Volkswagen Polo Service & Repair Manual: Possible Concerns
 Note
| The A/C system is functioning correctly when the air flowing
from the instrument panel vents has a temperature of 70C
or lower. |
| Setting on Climatronic “LO”. |
| Setting on A/C system “AC” on; “max”; “cold”. |
Note
| With all complaints marked with *. Refer to
→ Chapter „Pressures, Checking“. |
| Total cooling system failure. * |
| Insufficient cooling performance at all vehicles speeds or
engine speeds. * |
| None or insufficient cooling after driving a few miles. * |
| A/C compressor, A/C Clutch -N25- or A/C Compressor Regulator
Valve -N280- are switched off by A/C Refrigerant Low Pressure
Switch -F73-, A/C Refrigerant High Pressure Switch -F118-, A/C
Pressure Switch -F129- or by A/C Control Head -E87- or
Climatronic Control Module -J255- due to excessive or
insufficient pressure. * |
| None or sharp decrease in fresh-air supply after driving
several miles (evaporator iced up). * |
| From these, the following complaints may also occur: |
| The A/C compressor makes noises |
| – |
Re-tighten compressor securing bolts and compressor bracket
using a torque wrench. |
| – |
Check routing of refrigerant lines; they must not touch
other components and must not be subject to strain (align if
necessary). |
| Noise (refrigerant hammer) occurring immediately after
switching on air conditioner and/or when cornering or braking: |
| – |
Discharge, evacuate and charge refrigerant circuit (too much
refrigerant in circuit). |
Note
| Too much refrigerant oil in the circuit could also cause
this problem. This could occur if the amount of refrigerant oil
was not adjusted when replacing the A/C compressor. If this
occurs, flush the refrigerant circuit with refrigerant R134a.
Refer to
→ Chapter „Refrigerant Circuit, Flushing (Cleaning) with
Refrigerant R134a“. |
| Drain the refrigerant from the A/C compressor. To facilitate
this, the ribbed belt pulley or magnetic clutch plate on the A/C
compressor should be rotated by hand. After flushing, the entire
quantity of refrigerant oil specified by vehicle-specific repair
manual should be added to the refrigerant circuit (50 grams
directly in the A/C compressor). |
| Water sprays out of vents (in dash panel or footwell)
although air conditioning system is otherwise functioning
properly: |
| – |
Check proper routing of condensate drain; it must not be
crushed or kinked. |
| – |
Check condensation drain valve, it must not be clogged by
wax or underbody sealant and must open and close properly. |
| – |
Check plenum chamber cover; it must not be damaged and must
be properly installed (to stop water running into evaporator). |
| – |
Check water drains in plenum chamber; they must not be
blocked (e.g. by leaves). |
|
Note
The A/C system is functioning correctly when the air flowing
from the instrument panel vents has a temperature of 70C
or lower.
...
Other materials:
Refrigerant Circuit, Converting R12 to R134a and Servicing
Note
The laws and regulations listed below are applicable in
Germany. Different or additional laws and regulations may apply
in other countries.
Addresses in other countries can be obtained from the
relevant au ...
Safety Precautions
General Safety Precautions
As per VBG 20, German industrial liability insurance
association.
Follow the instructions for the workplace. They should be
displayed in the workplace.
...
Crimping Pliers - .35-2.5mm -VAS1978/1A
The Crimping Pliers - .35-2.5mm -VAS1978/1A- or the Wiring
Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2-
together with the Wiring Harness Repair - Crimping Head -
.35-2.5mm -VAS1978/1-1-, or the Wiring Harness Repair Set -
Crimping Head - 4-6 ...
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Test Requirements