Skoda Workshop Service and Repair Manuals

Repairing the air conditioning system - engine compartment

WARNING Disconnect earth strap from the battery before commencing work on the electrical system → Electrical System; Rep. Gr.27.

t	If the earth strap of the battery was disconnected, pay attention to the sequence when connecting it → Electrical System; Rep. Gr.27.

t	The parts marked with an * must only be repaired in specialist service centres which have suitably trained personnel and are fitted out for working on the refrigerant circuit!

t	Comply with the safety measures when working on vehicles with air conditioning system and when using refrigerant R134a and observe the instructions for working on the refrigerant circuit → Air conditioning system with refrigerant R134a; Rep. Gr.00 technical data.

1 -	Holder for refrigerant lines

q

→ Fig.

q	Properly secure the refrigerant lines

2 -	Exhaust valve*

q	Low-pressure side

q	for exhaust and measurement only

q	always screw on cap with gasket

q	removing and installing → Fig.

3 -	Quick coupling for refrigerant line*

q	Low-pressure side

q	separate → Chapter

4 -	High-pressure sender -G65-

q	function → Chapter

q	remove and install, test → Chapter

5 -	Holder for refrigerant lines

q	bolted with plastic nut (2.7 Nm)

6 -	Opening for air inlet of air conditioning unit

q	under cover in the cooling-water tank

7 -	Expansion valve*

q	Removing and installing the refrigerant lines → Fig.

q	removing and installing → Chapter

8 -	Valve for condensation water drain*

q	behind heat-protection matting of the bulkhead (assembly plate)

q	Fit only on removed air conditioning unit

q	check → Fig.

9 -	Extractor and filling valve*

q	High-pressure side

q	for exhausting, filling and measuring

q	always screw on cap with gasket

q	removing and installing → Fig.

10 -	Condenser*

q	Removing and installing the refrigerant lines → Fig. and → Fig.

q	Removing and installing the condenser → Chapter

11 -	Regulating valve for compressor, air conditioning system -N280-*

q	Elements of the compressor, do not replace individually

q	check → Chapter

q	Coil resistor-regulating valve at 20 °C: 10.6 ± 0.4 Ω

Depending on the required cooling output the regulating valve receives a PWM signal (500 Hz) (modulated by signal interval) from the air conditioning system control unit -J301- and regulates the displacement of the compressor via the position of the articulated disc.

12 -	Pressure relief valve*

q	O-Ring: 8.6 mm; 1.8 mm

q	Tightening torque: 10 Nm

q	function → Chapter

q	check → Chapter

13 -	Compressor*

q	Manufacturer: Denso, designation: 6 SEU 12C

q	Removing and installing the compressor on the holder → Fig.

q	Removing and installing the refrigerant lines → Fig.

q	Belt protection for blocked compressor → Fig.

q	Removing and installing the compressor → Chapter

q	Running-in instruction → Chapter

t	The compressor displacement is regulated on the suction side via the externally clock-pulsed regulating valve in accordance with the required cooling output.

t	If the air conditioning system is switched off due to a loss of refrigerant, the lubrication of the compressor is ensured.

t	Do not start engine if the refrigerant lines are not connected to the compressor and the compressor is closed with plugs (risk of overheating).

14 -	Oil drain plug*

q	with gasket

q	Tightening torque for:

M 8 - 30 Nm

M 10 - 40 Nm

To drain off refrigerant oil:

–	Remove compressor

–	Remove oil drain plug

–	Turn the compressor over the belt pulley to speed up drainage of the oil.

15 -	Fluid container with dessicator insert*

q	Element of the condenser

q	Replace dessicator insert after each opening of the refrigerant circuit → electronic catalogue of original parts

q	Summary of components of the dessicator insert → Fig.

q	Removing and installing dessicator insert → Chapter

16 -	Quick coupling for refrigerant line*

q	High-pressure side

q	separate → Chapter

Removing and installing refrigerant line - condenser inlet 1 -  5 Nm 2 -  Clamp 3 -  High-pressure valve 4 -  12 Nm 5 -  Connection fitting for refrigerant line t  Torsion stop with sleeve 6 -  O-ring 10.80 mm; 1.82 mm t  replace 7 -  Condenser   Note t  Shut off refrigerant line and condenser connection. t  Replacing dessicator insert → Chapter.

Removing and installing refrigerant line - condenser outlet 1 -  Quick coupling t  separate → Chapter 2 -  Clamp 3 -  5 Nm 4 -  Connection fitting for refrigerant line t  Torsion stop with sleeve 5 -  Condenser/fluid reservoir 6 -  O-ring 10.80 mm; 1.82 mm t  replace 7 -  15 Nm   Note t  Shut off refrigerant line and condenser connection. t  Replacing dessicator insert → Chapter.

