Volkswagen Golf / Golf GTI / Jetta. Manual — part 1007

- Refrigerant containers filled with contaminated used
refrigerant are referred to as "Recycling containers" .

- Always evacuate recycling containers prior to initial filling
with refrigerant (if there is air in a refrigerant container it is
not to be filled with refrigerant).

- Different types of refrigerant are not to be mixed
(refrigerant mixtures cannot be recycled and are to be
disposed of). If there is any doubt about the composition of
the contents of the container, the refrigerant recycling
company is to be informed accordingly.

Warning!

- When filling recycling containers (compressed-gas
vessels), observe applicable regulations, technical
rules and laws.

- Recycling containers are never to be overfilled
(overfilled containers do not have a sufficient gas
cushion to accommodate the liquid expansion caused
by the effects of heat. There is a danger of rupture).

- To ensure safety, make exclusive use of recycling
containers equipped with a safety valve.

- Recycling containers must be weighed on calibrated
scales during the filling process. The maximum
permissible capacity is 75% (charge factor 0.75) of the
charge weight indicated on the recycling container (the
possibility of refrigerant oil entering the recycling
container along with the refrigerant cannot be ruled
out).

Refrigerant circuit, cleaning (flushing) with
compressed air and nitrogen.

- Compressed air and nitrogen are to be used in order to
force out moisture and other contaminants as well as old
refrigerant oil as efficiently as possible, without wasting
refrigerant, without the need for extensive assembly work
and without endangering the environment.

Warning!

- Nitrogen can flow uncontrolled out of the cylinder.

- Make exclusive use of pressure reducers for nitrogen
cylinders.

- Use appropriate extraction units to draw off gas
mixture escaping from components.

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- Always flush components in direction opposite to
refrigerant flow.

Restrictor, expansion valve, compressor, receiver and
reservoir cannot be flushed with compressed air and
nitrogen.

- Remove dryer cartridge on condensers with dryer.

- First flush out old refrigerant oil and dirt using compressed
air and then use nitrogen to remove component moisture.

The compressed air must be routed through a compressed-
air purifier for cleaning and drying. Use is therefore to be
made of filter and dryer for compressed air (included in
scope of delivery as tool for painting work).

Workshop equipment and special tools catalog

Note:

- Observe the following items to prevent oil and moisture
from the compressed- air system penetrating into the
refrigerant circuit.

- For refrigerant pipes with thread or union nut at
connection, make use of adapters from adapter set V.A.G
1785 ( 1785/1 to adapter V.A.G 1785/8 ) for connection of
5/8" -18 UNF charging hoses.

- For refrigerant pipes with no thread or union nut at
connection (for connecting adapters), make use of
commercially available flushing gun with rubber end piece.

- Flush refrigerant circuit with compressed air and then with
nitrogen.

- Compressed air/nitrogen emerging from components is to
be drawn off by way of an appropriate system (workshop
extraction system).

The circuit must be flushed:

- In the event of dirt or other contamination in the circuit.

- If vacuum reading is not maintained on evacuating a leak-
free refrigerant circuit (pressure build-up due to moisture in
refrigerant circuit).

- If refrigerant circuit has been left open for longer than
normal (e.g. following an accident).

- If pressure and temperature measurements in the
refrigerant circuit indicate the likelihood of moisture.

- In the event of doubt about the amount of refrigerant oil in

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the circuit.

- The A/C compressor had to be replaced on account of
internal damage (e.g. noise or no output).

- If stipulated by the vehicle-specific repair manual following
replacement of certain components.

Refrigerant circuit, flushing

Note:

- In the case of vehicles on which the refrigerant pipes have
no threads for connection of adapter set V.A.G 1785 . Use
is to be made, for example, of a flushing gun with rubber
end piece for flushing the individual components. Special
care must be taken not to damage the connections
(crushing or scratching).

- Evaporator is to be flushed by way of connection for low-
pressure pipe (large diameter) after removing expansion
valve or removing restrictor.

- Always flush components in direction opposite to
refrigerant flow.

- Check expansion valve and replace if dirty or corroded.

- Replace any components on which dark, sticky deposits
cannot be removed with compressed air.

- Thin, light grey deposits on the insides of pipes do not
impair the function of the components.

- After flushing, always replace receiver or reservoir and
restrictor. Replace dryer cartridge on condensers with
dryer.

Refrigerant circuit, tracing leaks using leak
detector V.A.G 1796

Note:

- Minor leaks can be detected using an electronic leak
detector for example.

- Currents of air quickly disperse refrigerant gas. Draughts
must therefore be avoided during leak detection.

- If the refrigerant circuit is completely empty, charge with
about 100 g of refrigerant.

Leak detection:

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- Start up leak detector in line with relevant operating
instructions.

- Always hold test probe beneath suspected leak.

Depending on the model, leak detection is indicated by an
increase in clicking rate or a warning tone (refer to
operating instructions for leak detector).

Refrigerant circuit, tracing leaks using leak
detection system VAS 6196

Note:

- Minor leaks can be made visible e.g. using a fluorescent
substance leak detection additive VAS 6196/1 .

Leak detection:

- If the refrigerant circuit is completely empty, charge with
about 100 g of refrigerant.

- Add leak detection additive VAS 6196/1 to refrigerant
circuit and scan the refrigerant circuit using UV lamp.

Note:

- Leak detection additive may remain in the refrigerant
circuit.

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