage. In order to maintain A/C
operating efficiency, it is important to flush the refrigerant circuit after A/C component repairs.
Technical Background
In cases where an air conditioning system component (such as a compressor or other system component) has
failed and debris from the compressor or component is circulated throughout the refrigerant circuit, the refrigerant
circuit must be cleaned of any and all debris or damage to the replacement components will result.
Production Solution
No production change required.
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© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service
Tools
 Use the ROB134APF Air Conditioning Service
System with VAS 6337/1A Air Conditioning
System Flushing Device (Figure 1) Used for
effective refrigerant handling and air conditioning
circuit flushing after air conditioning component
failure.
 Now air conditioning system refrigerant recovery,
evacuation, recharge and refrigerant circuit
cleaning after component failure can be performed
with a single servicing station.
Figure 1. The ROB134APF Air Conditioning
Service System with VAS 6337/1A Air
Conditioning System Flushing Device.
The VAS 6338/1 Adapter Set for Refrigerant Circuits. Along with an additional adapter (VAS 6338/33 for the
front expansion valve bypass for the Touareg) this kit contains the adapters necessary to complete a thorough
flush operation of a contaminated circuit.
Elsa contains the technical information for each model regarding the necessary adapter applications
and connections of the servicing station for the flush operation. See Heating, Ventilation & Air
Conditioning >> Refrigerant R134A-Servicing >> 00 General Technical Data>> Refrigerant Circuit
removing contaminates>> Refrigerant Circuit, Flushing with Refrigerant R134A in Elsa.
Note:
MY2016 Jetta, Passat and Beetle have a new expansion valve and a flush adaptor is currently
unavailable. The expansion valve is always replaced after flushing. It is recommended to drill out the
old expansion valve and use as the flush adaptor as per the Elsa Repair Manual.
All other refrigerant recovery, evacuation and recharge operations are performed using the usual procedure
specified in Elsa. An operations manual will accompany each servicing station that will describe operation of
the unit.
Page 2 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Procedure
Front A/C:
1. If an air conditioning component has been diagnosed as the root cause of the failure and this component is
suspected of releasing debris through the circuit, continue the diagnosis to determine if this is the case.
2. Turn the power to the servicing station on and begin by recovering the refrigerant from the system through the
normal service fittings.
Tip:
During the entire process avoid interrupting the power to the station. The station's internal memory will keep a log
of all operations and can conveniently be recalled and printed. If the power is interrupted, the station will lose the
memory of the process, and the oil volume recovered, oil volume added, refrigerant volume recovered, etc. will
have to be manually determined.
3. Disconnect the service hoses. The VAS 6338/1 adapters will be used to bypass the following:
 Compressor.
 Receiver-drier.
 Expansion Valve/ Restrictor (if equipped).
If vehicle is equipped with a restrictor, remove the restrictor and reconnect the line.
Note:
For models with receiver drier desiccant cartridge the desiccant cartridge must be removed for the flushing
process.
Before flushing the A/C circuit, inspect the Receiver-drier cartridge screen for any tears and for any desiccant
material that may have been released into the A/C circuit. If the Receiver-drier screen is torn, replace the
condenser prior to starting the flushing procedure.
For vehicles where the receiver drier is located on the condenser and DOES NOT have a remove-able desiccant
cartridge, the receiver drier must be left in the system and flushed through.
After the flush procedure is complete replace the receiver drier or drier cartridge.
Page 3 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 2. A flushing attachment port.
 This connection strategy allows for a system flush in the opposite direction of the normal refrigerant
flow (Figure 4).
Figure 4. Connection strategy: Vehicle to service station to flushing device.
Page 4 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 The flush program will begin with an evacuation
of the system and a rate of rise test. This is
necessary to test the integrity of the connections
before the flush cycles begin. If the rate of rise
test passes, the program will proceed into the
flush cycles. (Figures 5 – 7). These cycles will
occur automatically in succession.
Figure 5. The first cycle.
Page 5 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 6. The second cycle.
Page 6 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 7. The third cycle.
 The debris is then rinsed from the circuit and contained within the filtration in the flusher. After the flush
program, the system will be evacuated.
5. After the system is evacuated, remove any adapters that were installed from the VAS 6338/1.
6. Replace Expansion Valve (if equipped), Receiver-drier and Restrictor (if equipped).
7. Connect the station in the usual manner through the service fittings and perform the normal evacuation and
refrigerant recharge operations.
8. Print a log of the job and attach to the repair order.
Touareg with Four Zone Climate Control – Rear A/C
For Touareg with four zone climate control, the flush process will be repeated for the additional air conditioning
unit (rear of vehicle) according to the repair information in Elsa.
Page 7 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
1. Separate the front and rear air conditioning
systems for individual rinse operations.
