Volkswagen New Beetle. Manual - part 2006

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Discharge A/C refrigerant system. See A/C refrigerant system, discharging . Then evacuate and 
recharge. See A/C refrigerant system, evacuating and recharging .  

WITH AN OTHERWISE PROPERLY OPERATING A/C SYSTEM, WATER SPRAYS OUT OF 
INSTRUMENT PANEL VENTS 

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Check evaporator drain pipe for proper routing (should not be kinked or pinched).  

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Check evaporator water drain valve. 

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Must not be plugged with wax, dirt or undercoating (clean if necessary)  

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Valve flap must open/close properly  

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Check plenum tray. 

{

Must be properly installed and not damaged  

A/C REFRIGERANT SYSTEM PRESSURES, CHECKING 

Check A/C refrigerant system pressures using these three tests: 

1. Air temperature drop from center instrument panel outlet (A/C system cooling performance)  

2. A/C system high pressure  

3. A/C system low pressure  

The combined results of all three steps determine which part of the A/C system is causing the problem. See 
SPECIFIED RESULT CHART . 

Test conditions 

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A/C refrigerant system fully charged; discharge, evacuate and recharge system if necessary  

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Condenser and radiator clean and free of obstructions (spray clean if necessary)  

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Air distribution can be adjusted correctly using control knobs (all air distribution flaps reach end 
positions)  

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Wiring OK per wiring diagram  

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Outside (ambient) air temperature between 20-30°C (68-86°F)  

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Drive belts for A/C compressor and Generator in good condition and properly tensioned  

Test 1: Air temperature drop from center instrument panel outlet, checking (A/C system cooling performance) 

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Start engine.  

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Set temperature control to maximum "cold".  

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Press "A/C" button and select second blower speed.  

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Adjust air distribution to instrument panel outlets.  

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Insert thermometer into center instrument panel outlet and raise engine speed to approximately 1500 
RPM.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

Specified result 

With humidity normal and outside (ambient) temperature between 20-25°C (68-77°F), system is cooling 
satisfactorily if air temperature from center instrument panel vent drops below 10°C (50°F) within 1 minute. 

For higher ambient temperatures and/or higher humidity, specified air temperature from center instrument panel 
vent can be slightly higher. 

If specified reading is not obtained, perform tests 2 and 3, then compare results of all three tests. See 
SPECIFIED RESULT CHART . 

Test 2: A/C system high pressure, checking 

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Connect high- and low-pressure hoses of refrigerant recovery/ recycling/recharging unit Kent-Moore 
ACR

4

 or equivalent, to high- and low-pressure service valves.  

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Disconnect electrical connector from coolant fan.  

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Start engine.  

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Set temperature control to maximum "hot".  

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Press "A/C" button and select highest blower speed.  

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Adjust air distribution to footwell outlets.  

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Raise engine speed to approximately 1500 RPM.  

Specified result 

System high pressure is normal if high-pressure gauge reads 232 psi (16 bar) within 30 seconds. 

If specified reading is not obtained, also perform test 3 and compare results of all three tests. See SPECIFIED 
RESULT CHART . 

Test 3: A/C system low pressure, checking 

z

Connect high- and low-pressure hoses of refrigerant recovery/recycling/recharging unit Kent-Moore 
ACR

4

 , or equivalent, to high- and low-pressure service valves.  

z

Start engine.  

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Set temperature control to maximum "cold".  

z

Press "A/C" button and select first blower speed.  

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Adjust air distribution to instrument panel outlets.  

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Raise engine speed to 1500 RPM.  

Specified result 

System low pressure is normal if low-pressure gauge reads 22-36 psi (1.5-2.5 bar) within 30 seconds. 

If specified reading is not obtained, compare results of all three tests. See SPECIFIED RESULT CHART .

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

Specified Result Chart 

SPECIFIED RESULT CHART 

A/C REFRIGERANT SYSTEM COOLING PERFORMANCE, CHECKING 

Test conditions 

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A/C refrigerant system fully charged  

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A/C clutch -N25- and compressor function OK  

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Condenser and radiator clean and free of obstructions  

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Air distribution can be adjusted properly  

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Wiring OK as per wiring diagram  

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Outside (ambient) temperature 20°C-30°C (68°F-86°F)  

Checking 

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Start engine.  

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Set temperature control to maximum "cold".  

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Press A/C button and select second blower speed. 

Test 1 Temperature 
from center air vent

(1)

Test 2 High 

pressure

(2)

Test 3 Low 

pressure

(1)

Possible causes of 

incorrect readings

Corrective measures

Normal

Normal

Normal

None

-

Too high

Normal

Normal

Temperature flap 

position incorrect

Adjust temperature flap 

cable

Too high

Too low

Normal

Compressor

Replace compressor

Normal

Too low

Normal

Compressor

Replace compressor

Normal

Normal

Too high or 

too low

 

 

Too high

Normal

Too high or 

too low

Expansion valve or 

compressor

Clean/replace expansion 

valve or replace 

compressor

Normal

Too high or 

too low

Too high or 

too low

 

 

(1)

Normal air outlet temperature approx. 6°C (43°F). For higher ambient temperatures and/or higher 
humidity, specified air temperature from center instrument panel vent can be slightly higher.

(2)

For normal system temperatures and pressures, See Pressure and temperature specifications .

NOTE:

A/C evaporator temperature switch -E33- (if equipped) switches A/C compressor 
OFF only in special instances so evaporator does not ice up; variable 
displacement A/C compressor maintains temperature of 0°C (32°F) in 
evaporator.

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

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Adjust air distribution to instrument panel outlets.  

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Insert thermometer into center instrument panel outlet.  

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Raise engine speed to approximately 1500 RPM.  

Specified result 

With normal humidity and outside (ambient) temperature between 20°-25°C (68°-77°F), system is sufficiently 
charged if air temperature from center instrument panel vent drops below 10°C (50°F) within one minute. 

For higher ambient temperatures and/or higher humidity, specified air temperature from center instrument panel 
vent can be slightly higher. 

A/C REFRIGERANT SYSTEM, CHECKING FOR LEAKS 

Use halogen leak detector, Hitec HI400A-TEL or equivalent, to check for refrigerant leaks, following the leak 
detector manufacturer's instructions. 

Refrigerant gas dissipates very quickly. To make the job easier, avoid drafty or windy areas when checking for 
leaks. 

If the refrigerant system is discharged (empty), recharge the system with approx. 100 g (3.5 oz.) of refrigerant in 
order to check for leaks. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle