Volkswagen Golf / Golf GTI / Jetta. Manual — part 1008

00 - 5

Complaints

Possible complaints at refrigerant circuit

Note:

- A/C system is functioning correctly when a temperature of
7

0

C or lower escapes at instrument panel air vents.

- Setting on Climatronic "LO" .

- Setting on A/C system "AC" on; "max" ; "cold" .

Test requirements:

- On Board Diagnostics (OBD) of A/C system using
diagnostic operation system VAS 5051A in "Guided Fault
Finding" cannot detect any malfunction, no shut-off
condition for A/C compressor is displayed in measuring
value block (only in vehicles with "A/C system" OBD).

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

Possible complaints

Note:

- For all complaints marked by *

00-7, Pressures,

checking on vehicles

.

- Total failure of cooling system.*

- Insufficient cooling performance at all vehicles speeds or
engine speeds.*

- None or insufficient cooling after driving a few miles.*

- A/C compressor, A/C Clutch N25 or A/C Compressor
Regulator Valve N280 are switched off by A/C Refrigerant
Low Pressure Switch F73 , A/C Refrigerant High Pressure
Switch F118 , A/C Pressure Switch F129 or by A/C Control
Head E87 or Climatronic Control Module J255 due to
excessive or insufficient pressure.*

- None or sharp decrease in fresh-air supply after driving
several miles (evaporator iced up).*

From these, the following complaints may also occur:

Complaints

13/2/2005

A/C compressor makes noise

- Re-tighten securing bolts for A/C compressor and A/C
compressor bracket using a torque wrench.

- Check routing of refrigerant pipes; they must not touch
other components and must not be subject to strain (align if
necessary).

Noise (refrigerant hammer) occurring immediately after
switching on air conditioner and/or when cornering or
braking:

- Discharge, evacuate and re-charge refrigerant circuit (too
much refrigerant in circuit).

Note:

- Too much refrigerant oil in the circuit may also result in
this problem (no adjustment of refrigerant oil quantity, for
example, on replacing compressor).

Water sprays out of vents (in dash panel or footwell)
although air conditioning system is otherwise
functioning properly:

- Check proper routing of condensate drain; it must not be
crushed or kinked.

- Check valve for condensation water hose, it must not
become stuck by wax or underbody sealant and must open
and close properly.

- Check plenum chamber cover; it must not be damaged
and must be properly installed (to stop water running into
evaporator).

- Check water drains in plenum chamber; they must not be
blocked (e.g. by leaves).

Complaints

13/2/2005

00 - 6

Service station, connecting

On vehicles with connection on low and
high-pressure side of refrigerant circuit

Service station, connecting for measurement
and testing

- Switch ignition off.

- Connect service station to power supply.

- Connect quick-release coupling adapter to charging
hoses of service station (handwheels not screwed in/hand
shut-off valve not open).

- Switch on service station and evacuate charging hoses
(only necessary if there is air in charging hoses).

- Switch off service station.

- Unscrew caps from service connections (with valve).

- Connect service station via service connections with
quick-release coupling adapters to vehicle refrigerant
circuit.

- Screw in handwheel of quick-release coupling adapters
until valves are definitely open at refrigerant circuit
connection (observe pressure gauge, do not strain valves).

- Perform planned tests and measurements.

Service station, connecting

13/2/2005

00 - 7

Pressures, checking on
vehicles

Pressures in refrigerant
circuit, checking (using
service station)

Note:

- Check cooling performance. A/C
system is functioning correctly
when a temperature of 7

0

C or

lower escapes at instrument panel
air vents.

- Setting on Climatronic "LO" .

- Setting on A/C system "AC" on;
"max" ; "cold" .

- Connections with valve and
service connections for measuring
and testing.

Test requirements

- Radiator and condenser clean
(clean if necessary)

- Thermal insulation at expansion
valve OK and properly installed.
See vehicle specific Repair
Manual

.

Repair Manual, Heating & Air

Conditioning, Repair Group 87 ,

- Ribbed belt is OK and properly
tensioned. Ribbed belt for A/C
compressor and generator are OK
and correctly tensioned. See
vehicle specific Repair Manual

Repair Manual, Heating & Air

Conditioning, Repair Group 87 ,

Pressures, checking on vehicles

13/2/2005