Volkswagen Polo Service & Repair Manual: Commercially Available Tools and Materials

Volkswagen Polo Service & Repair Manual / Refrrigerant R134a Servicing / Special Tools / Commercially Available Tools and Materials

Note

This list outlines the testers, tools and materials required for expert refrigerant circuit repair work.

Caution

Non-approved tools or materials such as leak sealing additives can cause damage or malfunctions in the system.

Only use tools and materials approved by the manufacturer.

The warranty is voided if non-approved tools or materials are used.

Overview

Page

A/C Service Station -VAS 6007A-. For additional A/C service stations. Refer to VAGWorkshop Equipment Catalog.

→ Fig. „“ A/C Service Station -VAS6007A- (and further or current A/C service station)”“

Electronic Leak Detector -VAG1796-

→ Fig. „“ Electronic Leak Detector -VAG1796- ”“

Leak Detection System -VAS6196-

→ Fig. „“ Leak Detection System -VAS6196- ”“

Leak Detection System - R-134a/PAG single dose Tracer-Stick® capsules -VAS6196/1-

Not illustrated

Leak Detection System -VAS6201- or succeeding model

→ Fig. „“Leak Detection Kit VAS6201A or succeeding model”“

A/C Service Station -VAS6380- with flushing device or Air Conditioning Flush Tool -VAS6337- other A/C service station. Refer to VAGWorkshop Equipment Catalog.

With installed program to flush refrigerant circuit with refrigerant R134a.

Not illustrated

Current flushing device Air Conditioning Flush Tool -VAS6337/1A-. Refer to the VAGWorkshop Equipment Catalog.

For flushing refrigerant circuit with refrigerant R134a. To be used also with older A/C service stations (flushing procedure must then be performed manually) with a reservoir volume of at least 10 kg of refrigerant R134a.

→ Fig. „“ Air Conditioning Flush Tool -VAS6337/1A- from the company Behr or succeeding model”“

Current flushing device Refrigerant Circuit Flushing Device -VAS6336/1-. Refer to the VAGWorkshop Equipment Catalog.

→ Fig. „“ Air Conditioning Flush Tool -VAS6336/1- from the company Waeco or succeeding model”“

VW/Audi passenger vehicle set adapter chest VAS6338/1 for refrigerant circuits with refrigerant R134a.

For connecting the A/C service station to the refrigerant circuit and bridging certain components when flushing with refrigerant R134 or compressed air and nitrogen.

Not illustrated

Commercial vehicle set adapter chest VAS6338/50 for refrigerant circuits with refrigerant R134a.

For connecting the A/C service station to the refrigerant circuit and for bridging certain components when flushing.

Not illustrated

Ultrasound A/C Cleaner -VAS6189B-

For eliminating unpleasant odors caused by A/C system.

Not illustrated

Suction Feed Spray Gun -VAG1538-

Spray nozzle VAG 1538/5 (short)

Spray nozzle VAG 1538/6 (long)

Spray nozzle VAG 1538/7 (700 mm, commercial vehicle)

Cleaning solution D 600 100 A1

Cleaning solution for evaporator D 600 100 A2

To remove unpleasant odors from the evaporator

Not illustrated

Release Tool -VAS6127- case

For opening refrigerant pipes.

→ Fig. „“ Spring Lock Release Tools -VAS6127A- case consists of the Release Tool -VAS6127/1A-Release Tool -VAS6127/2A- and Release Tool -VAS6127/3- ”“

Release Tools -VAS6127/1-3-

For opening refrigerant pipes.

→ Fig. „“ Release Tool -VAS6127/1-Release Tool -VAS6127/2- ”“

Magnetic Coupling Tool -VAG1616-

For clutch plate (A/C compressor manufactured by “Sanden”).

→ Fig. „“ Magnetic Coupling Tool -VAG1616- for clutch plate (for Sanden A/C compressors)”“

Magnetic Coupling Tool Puller -VAG1616/1- for the magnetic coupling (Sanden A/C compressor).

→ Fig. „“ Magnetic Coupling Tool Puller -VAG1616/1- (for Sanden A/C compressors)”“

A/C Clutch Set -VAG1719- (Zexel A/C compressor).