Remove exhaust valve - Low-pressure side Special tools and workshop equipment required t  Octagon wrench socket -T10364/1- –  Drain the refrigerant circuit with the aid of the A/C service station. –  Release cap -5- with gasket ring -4-. –  Use wrench -T10364/1- to release the valve -3- from the pipe. –  Screw in new valve (8 Nm) with new O-ring -2- 7.6 mm; 1.8 mm. –  Again screw on cap with gasket ring.

Removing and installing extractor and filling valve - high-pressure side Special tools and workshop equipment required t  Octagon wrench socket -T10364/2- –  Drain the refrigerant circuit with the aid of the A/C service station. –  Release cap -5- with gasket ring -4-. –  Use wrench -T10364/2- to release the valve -3- from the pipe. –  Screw in new valve (8 Nm) with new O-ring -2- 10.8 mm; 1.8 mm. –  Again screw on cap with gasket ring.

Summary of components of the dessicator insert for vehicles up to 05.04 1 -  Screw plug, 15 Nm 2 -  O-ring t  replace 3 -  Dessicator insert t  replace t  removing and installing → Chapter 4 -  Fluid reservoir/condenser

Summary of components of the dessicator insert for vehicles as of 06.04 1 -  Rubber cap 2 -  Circlip 3 -  Cap 4 -  O-ring t  replace 5 -  Dessicator insert t  replace t  removing and installing → Chapter 6 -  Condenser/fluid reservoir

Removing and installing the compressor from/on the holder 1 -  Support t  engine specific different versions 2 -  45 Nm 3 -  Compressor t  removing and installing → Chapter 4 -  Combination screws t  M8 = 25 Nm t  M10 = 45 Nm 5 -  Sleeves for compressor t  must be fitted in the holder -1- or in the compressor -3-   Note After removal attach the compressor to the lock carrier and do not suspend on the refrigerant lines.

Removing and installing the refrigerant lines of the compressor 1 -  22 Nm 2 -  Connection fittings for suction line t  Torsion stop with sleeve -4- 3 -  O-ring 23.80 mm; 2.40 mm t  replace 4 -  Fitting sleeve 5 -  O-ring 10.80 mm; 1.82 mm t  replace 6 -  Connection fittings for pressure line    Torsion stop with sleeve -4-   Note t  The different versions of the refrigerant lines are engine specific. Fixing to the compressor is identical for all versions. t  Shut off refrigerant lines and compressor connections. t  Replacing dessicator insert → Chapter.

Belt protection for blocked compressor Compressor operates continuously via a driver clutch -1- and -2- in the belt drive, whether or not the air conditioning system is switched on. If the compressor blocks, the rubber elements -2- will shear off or the driver disc -1- will become deformed depending on the compressor temperature. In any case the belt pulley of the compressor can rotate while the driver disc/compressor shaft is at a standstill. Replace the compressor.

Holder for refrigerant lines 1 -  Quick coupling t  separate → Chapter 2 -  Low-pressure valve 3 -  Support t  screwed onto the frame side rail t  Properly secure the refrigerant lines 4 -  2 Nm

Removing and installing the refrigerant lines on the expansion valve 1 -  Expansion valve t  removing and installing → Chapter 2 -  O-ring 10.80 mm; 1.82 mm t  replace 3 -  Connection fittings for pressure line t  Torsion stop with sleeve 4 -  O-ring 14.30 mm; 2.40 mm t  replace 5 -  10 Nm 6 -  Connection fittings for suction line t  Torsion stop with sleeve   Note t  Shut off refrigerant lines and expansion valve connections. t  Replacing dessicator insert → Chapter.

Check valve for condensation water drain Perform the inspection if the floor covering under the air conditioning unit becomes damp when the air conditioning is on. –  Open perforation of the cap -1- at the bottom of the heat-protection matting -4- and fold up cap. To guarantee the perfect operation of the valve for condensation water drain, check the following: t  The valve for condensation water drain -5- must not stick. t  Sealing lips -3- of the gasket in the bulkhead (assembly plate) must fit all round in the holder slot -2--arrows-.    The valve for condensation water drain is positioned in the holder -2- and on the air conditioning unit. t  The heat-protection matting must neither be deformed nor damaged around the valve for condensation water drain.   Note When closed the cover -1- must be flush with the heat-protection matting -4-. If the cover -1- is pressed too far inwards, the cap of the valve for condensation water drain -5- may become stuck.