Volkswagen New Beetle. Manual - part 2005

 

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Volkswagen New Beetle. Manual - part 2005

 

 

Discharging The A/C System 

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Connect red high-pressure hose -A- of refrigerant recovery/recycling/recharging unit to high side fitting 
on vehicle and open coupler valve. See Fig. 25 .  

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Connect blue low-pressure hose -B- of refrigerant recovery/recycling/recharging unit to low side fitting 
on vehicle and open coupler valve. 

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Following refrigerant recovery/recycling/recharging unit manufacturer's instructions, discharge A/C 
system into refrigerant recovery/recycling/recharging unit.  

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Disconnect power supply from A/C clutch to prevent accidental compressor operation with A/C system 
discharged. 

CAUTION:

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Always use separate refrigerant recovery/recycling/recharging 
servicing equipment for R-12 and R-134a systems. DO NOT use one 
piece of equipment for both R-12 and R-134a systems. The residual 
traces of refrigerant inside the equipment will contaminate and 
damage the equipment. Servicing equipment includes 
recovery/recycling/recharging unit, charging station, vacuum pump, 
manifold gauges, etc.  

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DO NOT use R-12 servicing equipment on R-134a systems or R-134a 
equipment on R-12 systems or damage to both the vehicle A/C 
system and servicing equipment may result. Use only equipment 
designed to meet Society of Automotive Engineers (SAE) standards.  

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R-134a and R-12 systems use different size service fittings. NEVER 
use adaptors to convert an R-12 fitting to R-134a size or R-134a 
fitting to R-12 size.  

NOTE:

Refer to safety measures starting on A/C refrigerant system prior to discharging 
or charging A/C refrigerant system.

NOTE:

Make sure that initial set-up of the refrigerant recovery/recycling/recharging unit 
has been completed before discharging the A/C system.

CAUTION: Always follow manufacturer's instructions when using a refrigerant 

recovery/recycling/recharging unit.

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

Fig. 25: Identifying Refrigerant Recovery/Recycling/Recharging Unit 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A/C REFRIGERANT SYSTEM, FLUSHING WITH COMPRESSED AIR AND NITROGEN 

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Use compressed air and nitrogen (available locally) to remove moisture, impurities and old refrigerant oil 
from A/C refrigerant system.  

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First blow out old refrigerant oil and dirt with compressed air, then dry components with nitrogen.  

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DO NOT blow compressed air and nitrogen through the compressor or expansion valve. Only blow 

CAUTION:

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When using compressed nitrogen always use a pressure regulator 
and the proper adaptor hoses and fittings (available locally). During 
flushing, use existing exhaust/ventilation systems to draw off the gas 
mixture escaping from the A/C system.  

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DO NOT flush R-134a refrigerant system with R-11. R-11 is not 
compatible with R-134a refrigerant and PAG oil and will cause total 
system contamination.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

compressed air and nitrogen through disconnected, free flowing components (i.e. disconnected hose, 
condenser, evaporator, etc.)  

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DO NOT blow compressed air and nitrogen into a capped off A/C component. Pressurized R-134a 
refrigerant in the presence of oxygen may form a combustible mixture.  

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Always flush components in opposite direction of refrigerant flow.  

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Flush evaporator through the low-pressure line with the high-pressure line removed.  

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If any component has dark thick deposits that cannot be removed with compressed air, replace 
component.  

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Thin light gray deposits in refrigerant lines and hoses are normal and do not impair the function of the 
system.  

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Always replace receiver drier and restrictor after flushing.  

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Dispose of contaminated refrigerant (PAG) oil following laws governing hazardous waste disposal. Do 
not combine PAG oil with any other old oils such as engine oil or transmission fluid.  

Flush refrigerant system with compressed air and nitrogen if: 

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Refrigerant oil is dark and viscous (thick)  

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Too much refrigerant oil is in the system following compressor replacement  

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Unclear or do not know how much refrigerant oil is in the system  

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Moisture, dirt or other impurities have entered the refrigerant system (i.e. following an accident)  

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Unable to pull a constant vacuum during evacuation of a leak-free system due to excessive moisture in 
the system  

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Refrigerant system has been open longer than the time required for normal repairs (i.e. following an 
accident)  

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Based on temperature and pressure measurements, system is diagnosed with moisture contamination  

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Compressor is replaced due to noises or internal damage  

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Flushing is required after replacing certain components in certain situations, See A/C refrigerant system, 
replacing components
 .  

A/C REFRIGERANT SYSTEM, EVACUATING AND RECHARGING 

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, when evacuating and recharging 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.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

A/C REFRIGERANT SYSTEM, TROUBLESHOOTING 

REQUIREMENTS 

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Electrical systems OK  

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Air flow distribution systems (controls and cables) OK 

Correct and repair as necessary before proceeding. 

If any one of the following system conditions exists, check A/C refrigerant system pressures. See A/C 
refrigerant system pressures, checking
 . 

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A/C does not cool (cooling has stopped completely)  

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Insufficient cooling during all driving speeds or engine speeds (RPM)  

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No cooling or insufficient cooling after a period of driving  

COMPRESSOR NOISY 

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Tighten compressor and compressor bracket mounting bolts using torque wrench.  

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Check routing of A/C refrigerant hoses and lines; hoses and lines must not contact other components and 
must be installed without tension or kinks, reposition or realign as necessary.  

A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking (refrigerant 
shock) - system overcharged 

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Always wear safety goggles when discharging, evacuating and 
recharging an A/C system.  

CAUTION: Always follow manufacturer's instructions when using a refrigerant 

recovery/recycling/recharging unit.

NOTE:

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Refer to R-134a safety measures prior to discharging or charging A/C 
refrigerant system, See A/C refrigerant system .  

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Follow refrigerant recovery/recycling/recharging unit manufacturer's 
instructions for evacuating and recharging A/C system.  

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Evacuate refrigerant system for a minimum of 30 minutes.  

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When recharging A/C system, add correct amount of refrigerant and PAG 
oil to system. See A/C refrigerant system, capacities .  

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After system recharge, manually rotate A/C compressor approx. 10 turns 
before starting engine. Start engine with A/C OFF. After idle speed has 
stabilized, switch A/C ON and let engine idle (compressor running) for a 
minimum of two minutes before raising engine speed.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

 

 

 

 

 

 

 

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