→ Fig. „“ A/C Clutch Set -VAG1719- (for Zexel A/C compressors)”“

A/C Adapter Set -VAG1785/1-10- R134a.

→ Fig. „“ A/C Adapter Set -VAG1785/1-10- ”“

Combined fine filter unit for compressed-air system (oil, dirt and water separator as used for painting facilities). Refer to catalog workshop equipment.

Not illustrated

O-ring seals. Refer to the Parts Catalog.

Not illustrated

Refrigerant oil. Refer to the Parts Catalog.

Not illustrated

Refrigerant Sockets -T10364- for high pressure/low pressure side service connection valves on refrigerant circuit.

→ Fig. „“ Refrigerant Sockets -T10364- for the high pressure/low pressure side service connection valves in the refrigerant circuit”“

Caution

Non-approved tools or materials such as leak sealing additives can cause damage or malfunctions in the system.

Only use tools and materials approved by the manufacturer.

The warranty is voided if non-approved tools or materials are used.

Overview	Page
Fin comb	→ Fig. „“Fin comb”“
5/8" - 18 UNF charging hoses with valve opener.	→ Fig. „“Charging hoses”“
Connection piece for refrigerant cylinder and seal with quick-release coupling connection or threaded connection 5/8" - 18 UNF.	→ Fig. „“Connection piece for refrigerant cylinder and seal with quick-release coupling connection or threaded connection 5/8" - 18 UNF.”“
Valve caps 5/8"-18 UNF.	→ Fig. „“Valve caps with spare seals (for 5/8"-18 UNF thread)”“
Pressure gauge set with pressure reducer for nitrogen.	→ Fig. „“Pressure gauge set with pressure reducer for nitrogen (max. reducing pressure: 15 bar (218 psi))”“
Quick-release coupling adapter for service connections (quantity: 2) included in scope of delivery of A/C service station.	→ Fig. „“Quick-release coupling adapter for service connections”“
The wrench size depends on the threaded connections on the refrigerant lines.	Not illustrated
Valve opener for charging hoses.	Not illustrated
Connecting nipple for conical seal 5/8"-18 UNF.	Not illustrated
Compressed-air gun with rubber mouthpiece.	Not illustrated
Hand shut-off valve 5/8"-18 UNF.	Not illustrated
Recycling container for refrigerant R134a.	Not illustrated
Digital thermometer	Not illustrated
Protective gloves	Not illustrated
Protective glasses	Not illustrated
Refrigerant R134a with cylinder (capacity as required).	Not illustrated
Nitrogen with compressed gas cylinder.	Not illustrated
Band wrench (oil filter) as counterhold for ribbed belt pulley.	Not illustrated

Caution

Non-approved tools or materials such as leak sealing additives can cause damage or malfunctions in the system.

Only use tools and materials approved by the manufacturer.

The warranty is voided if non-approved tools or materials are used.

A/C Service Station -VAS6007A- (and further or current A/C service station)

Refer to the Workshop Equipment Catalog.

Work procedures: The operations "testing, extraction (recycling), evacuation and charging" are to be performed in line with the relevant operating instructions.

The filters and dryers installed are to be replaced at the latest at the end of the period of use specified in the operating instructions and whenever the station has been drained (keep replacement filter to hand. available from equipment manufacturer. Refer to operating instructions).

Other A/C service stations or flushing equipment that is approved by VW but not illustrated here may also be used.

Refer to the Workshop Equipment Catalog.

Note

The following known units are assembled in this A/C service station: Charging cylinder, pressure gauge set, vacuum pump, shutoff valves and charging hoses.

One quick-release coupling each (for service connections on high and low-pressure side) is included in the scope of delivery of this A/C service station.

Commercially Available Tools and Materials

Air Conditioning Flush Tool -VAS6337/1A- from the company “Behr” or succeeding model

Note

With a filter -1- and two large cylindrical viewing glasses.

The filter in the refrigerant circuit flushing device depends on the type and degree of contamination in the flushed refrigerant circuit, it should be changed after 2 flushing cycles at the latest. If a heavily contaminated refrigerant circuit is flushed (the refrigerant oil from the circuit is black and viscous or there are many shavings in the refrigerant circuit), the filter should be replaced after flushing.

