Volkswagen New Beetle. Manual - part 2004

 

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Volkswagen New Beetle. Manual - part 2004

 

 

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Installing, See Fig. 23 .  

4. Evaporator  

5. Housing, lower part  

Fig. 23: Installing Evaporator Seal 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Glue seal -B- evenly to top and sides of the evaporator -A-. 

A/C REFRIGERANT SYSTEM PRESSURES AND TEMPERATURES, CHECKING 

The pressures and temperatures in the A/C system will vary depending on engine speed (RPM), coolant fan 
speed, engine coolant temperature, A/C clutch engagement, outside temperature, humidity, etc. 

Pressure and temperature specifications are based on the following:

NOTE:

Evaporator water (condensation) must be able to drain from housing. 
Evaporator seal must NOT be installed on the bottom of the evaporator (see 
detail).

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

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Engine speed (RPM) at 1500  

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Fresh air blower on high speed  

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A/C adjusted to Max. cooling 

Pressure and temperature specifications, See Pressure and temperature specifications . 

Fig. 24: A/C Refrigerant System 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Evaporator  

2. Low pressure service valve  

3. Compressor, low pressure side  

4. Compressor, high pressure side  

NOTE:

The following list refers to items in Fig. 24 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

5. Condenser  

6. Receiver drier  

7. Sight glass 

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If equipped  

8. High pressure service valve  

9. Expansion valve  

Pressure and temperature specifications 

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Refer to A/C refrigerant system pressures and temperatures, checking and A/C refrigerant system, 
component overview
 for component identification.  

PRESSURE AND TEMPERATURE SPECIFICATIONS 

A/C REFRIGERANT SYSTEM, TESTING WITH PRESSURE GAUGES 

Due to the constant temperature/pressure relationship of refrigerant R-134a, approximate high-side system 
temperature can be determined based on system pressure. 

Pressure gauges may have one or more temperature scales in addition to the pressure scale. Since various 

Component

Refrigerant state

Approximate pressure 

(bar/psi)

Approximate 

temperature

1 - Evaporator, inlet to outlet

Vapor to Gas

 

-7°C (19°F)

(2)

2 - Low pressure service 
valve

Gas

1.2 bar (17.4 psi)

(1)

-1°C (30°F)

3 - Compressor, low 
pressure side

 

 

Gas

4 - Compressor, high 
pressure side

Gas

 

65°C (149°F)

5 - Condenser

Gas

 

 

5 - Condenser

to Vapor

 

55°C (131°F) at outlet

5 - Condenser

to Liquid

14bar (203psi)

 

6 - Receiver drier

Liquid

 

 

7 - Sight glass (if equipped)

Liquid

 

55°C (131°F)

8 - High pressure service 
valve

Liquid

 

 

9 - Expansion valve

Liquid to Vapor

Inlet: 14 bar (203 psi) 

Outlet: 1.2 bar (17.4 psi)

Inlet: 55°C (131°F)
Outlet: -7°C (19°F)

(1)

Pressure maintained in the refrigerant system by the variable displacement compressor despite 
variables in temperature, load and engine speeds (RPM).

(2)

Temperature maintained in the refrigerant system by the variable displacement compressor despite 
variables in temperature, load and engine speeds (RPM).

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

refrigerants have different temperature/pressure relationships, each gauge is specific for a particular refrigerant.

Measuring pressure and temperature in a "switched-on" refrigerant system 

Use the A/C refrigerant high-pressure gauge to measure high pressure between the compressor and restrictor 
(including condenser) with the A/C switched on. 

Use the A/C refrigerant low-pressure gauge to measure low pressure between the restrictor and the compressor 
inlet (including evaporator) with the A/C switched on. 

The temperature displays of the low- and high-pressure gauges apply only to a portion of the low- and high-
pressure sides. The low-pressure gauge displays approximate temperature between the restrictor and evaporator 
outlet. The high-pressure gauge displays approximate temperature between the compressor outlet and restrictor. 

Measuring pressure and temperature in a closed container or "switched-off" refrigerant system 

Due to the constant temperature/pressure relationship of R-12 and R-134a, approximate temperature in a closed 
container or in a switched-off A/C system can be determined based on its pressure. 

If the temperature displayed on a gauge is lower than the actual temperature of the refrigerant, the refrigerant 
container or system is empty (discharged). 

A/C REFRIGERANT SYSTEM, DISCHARGING 

NOTE:

The temperature/pressure relationship only holds true when the refrigerant 
system contains liquid and vapor, but not when it contains only gas. In the 
gaseous state, the temperature is approx. 10-30°C (18-54°F) higher than 
indicated on the pressure gauge.

NOTE:

The temperature/pressure relationship only holds true when the refrigerant 
system contains liquid and vapor, but not when it contains only gas. In the 
gaseous state, the temperature is approx. 10-30°C (18-54°F) higher than 
indicated on the pressure gauge.

WARNING:

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Always use an Underwriter's Laboratory (UL) approved refrigerant 
recovery/recycling/recharging unit such as Kent-Moore ACR

4

 , or 

equivalent, whenever discharging an R-134a A/C system.  

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Any person who services a motor vehicle air conditioner MUST, by 
law, be properly trained and certified and use approved refrigerant 
recycling equipment. Technicians must complete an EPA approved 
recycling course to be certified.  

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State and local governments may have additional requirements 
regarding air conditioning servicing. Always comply with state and 
local laws.  

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Always wear safety goggles when charging or discharging system.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

 

 

 

 

 

 

 

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