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

13/2/2005

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

13/2/2005

- 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. 

Refrigerant circuit

13/2/2005

- 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

13/2/2005