Total system oil capacities are the maximum allowed for each compressor and Refrigerant Circuit combination. Do not exceed the Total System Oil Capacity. Compressor damage and a decrease in cooling performance will result.
Total system oil capacities are the maximum allowed for each compressor and Refrigerant Circuit combination. Do not exceed the Total System Oil Capacity. Compressor damage and a decrease in cooling performance will result.
Total system oil capacities are the maximum allowed for each compressor and Refrigerant Circuit combination. Do not exceed the Total System Oil Capacity. Compressor damage and a decrease in cooling performance will result.
Total system oil capacities are the maximum allowed for each compressor and Refrigerant Circuit combination. Do not exceed the Total System Oil Capacity. Compressor damage and a decrease in cooling performance will result.
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Technical Bulletin
Refrigerant Circuit with Sanden SDV 710 Compressor Condenser Evaporator Receiver Drier High Pressure Hose Low Pressure Hose 20 cc (0.7 fl oz) 30 cc (1.0 fl oz) 20 cc (0.7 fl oz) 10 cc (0.3 fl oz) 10 cc (0.3 fl oz)
Total System Oil Capacity 120 cc (4.0 fl oz) Refrigerant Circuit with Sanden SD 709 Compressor (only passenger vehicles) Condenser Evaporator Receiver Drier High Pressure Hose Low Pressure Hose 15 cc (0.5 fl oz) 20 cc (0.7 fl oz) 10 cc (0.3 fl oz) 10 cc (0.3 fl oz) 10 cc (0.3 fl oz)
Total System Oil Capacity 135 cc (4.5 fl oz) Refrigerant Circuit with Sanden SD 709 Compressor (only Vanagon) Condenser Evaporator Receiver Drier High Pressure Hose Low Pressure Hose 0 cc 60 cc (2.0 fl oz) 10 cc (0.3 fl oz) 10 cc (0.3 fl oz) 10 cc (0.3 fl oz)
Total System Oil Capacity 240 cc (8.0 fl oz) Refrigerant Circuit with Sanden SD 709 Compressor (only for EuroVan with one evaporator) Total System Oil Capacity 135 cc (4.5 fl oz)
9 1995 Volkswagen United States, Inc.
Technical Bulletin R134a Retrofit, Refrigerant Oil Distribution If replacement of defective components is necessary before retrofitting to R134a, identify refrigerant circuit by compressor type and add PAG refrigerant oil directly to component according to following application charts.
Caution! The following total system oil capacities are the maximum allowed for each compressor and refrigerant circuit combination. Do not exceed the total system oil capacity. Compressor damage and a decrease in cooling performance will result.
Refrigerant Circuit with York Compressor Condenser Evaporator Receiver Drier High Pressure Hose Low Pressure Hose 10 cc (0.3 fl oz) 50 cc (1.7 fl oz) 20 cc (0.7 fl oz) 15 cc (0.5 fl oz) 15 cc (0.5 fl oz)
Total System Oil Capacity 300 cc (10.0 fl oz) Refrigerant Circuit with Sanden SD 508 Compressor Condenser Evaporator Receiver Drier High Pressure Hose Low Pressure Hose 20 cc (0.7 fl oz) 30 cc (1.0 fl oz) 20 cc (0.7 fl oz) 15 cc (0.5 fl oz) 15 cc (0.5 fl oz)
Total System Oil Capacity 175 cc (5.8 fl oz)
8 1995 Volkswagen United States, Inc.
Technical Bulletin Capacity Tables PAG Refrigerant Oil Passenger cars: Part No. G 052 154 A2 Vanagon/EuroVan: Part No. G 052 100 A2 Compressor York Sankyo, Sanden SD 508 Sanden SD 510 Sanden SD 709 Capacity 100 cc (3.3 fl oz) 100 cc (3.3 fl oz) 100 cc (3.3 fl oz) 135 cc (4.5 fl oz) (passenger cars incl. EuroVan) 240 cc (8 fl oz) (Vanagon)
Refrigerant R134a Model Golf Cabriolet Golf/Jetta/Vento Scirocco Corrado Passat Quantum Vanagon EuroVan (Canada only) m.y. 1985 1992 1985 1992 1985 1989 1989 1992 1990 1992 1985 1988 1985 1991 1992 Capacity 800 g (28.2 oz) 800 g (28.2 oz) 800 g (28.2 oz) 800 g (28.2 oz) 1050 g (37 oz) 1200 g (42.3 oz) 1350 g (47.6 oz) 950 g (33.5 oz)
7 1995 Volkswagen United States, Inc.
