VW Golf manuals

Volkswagen Golf Service & Repair Manual: Basics for working on refrigerant circuit

Observe instructions specific to the workplace; → Volkswagen ServiceNet; Handbooks; Service handbook; Environmental protection. Refrigerant from air conditioning systems / refrigerant oils - to be displayed at refrigerant designated working area.
Observe the utmost cleanliness when working.
When handling refrigerants and nitrogen, wear protective clothing, protective glasses and protective gloves.
Switch on exhaust gas fume extractor (if there is one).
Extract the refrigerant circuit using only the air conditioner service station, and only then loosen the threaded joints and renew the defective components.
Protect units and hoses against moisture and dirt using sealing caps.
Use only tools and materials that are intended for use with refrigerant R134a.
Protect refrigerant oil by sealing container to prevent ingress of moisture.
–  Blow through refrigerant circuit with compressed air and nitrogen → Chapter:
–  Purge refrigerant circuit with refrigerant R134a. → Chapter
In vehicles that have an air conditioner compressor without a magnetic clutch:
  Note
If the engine is being started for the first time after the refrigerant circuit has been reassembled.
If possible, start engine only with refrigerant circuit charged.
The air conditioner compressor is driven permanently by the poly V-belt pulley or elastic drive coupling (it is not fitted with a magnetic clutch).
If an air conditioner compressor seizes, the overload protection separates from the air conditioner compressor shaft. Even if no bulges are visible in the V-belt pulley or overload protection, it may be that the air conditioner compressor has seized. Another indication is abraded rubber material around the poly V-belt pulley or overload protection.
The air conditioner compressor has an internal oil circuit to ensure that the air conditioner compressor is not damaged when the refrigerant circuit is empty. This means that about 40 to 50 cm3 refrigerant oil remain in the air conditioner compressor.
The engine may be started only when the refrigerant circuit is properly assembled. If, for example, the refrigerant lines are not connected to the air conditioner compressor and the engine is running, the compressor may heat up so much through internal warming that it will be destroyed.
The air conditioner compressor regulating valve -N280- is not activated when the refrigerant circuit is empty and the air conditioner compressor idles with the engine.
If it is necessary to start engine with an empty refrigerant circuit:
The refrigerant circuit must be fully assembled.
At least ј of the quantity of refrigerant oil specified for this refrigerant circuit must be in the air conditioner compressor.
The engine speed must not exceed 2000 rpm.
The engine should run < 10 minutes.
   
Safety precautions for when working on vehicles with air conditioning and when handling refrigerant R134a
Air conditioning service station -VAS 6007A- (and further service stations currently available) → Workshop equipment ...

O-ring
Use only O-rings that are resistant to refrigerant R134a and related refrigerant oils. O-rings are no longer colour-coded. Coloured and black O-rings are used. ...

Other materials:

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Assembly overview - bumper cover
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Areas exposed to stone chipping
Body areas exposed to stone chipping   Note The marked areas are exposed to stone chipping. When sanding these areas, note thicknesses of the paint structure and avoid sanding through. This is the only way to ensure long-term corrosion protection. ...

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