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. 

Refrigerant circuit

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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 

Refrigerant circuit

13/2/2005

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:

Refrigerant circuit

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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. 

Refrigerant circuit

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