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. |
|
|
|
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Service Station)
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A/C System and Refrigerant R134a Safety Precautions