Technical Bulletin Retrofit Procedure Discharge and capture refrigerant R12 using Kent Moore ACR3 or equivalent. Evacuate system to remove any R12 contaminants Remove refrigerant oil from compressor; depending on accessibility, use one of the following methods: Use refrigerant oil evacuation feature of Kent Moore ACR 3, ACR 4 or equivalent. Remove compressor, unscrew oil drain plug and drain refrigerant oil. Identify compressor type and fill with quantity of PAG refrigerant oil specified in table on page 6. Reinstall compressor (if removed). Install new Orings on compressor suction and discharge hose fittings. Replace receiver drier. Use new Orings Identify and install correct R134a adapters (from Kit Part No. 357 820 794) to high pressure and low pressure service valves. A A Low pressure valve 1, 7/16 connection Part No. 357 820 797 A High pressure valve 2, 3/8 connection Part No. 357 820 797 or high pressure valve 2, 7/16 connection Part No. 357 820 797B
Evacuate system for a minimum of 30 minutes using Kent Moore ACR4 or equivalent. N87-0093
Charge system with refrigerant R134a, Refrigerant capacity table, page 6. Perform A/C system quality check and leak test Repair Manual, Air Conditioning, Repair Group 87. Install new R134a adhesive label over original R12 label on radiator support.
6 1995 Volkswagen United States, Inc.
Technical Bulletin Parts Requirement All models require the following parts:
Adapter/label kit: Part No. 357 820 794
PAG refrigerant oil:
Part No. G 052 154 A2 (passenger cars) Part No. G 052 100 A2 (Vanagon/EuroVan)
*Refer to the chart below for applicable part numbers. Model/m.y. Golf Cabriolet 8592 Golf/Jetta 8592 Scirocco 8589 Corrado 8992 Passat 9092 Quantum 8588 Vanagon 8591 Receiver Drier 171 820 191 B 191 820 191 A 171 820 191 B 191 820 191 A 357 820 191 D 323 820 193 A up to 24 G 075000: 253 260 633 D from 24 G 075001: 253 260 633E 701 260 191 E Receiver Drier Orings 803 260 749 803 260 749 803 260 749 803 820 749 A 803 260 749 803 260 749 803 260 749 Compressor Orings 803 260 749 A 803 260 749 B 803 260 749 A 803 260 749 B 803 260 749 A 803 260 749 B 1H0 820 749 803 260 749 A 803 260 749 B 171 820 749 253 260 749
EuroVan 92 (Canada only)
803 260 749 803 820 749 A
803 260 749 B
Caution! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.
5 1995 Volkswagen United States, Inc.
Technical Bulletin R134a Retrofit, Preparation, continued If a component is replaced prior to retrofitting the system to R134a, an appropriate amount of PAG refrigerant oil must be added to the circuit. For oil quantities per component, refer to Oil Distribution charts starting on page 8.
Replacement compressors are factory filled
with R12 compatible compressor oil. If compressor replacement is necessary, the factory filled compressor oil must be drained and replaced with appropriate quantity of PAG refrigerant oil; Identify compressor type and fill according to table on page 7.
4 1995 Volkswagen United States, Inc.
Technical Bulletin R134a Retrofit, System Preparation Review all Cautions, Warnings and A/C refrigerant system safety measures stated in appropriate model repair information, Repair Manual, Air Conditioning, Repair Group 87.
Always use Underwriters Laboratory (UL)
approved refrigerant service equipment such as Kent Moore ACR3, ACR4 or equivalent.
Before proceeding with retrofit, perform a visual
inspection and functional test of complete A/C system; including instrument panel outlet temperature, air distribution, refrigerant system components, system pressure and leak test. Repair Manual, Air Conditioning, Repair Group 87. Repair/replace parts as necessary .
Always refer to the most recent parts
information for affected models when replacing damaged or defective R12 refrigerant system parts (including the routine replacement of Orings).
If replacement of damaged or leaking
refrigerant hoses, compressors, evaporators and condensers is necessary, blow compressed air (followed by nitrogen) through all remaining, disconnected, free flowing system components before assembly in order to remove moisture, impurities and remaining refrigerant oil.
3 1995 Volkswagen United States, Inc.
Technical Bulletin Caution! Always use separate refrigerant recovery, recycling and recharging service equipment for R12 and R134a systems. If the same piece of equipment is used for both R12 and R134a systems, residual traces of refrigerant will contaminate and damage the equipment. Service equipment includes recovery, recycling, recharging station, vacuum pump, manifold gauges, etc.
Caution! Do Not blow compressed air and nitrogen through the compressor or expansion valve. Refrigerant circuits retrofitted to use R134a must not be rinsed with agent R11. Replacement compressors are filled with nitrogen. If gas does not escape when removing protective caps on suction and discharge ports, assume leakage and do not install compressor. When replacing damaged compressors, ensure existing mineral based refrigerant oil is drained and replaced with PAG oil. Always replace receiver drier if refrigerant circuit is left open. Due to residual amounts of mineral based refrigerant oil in systems retrofitted to use refrigerant R134a, the newly installed PAG refrigerant oil will discolor immediately after use. This is normal and does not indicate a refrigerant related fault.
2 1995 Volkswagen United States, Inc.
Technical Bulletin Subject:
A/C System, Retrofitting R12 to R134a All (except Fox) m.y. 1985 to m.y. 1992
Model(s):
87 Number: 9503 Date: May 31, 1995
Group:
Please read all sections of this Bulletin thoroughly before proceeding with retrofit! At customers request and expense, A/C systems on the following models may be retrofitted to use refrigerant R134a. Golf Cabriolet Golf/Jetta Scirocco Corrado Passat Quantum Vanagon EuroVan (Canada only) 1985 1992 1985 1992 1985 1989 1989 1992 1990 1992 1985 1988 1985 1991 1992
