Volkswagen Polo Service & Repair Manual: Refrigerant Circuit, General Precautions
| Follow the instructions for the workplace. They should be
displayed in the workplace. |
| Ensure absolute cleanliness when working. |
| Wear work clothing, safety goggles and gloves when working
with refrigerant and nitrogen. |
| Turn on the exhaust gas ventilation system |
| 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. |
| Be sure to close the container to prevent the refrigerant
from absorbing moisture from the air. |
| – |
Refrigerant Circuit, Flushing with Compressed Air and
Nitrogen. Refer to
→ Chapter „Refrigerant Circuit, Flushing with Compressed Air and
Nitrogen“. |
| – |
Flush the refrigerant circuit with R134a refrigerant. Refer
to
→ Chapter „Refrigerant Circuit, Flushing (Cleaning) with
Refrigerant R134a“ |
| On vehicles with A/C compressor without magnetic clutch: |
 Note
| The engine should only be started after assembling the
refrigerant circuit. |
| If possible start engine only with a filled refrigerant
circuit. |
| The A/C compressor is always driven by the ribbed belt
pulley/torsion elastic clutch. It does not have a magnetic
clutch. |
| If an A/C compressor locks-up the overload protection for
the A/C compressor shaft is triggered. If no bumps are visible
on the ribbed belt pulley/overload protection, the A/C
compressor may be blocked. Another indicator is abraded rubber
material in the area of the ribbed belt pulley/overload
protection. |
| 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 approximately 40 to 50 cm3
of refrigerant oil remains in the A/C compressor. |
| The engine may only be started when the refrigerant circuit
is installed correctly. For example; if the refrigerant pipes
are not connected to A/C compressor, when the engine is running
the A/C compressor may heat up (via internal heat generation) so
much that the A/C compressor will be damaged. |
| 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 a quarter of the prescribed refrigerant oil must be
in the A/C compressor. |
| Do not let the engine RPM go above 2,000. |
| The engine should run less than 10 minutes. |
| Only O-rings that are resistant to refrigerant R134a and
refrigerant oil must be installed. Color coding of O-rings is no
longer employed. Colored and black O-rings are used. |
| Ensure inner diameter on seals used is correct. |
| Refer to the Parts Catalog. |
| O-rings may only be used once. |
| Before installing, coat the O-rings lightly with refrigerant
oil (PAG oil). |
Note
| When flushing components with compressed air and nitrogen,
always extract the gas mixture escaping from the components with
suitable extraction units (workshop extraction system). |
| After engine all service work, screw sealing caps (with
seals) onto all connections with valve and service connections. |
| Before starting up A/C system. Pay attention to the
vehicle-specific filling capacities. Refer to
→ Rep. Gr.87. |
| Do not fill refrigerant, extract the refrigerant present and
refill the system. |
| After Charging A/C System |
| – |
After installing a new A/C compressor or fresh refrigerant
oil has been filled into compressor (e.g. after blowing through
the A/C system), turn ribbed belt pulley of A/C compressor 10
rotations by hand before starting the engine. This prevents
damage to the A/C compressor. |
| – |
For 5-cylinder and 10-cylinder diesel engines, rotate A/C
compressor 10 rotations by hand at overload protection. Then
install A/C compressor. This prevents damage to the A/C
compressor. |
| – |
Start the engine with the A/C turned off (A/C Clutch -N25-
and A/C Compressor Regulator Valve -N280- are not actuated). |
| – |
Following engine idling speed stabilization, switch on A/C
compressor and run it for at least 10 minutes at idling speed
with maximum cooling output. |
|
|
|
A/C Service Station -VAS6007A- (and further or current A/C
Service Station)
Refer to the Workshop Equipment Catalog.
...
Other materials:
Parking
First read and observe the introductory information
and safety warnings Please adhere to relevant legislation when
stopping and parking your vehicle.
Stopping the vehicle
The steps should only be carried out in the specified order.
Stop the vehicle on a suitable surface  .
Depre ...
Replacing Reservoir, No Contaminants, No Loss of Refrigerant
Discharge the refrigerant circuit.
–
Replace the restrictor depending on the vehicle.
–
Remove receiver or accumulator.
–
Remove dirt from receiver or res ...
Indicator lamps and fuel gauge
Fig. 129 In the instrument cluster: Variants
A and B: fuel gauges for petrol and diesel. Variant C: fuel gauge for autogas
First read and observe the introductory information
and safety warnings 
Lit up
Needle position 
Possible cause †...
© 2016-2024 Copyright www.vwpolo.net
A/C System and Refrigerant R134a Safety Precautions