Volkswagen Golf / Golf GTI / Jetta. Manual — part 997

system.

- Before disconnecting the charging system from the air
conditioning system, make sure the charging process has
been completed to stop refrigerant escaping into the
atmosphere.

- Once the purified refrigerant from the charging system
has been transferred to an external compressed-gas
cylinder, close the hand shut-off valves at the cylinder and
charging system.

- Do not expose charging system to moisture or use it in a
wet environment.

- Disconnect from power supply before performing service
work on the charging system.

- Never use an extension cable on account of the fire
hazard. If the use of an extension cable is unavoidable, the
minimum cross-section should be 2.5 mm

2

.

- In case of fire, remove external cylinder.

- Entrained oil from the air conditioning system drawn by
the suction unit into the measurement vessel supplied is
subsequently to be transferred to a sealed container, as it
contains a small quantity of refrigerant which must not be
released into the environment.

- Following shutdown, service station is to be secured to
stop it rolling away.

Safety measures for working on vehicles
with air conditioning system and for
handling refrigerant R134a

A/C service station VAS 6007A

Warning!

General information for A/C system

13/2/2005

- It is recommended to have an eye-flushing bottle
available.

- If liquid refrigerant has come in contact with your skin
and eyes, immediately flush with cool water for 15
minutes. Afterwards instill eye drops and consult a
doctor immediately, even when the eyes are not
hurting.

- The doctor must be informed that the injury was
caused by refrigerant R134a. Should refrigerant come
into contact with other parts of the body despite
compliance with safety regulations, these must
likewise be rinsed immediately for at least 15 minutes
with cold water.

- Work on refrigerant system should only be performed
in ventilated areas (workshops). Switch on existing
ventilation systems.

- Refrigerant must not be stored in low-level areas (e.g.
cellars) and corresponding exits or light wells.

- Do not attempt repair on filled air conditioning systems by
soldering, brazing or welding. This applies also for welding
and soldering work on the vehicle, in the event that parts of
the A/C system may heat up. When performing paintwork
repairs, the temperature in the drying booth or preheating
zone must not exceed 80 C.

Reason:

Exposure to heat gives rise to considerable pressure in the
system, which could cause the pressure relief valve to
open.

Corrective action:

- Discharge refrigerant circuit using service station.

Note:

- Always replace damaged and/or leaking A/C system
components. Do not attempt repair by soldering, brazing or
welding.

Refrigerant vessels (e.g. charging cylinders of service
station) must never be subjected to excessive heat or
exposed to direct sunlight.

Corrective action:

- Vessels must never be completely filled with liquid
refrigerant. Without sufficient room for expansion (gas

General information for A/C system

13/2/2005

cushion), vessels will rupture with devastating effect in the
event of an increase in temperature

00-1,

Characteristics of refrigerant R134a

.

Refrigerant is never to be transferred to systems or vessels
in which air is present.

Corrective action:

- Evacuate systems and vessels before charging with
refrigerant.

Basic rules for working on refrigerant
circuit

- Observe workplace-specific instructions

refer to

Environmental Protection Vol. 2-2. 23.0 .

- Ensure absolute cleanliness when working.

- Wear safety goggles and gloves when working with
refrigerant and nitrogen.

- Switch on existing ventilation systems.

- Use service station to discharge refrigerant circuit, only
then open screw connections and replace malfunctioning
components.

- Use caps to seal off opened assemblies and hoses to
prevent ingress of moisture and dirt.

- Make exclusive use of tools and materials intended for
refrigerant R134a.

- Re-seal opened refrigerant oil vessels to guard against
moisture.

- Flush refrigerant circuit with compressed air and nitrogen
if:

- Moisture or dirt has penetrated into refrigerant circuit (e.g.
following an accident)

- Refrigerant oil is dark and viscous.

- There is too much refrigerant oil in the refrigerant circuit
after compressor replacement.

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

In vehicles with A/C compressor without A/C clutch:

Note:

General information for A/C system

13/2/2005

- The engine is only to be started following complete
assembly of the refrigerant circuit.

- If possible start engine only with a filled refrigerant circuit.

- A/C compressor is driven permanently by the ribbed belt
pulley/torsion elastic clutch (not installed with an A/C
clutch):

- If an A/C compressor locks-up the overload safeguard for
the A/C compressor shaft is triggered. Also if no outward
bulges are visible on ribbed belt pulley/ overload safeguard,
it may also be that the A/C compressor is locked up.
Another indicator is abraded rubber material in the area of
the ribbed belt pulley/overload safeguard

- The A/C compressor is equipped with a protected oil
supply, this prevents A/C compressor damage in the event
that the system is empty. This means that approx.40 to 50
cm

3

of refrigerant oil remains in the A/C compressor.

- The engine should only be started when the refrigerant
circuit is completely and properly installed. For example; if
the refrigerant lines are not connected to the A/C
compressor, when the engine is running the A/C
compressor may heat up (via internal heat generation) so
much that the compressor will be destroyed.

- A/C Compressor Regulator Valve N280 is not activated
when the refrigerant circuit is empty and the A/C
compressor idles with the engine.

- If it is necessary to start the engine with a discharged
refrigerant circuit:

- Refrigerant circuit must be fully assembled.

- At least 1 4 of the prescribed refrigerant oil must be in the
A/C compressor.

- Engine speed should not increase above 2500 RPM.

- The engine should only run as long as absolutely
necessary

O-ring seals

- Make exclusive use of seals which are resistant to
refrigerant R134a and the related refrigerant oils. Color
coding of O-rings is no longer employed. Colored and black
O-rings are used.

- For used O-rings, make sure inner diameter is correct.

General information for A/C system

13/2/2005