The VAS 6338/1 contains the necessary adapters to
separate the systems for the individual rinse
operations.
Figure 8. The location of the connections inside
the left front wheelhouse on a Touareg with four
zone climate control.
Figure 9. Location of rear air conditioning unit
and expansion valve.
4. When complete, remove any adapters that were installed from the VAS 6338/1.
5. Replace defective components.
6. Connect the station in the usual manner through the service fittings and perform the normal evacuation and
refrigerant recharge operations.
7. Print a log of the job and attach to the repair order.
Page 8 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
A/C Components Replacement
The following components must be replaced:
 Expansion Valve (if equipped)
 Restrictor (if equipped)
 Receiver-drier
Warranty
Note:
The procedure outlined in this Technical Bulletin must be included with the warranty repair(s) and not claimed
independently.
You may claim $4.25 per A/C System flush for the A/C System Flush Machine Behr filter BAI783400103 (which
represents ¼ the cost of a replacement filter).
You may claim $17.88 per A/C System flush for the A/C System Flush Machine Bosch filter 17707-6 (which
represents ¼ the cost of a replacement filter).
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
All Models
(except Routan)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
1998 - 2017
All
All
All
All
SAGA Coding
Claim Type:
Service Number:
Use Service
Number of
Damaged
Component
Use applicable Claim Type 1)
Damage
Code
Use damage code
appropriate for root
cause of failure
Damage Location
HST
--
(Depends on
Service No.)
Use applicable
when indicated in
Elsa (L/R)
Parts Manufacturer
(removed part)
Use Vendor code
from failed
component
_ _ _2)
Page 9 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Labor Operation 3): Air Conditioner Clean, All
Vehicles, Front A/C only (except Touareg with four
zone climate control)
87012999 = 140 TU
Labor Operation 3) : Refrigerant drain and fill
87031700 = 60 TU
(2015> Golf/GTI, Golf R, Golf SportWagen Only)
Labor Operation 3) : Refrigerant drain and fill
87031700 = 50 TU
Labor Operation 3): Air Conditioner Clean, Touareg
with four zone climate control.
87013099 = 310 TU
Labor Operation 3): Air Conditioner Check, All
Vehicles.
87010150 = 30 TU
Labor Operation 3): Replace Expansion Valve, if
equipped.
8770XXXX = Claim appropriate SRT for vehicle and
engine in Elsa
Labor Operation 3): Replace Restrictor, if equipped.
8777XXXX = Claim appropriate SRT for vehicle and
engine in Elsa
Labor Operation 3): Replace Receiver-Drier
8755XXXX = Claim appropriate SRT for vehicle and
engine in Elsa
Outside Material: A/C Flush Machine Behr filter, Part $4.25 total per A/C System Flush which
No. BAI783400103
accompanies a repair (this amount equals ¼ of the
cost of the A/C flush machine filter)
OR
Outside Material: A/C Flush Machine Bosch filter,
Part No. 17707-6
$17.88 total per A/C System Flush which
accompanies a repair (this amount equals ¼ of the
cost of the A/C flush machine filter)
Diagnostic Time 4)
GFF Time expenditure
01500000 = 00 TU max.
NO
Road Test
01210002 = 00 TU
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = 00 TU max.
NO
Claim Comment: Input “As per Technical Bulletin 2019947” in comment section of Warranty Claim.
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
Page 10 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
2)
Code per warranty vendor code policy.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policy & Procedures Manual.
Required Parts and Tools
Part Description
Part No:
Quantity
Expansion Valve
Vehicle Specific
1
Receiver-Drier
Vehicle Specific
1
Restrictor
Vehicle Specific
1
Tool Description
Tool No:
Air Conditioning Service System.
ROB134APF
Air Conditioning System Flushing Device
VAS 6337/1A
Page 11 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Air Conditioning System Flushing Device Filter
Behr - BAI783400103
OR
Bosch – 17707-6
OR
Air Conditioning System Flushing Device Filter
Adapter set for refrigerant circuits
Bosch – 17707-6
VAS 6338/1
Page 12 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Additional adapter for bypass of the front
expansion valve for Touareg
VAS 6338/33
Additional refrigerant circuit adapter
VAS6338/36
Additional refrigerant circuit adapter
VAS6338/38
Page 13 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Additional refrigerant circuit adapter
VAS6338/40
Additional refrigerant circuit adapter
VAS6338/41
Additional refrigerant circuit adapter
VAS6338/42
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Document Control Revision Table
Instance Number
Published Date
Version Number
Reason For Update
2019947/10
10/24/16
V871622
Update model year
applicability.
2019947/1
4/29/09
V870903
Original publication.
Page 14 of 14
© 2016 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.