Volkswagen Golf / Golf GTI / Jetta. Manual - part 1017

00 - 8

Components, replacing

- All components of the refrigerant circuit submitted for
quality observation are always to be sealed (use original
sealing caps of replacement part).

- To date, the following replacement parts (compressor,
reservoir, receiver, evaporator and condenser) have been
filled with nitrogen gas. This charge is being gradually
discontinued/the pressure of the nitrogen charge is now so
low that escape of gas is no longer perceptible on initial
opening.

- On vehicles installed with a compressor with no A/C
clutch, the engine is only to be started following complete
assembly of the refrigerant circuit (compressor always in
operation as well)

00-1, Basic rules for working on

refrigerant circuit

- So that the compressor with A/C Compressor Regulator
Valve N280 (without A/C clutch) is not damaged when the
refrigerant circuit is empty, it is equipped with a secured oil
supply. This means that approx.40 to 50 cm

of refrigerant

oil remains in the A/C compressor

00-1, Basic rules for

working on refrigerant circuit

Note:

- As parts are sometimes stored for lengthy periods and at
different locations within the spare parts organization, it is
entirely possible that gas will escape from some parts and
not from others on initial opening (even in the case of
identical spare part numbers). Sealing caps at replacement
part connections are therefore to be removed carefully and
the nitrogen gas allowed to escape slowly.

- The refrigerant circuit is installed either with a restrictor
and reservoir or an expansion valve and receiver.

- Seal open connections and pipes (to prevent absorption
of moisture).

- Always replace restrictor.

- Reservoir / receiver or desiccant bag/dryer cartridge must
not be replaced under the following conditions.

- After an accident, however there is no damage at
reservoir / receiver.

- Repairs are performed quickly (not beyond the normal
repair time) and no moisture has penetrated. Vehicle is not
older than 5 years.

Components, replacing

13/2/2005

- Reservoir / receiver or dryer cartridge is to be replaced
under the following conditions.

- Refrigerant circuit was opened and vehicle is older than 5
years.

- Refrigerant circuit has been open for an uncertain time
period (creeping leak).

- Repairs proceed beyond the normal repair time period
and moisture has penetrated.

- Always replace reservoir / receiver or dryer cartridge after
flushing the refrigerant circuit, and keep them sealed for as
long as possible so that the absorption of moisture is
minimized.

- A/C compressor has locked-up.

- Reservoir / receiver is damaged (due to accident).

Warning!

- Contaminated refrigerant oils are to be disposed of as
used oils of unknown origin.

HSO Environment Vol. 2-2. 43. 1

Components (except compressor, reservoir
or receiver) leaking or damaged

Refrigerant circuit completely empty

- Remove malfunctioning component.

- Remove A/C compressor.

- Remove oil drain plug from compressor.

Note:

- The oil drain plug of "Denso" and "Nippondenso"
compressors is equipped with an oil seal instead of an O-
ring and this is always to be replaced

Parts Catalog

- To accelerate drainage of refrigerant oil, rotate
compressor by way of clutch plate of A/C clutch for
example.

- Pour old refrigerant oil out of compressor, see

HSO

Environment Vol. 2-2. 43. 1 .

- Then fill compressor with quantity of fresh refrigerant oil
corresponding to quantity of refrigerant oil in replacement
compressor

Components, replacing

13/2/2005

Repair Manual, , Repair Group 87,

- Use different refrigerant oils and quantities for the various
compressors

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- To ensure compressor lubrication on start-up, at least 80
cm

of refrigerant oil must be poured into the compressor,

the remainder can be added for example to the new
reservoir or receiver

Repair Manual, , Repair Group 87,

- If dirt has penetrated into the compressor with the
refrigerant circuit open (e.g. after an accident), compressor
is to be replaced.

- Clean (flush) refrigerant circuit with compressed air or
nitrogen

00-4, Refrigerant circuit, cleaning (flushing) with

compressed air and nitrogen.

- Replace receiver or reservoir and restrictor.

- Assemble, evacuate and re-charge refrigerant circuit.

There is still refrigerant in the refrigerant circuit

- Discharge refrigerant circuit.

- Remove malfunctioning component, flush with
compressed air, collect escaping refrigerant oil.

- The new component is to be filled with the amount of
refrigerant oil flushed out (plus 20 cm

for evaporator, plus

10 cm

for condenser, refrigerant pipes and refrigerant

hoses) as fresh refrigerant oil fill.

- Replace restrictor.

- Assemble, evacuate and charge refrigerant circuit.

A/C compressor. replacing

Components, replacing

13/2/2005

Compressor, replacing without the need for
flushing refrigerant circuit with compressed air
and nitrogen (e.g. in the event of external
damage following an accident)

- Discharge refrigerant circuit.

- Remove A/C compressor.

- Remove oil drain plug from compressor.

Note:

- The oil drain plug of "Denso" (Nippondenso) compressors
is equipped with an oil seal instead of an O-ring and this is
always to be replaced.

Parts Catalog

- To accelerate drainage of refrigerant oil, rotate
compressor e.g. by way of clutch plate of A/C clutch for
example.

- Pour old refrigerant oil out of compressor (observe
disposal

HSO Environment Vol. 2-2. 43. 1 ).

- Remove oil drain plug from replacement compressor,
pour out refrigerant oil and only add a quantity of fresh
refrigerant oil equal to the amount poured out of the
malfunctioning compressor.

Note:

- If, for example, 70 cm

of refrigerant oil has been poured

out of the malfunctioning compressor and 220 cm

out of

the replacement compressor (a small quantity of refrigerant
oil remains in the compressor). Fill the compressor to be
installed with 70 cm

of refrigerant oil (use can be made of

oil poured out of replacement compressor).

- Use different refrigerant oils and quantities for the various
compressors

Repair Manual, Heating & Air Conditioning, Repair

Group 87 ,

- If a greater quantity of refrigerant oil (more than approx.
80 cm

) has been poured out of the malfunctioning

compressor, the remaining refrigerant oil can also be
added to the evaporator or reservoir/receiver

Components, replacing

13/2/2005

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