Volkswagen Golf / Golf GTI / Jetta. Manual — part 1018

.

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- Replace restrictor.

- Assemble, evacuate and charge refrigerant circuit.

Compressor, replacing on account of leakage or
internal damage (e.g. noise or no output)

- Discharge refrigerant circuit.

- Remove A/C compressor.

Note:

- In the event of internal (compressor) damage, check
refrigerant hoses and condenser, If, e.g. swarf has
penetrated, replace these refrigerant hoses.

- Clean (flush) refrigerant circuit with compressed air and
nitrogen

00-4, Refrigerant circuit, cleaning (flushing) with

compressed air and nitrogen.

.

- Replace receiver or dryer cartridge, reservoir and
restrictor.

- Examine expansion valve for dirt or corrosion; replace if
necessary.

- Assemble, evacuate and charge refrigerant circuit.

Receiver or reservoir and restrictor,
replacing

Replacing after flushing refrigerant circuit, e.g.
on account of ingress of moisture (refrigerant
circuit open for lengthy period) or contamination

- Discharge refrigerant circuit.

- Remove A/C compressor.

- Rectify cause of trouble.

- Clean (flush) refrigerant circuit with compressed air and
nitrogen

00-4, Refrigerant circuit, cleaning (flushing) with

compressed air and nitrogen.

.

- Examine expansion valve for dirt or corrosion; replace if
necessary.

Components, replacing

13/2/2005

- Remove oil drain plug from compressor.

Note:

- The oil drain plug of "Denso/Nippondenso" compressors
is installed with an oil seal instead of an O-ring and this is
always to be replaced

Parts Catalog

- To accelerate drainage of refrigerant oil, rotate
compressor e.g. by way of clutch plate of A/C clutch for
example.

- Pour old refrigerant oil out of compressor, see

HSO

Environment Vol. 2-2. 43. 1 .

- Then fill compressor with quantity of fresh refrigerant oil
corresponding to quantity of refrigerant oil in replacement
compressor

Repair Manual, , Repair Group 87,

Note:

- Use different refrigerant oils and quantities for the various
compressors

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- To ensure compressor lubrication on start-up, at least 80
cm

3

of refrigerant oil must be poured into the compressor,

the remainder can be added for example to the new
reservoir or receiver

.

Repair Manual, , Repair Group 87,

- If dirt has penetrated into the compressor with the
refrigerant circuit open (e.g. after an accident), compressor
is to be replaced.

- Replace receiver or reservoir and restrictor.

- Assemble, evacuate and charge refrigerant circuit.

Replacing without the need for flushing
refrigerant circuit with compressed air and

Components, replacing

13/2/2005

nitrogen (e.g. in the event of accident damage);
no escape of refrigerant and no penetration of
moisture and dirt into circuit

- Discharge refrigerant circuit.

- Replace restrictor.

- Remove receiver or reservoir.

- Remove dirt from receiver or reservoir.

- Weigh receiver or reservoir removed.

Note:

- Add refrigerant oil to new receiver or reservoir until weight
of component removed has been attained.

- Install new receiver or reservoir.

- Assemble, evacuate and charge refrigerant circuit.

Components, replacing

13/2/2005

00 - 9

Testing equipment and
tools

List of testing equipment,
tools and materials

Note:

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

Tools and materials
available from regional sales
center or importer

Overview

page

A/C service station VAS 6007A , other service stations

Catalog V.A.G workshop equipment

00-9, (and other or

currently available service

stations)

Leak detector V.A.G 1796

00-9, null

Leak detection system VAS 6196

00-9, null

Leak detection additive VAS 6196/1

Not illustrated

Disengaging tool V.A.G 1795+1795/1

00-9, null

Retainer

V.A.G 1616

00-9, for clutch plate (for

Puller V.A.G 1616/1 for A/C clutch (Sanden compressors)

00-9, (for

A/C clutch set V.A.G 1719 (Zexel compressors)

00-9, (for

Adapter set

V.A.G 1785 -10 R134a

00-9, null

Combined fine filter unit for compressed-air system (oil, dirt and
water separator as used for painting facilities)

Catalog

workshop equipment

Not illustrated

O-ring seals

Parts Catalog

Not illustrated

Refrigerant oil

Parts Catalog

Not illustrated

Commercially available
tools and materials

Overview

page

Fin comb

00-9, Fin comb

Charging hoses 5/8" - 18 UNF with valve
opener

00-9, Charging hoses

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

00-9, Connection piece for refrigerant

cylinder with seal, quick-release coupling

connection or threaded connection 5/8" - 18

UNF

Valve caps 5/8"-18 UNF

00-9, Valve caps with spare seals (for 5/8"-

18 UNF thread)

Pressure gauge set with pressure reducer for

00-9, Pressure gauge set with pressure

Testing equipment and tools

13/2/2005