Commercially Available Tools and Materials

Air Conditioning Flush Tool -VAS6336/1- from the company “Waeco” or succeeding model

Note

With a filter -1- and one viewing glass.

Commercially Available Tools and Materials

Electronic Leak Detector -VAG1796-

Commercially Available Tools and Materials

Leak Detection System -VAS6196-

Commercially Available Tools and Materials

Leak Detection Kit VAS6201A or succeeding model

Commercially Available Tools and Materials

Spring Lock Release Tools -VAS6127A- case consists of the Release Tool -VAS6127/1A-Release Tool -VAS6127/2A- and Release Tool -VAS6127/3-

Commercially Available Tools and Materials

Release Tool -VAS6127/1-Release Tool -VAS6127/2-

blue 1/2 inch

black 5/8 inch

red 3/8 inch

white 3/4 inch

Commercially Available Tools and Materials

Release Tool -VAS6127/3-

green NW 8 for the high pressure line

black NW 13 for the low pressure line

Commercially Available Tools and Materials

Magnetic Coupling Tool -VAG1616- for clutch plate (for “Sanden” A/C compressors)

Commercially Available Tools and Materials

Magnetic Coupling Tool Puller -VAG1616/1- (for “Sanden” A/C compressors)

Commercially Available Tools and Materials

A/C Clutch Set -VAG1719- (for “Zexel” A/C compressors)

Commercially Available Tools and Materials

A/C Adapter Set -VAG1785/1-10-

Adapter for cleaning refrigerant circuit (flush with refrigerant R134a. Refer to → Chapter „Refrigerant Circuit, Flushing (Cleaning) with Refrigerant R134a“ or blow through with compressed air and nitrogen. Refer to → Chapter „Refrigerant Circuit, Flushing with Compressed Air and Nitrogen“)

A -	5/8" 18 UNF thread for conical seal

B -	Union nut (for connection with O-ring) with thread

M 18x1.5VAG1785/1

M 20x1.5VAG1785/2

M 24x1.5VAG1785/3

M 28x1.5VAG1785/4

A -	5/8"-18 UNF thread for conical seal

B -	Threaded connection for O-ring

M 18x1.5VAG1785/5

M 20x1.5VAG1785/6

M 24x1.5VAG1785/7

Commercially Available Tools and Materials

M 28x1.5VAG1785/8

Commercially Available Tools and Materials

Valve adapter

A -	5/8"-18 UNF thread for conical seal

B -	Internal threads with valve opener M 10x1.25 VAG 1785/9 (for connections with valve on high pressure side) M 12x1.5 VAG 1785/10 (for connections on low pressure side)

Note

A Schrader valve is screwed into connection -A-.

A valve opener must be installed in the charging hose connection.

Commercially Available Tools and Materials

Refrigerant Sockets -T10364- for the high pressure/low pressure side service connection valves in the refrigerant circuit

Commercially Available Tools and Materials

Fin comb

Commercially Available Tools and Materials

Charging hoses

5/8"-18 UNF thread

Note

Use differently colored charging hoses (1800 mm long).

Have valve opener and spare seals to hand.

Commercially Available Tools and Materials

Connection piece for refrigerant cylinder and seal with quick-release coupling connection or threaded connection 5/8" - 18 UNF.

Commercially Available Tools and Materials

Valve caps with spare seals (for 5/8"-18 UNF thread)

Seals can also be used for charging hoses.

Commercially Available Tools and Materials

Pressure gauge set with pressure reducer for nitrogen (max. reducing pressure: 15 bar (218 psi))

1 -	Manometer battery with pressure reducer

2 -	Pressure hose (inner diameter 5 mm, length 2 m) with hose fittings

3 -	Nitrogen cylinder

4 -	Hose fitting

Note

Hose fittings for connecting on A/C Adapter Set -VAG1785- with threads 5/8" 18 UNF for service connection quick-release coupling adapter to refrigerant circuit.

Commercially Available Tools and Materials

Quick-release coupling adapter for service connections

High-pressure side, nominal size 16 mm

Low-pressure side, nominal size 13 mm

Note

These quick-release couplings are supplied with the A/C service station.

Commercially Available Tools and Materials

Special Tools

...

Improvised Tools

Note This list outlines the testers, tools and materials required for expert refrigerant circuit repair work. ...

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