Volkswagen Golf / Golf GTI / Jetta. Manual — part 1006

- Open quick-release couplings at service connections.

Refrigerant circuit, discharging using
service station

- Work procedure may vary depending on the type of tools
selected (the tool-specific operating instructions should
therefore be followed).

- The refrigerant circuit is to be discharged if parts of the
refrigerant circuit are to be removed, if there is any doubt
about the quantity of refrigerant in the circuit or if safety
precautions so require.

- All the necessary usage information for working with the
refrigerant service station can be found in the service
station operating instructions.

Draining:

- Switch off ignition.

- Connect service station in line with operating instructions
to vehicle service connections

and start up service station.

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

Note:

- There is a possibility of refrigerant oil being extracted from
the refrigerant circuit together with the refrigerant. To
ensure compressor lubrication, the refrigerant oil in the
circuit must be topped up with fresh oil

.

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- On vehicles equipped with a compressor with no A/C
clutch (with A/C Compressor Regulator Valve N280 ) the
engine should not be run for longer than absolutely
necessary with the refrigerant circuit empty (compressor
always in operation as well).

- On vehicles with a compressor with A/C clutch, the engine
is only to be started following complete assembly of the

Refrigerant circuit

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refrigerant circuit.

Refrigerant circuit, evacuating using service
station

- The work procedure is always to be performed as
described in the operating instructions for the A/C service
station.

- The procedure described here is for the A/C service
station VAS 6007A .

The refrigerant circuit must be evacuated before it is filled
with refrigerant (vacuum). Moisture is also extracted from
the circuit.

Evacuating:

- Switch ignition off.

- Correct the refrigerant oil quantity in the refrigerant circuit
if necessary, see vehicle specific Repair Manual

.

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- Connect service station to power supply.

- Check quantity of refrigerant in the service station.

- Connect charging hoses of service station to vehicle
refrigerant circuit with quick-release coupling adapter (refer
to vehicle-specific refrigerant circuit).

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- Screw in handwheel of quick-release coupling adapters
until valves of service connections are definitely open (take
care not to strain valve).

Note:

- If pressure is to be measured after charging system on
vehicles with a service connection on one side of the
refrigerant circuit only, use valve adapter and charging
hose with valve opener.

Refrigerant circuit

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- Initiate vacuum phase on the service station. Refrigerant
circuit is evacuated automatically.

Once vacuum phase has ended, begin testing refrigerant
circuit for proper seal. Negative pressure in bar and
seconds will be displayed.

Proceed as follows if the vacuum is not maintained:

- Fill the circuit with 100 g of refrigerant, localize any leaks
using leak detection system VAS 6196 and eliminate
accordingly.

Leak detector V.A.G 1796 can also be used.

- Evacuate refrigerant circuit once more. Only when the
vacuum is maintained can the refrigerant circuit be
charged.

Refrigerant circuit, charging using service
station

- The work procedure is always to be performed as
described in the operating instructions for the A/C service
station.

- Before pouring in refrigerant, correct the quantity of
refrigerant oil

.

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- The entire refrigerant charge can be added to either the
high or low pressure side.

Charging refrigerant circuit

- Switch ignition off.

- Evacuate refrigerant circuit using service station

00-4,

Refrigerant circuit, evacuating using service station

.

- Screw out handwheel at quick-release coupling adapter
(to close it).

- Allow refrigerant to flow into charging hose.

- Screw in handwheel at quick-release coupling adapter (do
not strain valve) and charge with the specified quantity of
refrigerant.

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- Switch off service station.

Note:

- If the compressor has been removed, rotate it about 10
times by hand at ribbed belt pulley / freewheel prior to initial
start-up to prevent damage caused by liquid impact when
first switched on (any oil in compressor cylinder is forced
out on rotation).

- Start engine with compressor switched off (version with
A/C clutch).

- Set compressor to minimum output, i.e. "Econ" or A/C off
mode (version with no A/C clutch with regulating valve).

- Wait until idle speed has stabilized.

- Switch on compressor and operate system for at least 2
minutes at idling speed.

- If necessary, check pressures in refrigerant circuit using
service station.

- Turn engine off.

- Screw out handwheel on quick-release coupling adapter.

- Disconnect charging hoses from refrigerant circuit.

- Screw protective caps back on.

Refrigerant, transferring to charging
cylinder of service station

- The work procedure is always to be performed as
described in the operating instructions for the A/C service
station.

- A certain quantity of refrigerant is specified as charge for
each air conditioning system. To ensure that neither too
much nor too little refrigerant is added (either would reduce
the cooling output), the charging cylinder has a scale
indicating the weight.

Service station, draining

Note:

- If it is necessary to drain the service station (e.g. due to
extraction of contaminated refrigerant), all filters and dryers
must always be replaced (do not remove filter and dryer
from the air-tight packaging until immediately before
installation to minimize moisture absorption).

Refrigerant circuit

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