871409

Technical Bulletin
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
1998 - 2015
All
All
All
All
All Models
(except Routan)
Condition
87 14 09 September 24, 2014 2019947 Supersedes T.B. V871205 dated September 7, 2012 to include additional
models, model years and add additional flushing adapters.
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.
Page 1 of 13
© 2014 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.
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.
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.
Page 2 of 13
© 2014 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
3. Disconnect the service hoses. The VAS 6338/1 adapters will be used to bypass the following:
Note:
For models in which the Receiver-drier is not over flushed as per the repair manual, 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.
• Compressor.
• Receiver-drier.
• Expansion Valve/ Restrictor (if equipped).
If vehicle is equipped with a restrictor, remove the restrictor and reconnect the line.
4. Once the appropriate adapters are in place, connect the service station to the vehicle through the air
conditioning compressor hoses. The flushing attachment ports are labeled on the flusher (Figure 2 and Figure 3).
Figure 2. A flushing attachment port.
Figure 3. A flushing attachment port.
• This connection strategy allows for a system flush in the opposite direction of the normal refrigerant flow
(Figure 4).
Page 3 of 13
© 2014 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 4. Connection strategy: Vehicle to service station to flushing device.
• 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 4 of 13
© 2014 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.
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.
Page 5 of 13
© 2014 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
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.
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.
2. Bypass the rear expansion valve with an adapter from the VAS
6338/1.
3. Flush rear A/C.
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.
Page 6 of 13
© 2014 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
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.
A/C Components Replacement
The following components must be replaced:
• Expansion Valve (if equipped)
• Restrictor (if equipped)
• Receiver-drier
Page 7 of 13
© 2014 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
Warranty
Note:
The procedure outlined in this Technical Bulletin must be included with the warranty repair(s) and not claimed
independently.
You may claim $3.51 per A/C System flush for the A/C System Flush Machine filter BAI783400103 (which
represents ¼ the cost of a replacement filter).
Tip:
Time for evacuation and recharge not included; claim accordingly as per Elsa.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
1998 - 2015
All
All
All
All
All Models
(except Routan)
Claim Type:
Use applicable Claim Type
1)
SAGA Coding
Damage Location
Damage
HST
Service Number:
Use Service
Number of
Damaged
Component
Code
(Depends on
Service No.)
Use damage code
appropriate for root
cause of failure
Use applicable
when indicated in
Elsa (L/R)
--
Parts Manufacturer
(removed part)
Use Vendor code
from failed
component
2)
___
3)
87012999 = 140 TU
3)
87013099 = 310 TU
3)
87010150 = 30 TU
Labor Operation : Air Conditioner Clean, All
Vehicles, Front A/C only (except Touareg with four
zone climate control)
Labor Operation : Air Conditioner Clean, Touareg
with four zone climate control.
Labor Operation : Air Conditioner Check, All
Vehicles.
Page 8 of 13
© 2014 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
3)
8770XXXX = Claim appropriate SRT for vehicle and
engine in Elsa
3)
8777XXXX = Claim appropriate SRT for vehicle and
engine in Elsa
Labor Operation : Replace Receiver-Drier
3)
8755XXXX = Claim appropriate SRT for vehicle and
engine in Elsa
Outside Material: A/C Flush Machine filter, Part No.
BAI783400103
$3.51 total per A/C System Flush which
accompanies a repair (this amount equals ¼ of the
cost of the A/C flush machine filter)
Labor Operation : Replace Expansion Valve, if
equipped.
Labor Operation : Replace Restrictor, if equipped.
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
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.
.
Page 9 of 13
© 2014 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
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
Air Conditioning System Flushing Device Filter
BAI783400103
Page 10 of 13
© 2014 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
Adapter set for refrigerant circuits
VAS 6338/1
Additional adapter for bypass of the front expansion
valve for Touareg
VAS 6338/33
Additional refrigerant circuit adapter
VAS6338/36
Page 11 of 13
© 2014 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
VAS6338/38
Additional refrigerant circuit adapter
VAS6338/40
Additional refrigerant circuit adapter
VAS6338/41
Additional refrigerant circuit adapter
VAS6338/42
Page 12 of 13
© 2014 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 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.
Page 13 of 13
© 2014 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.