Removing and installing refrigerant lines to air conditioner compressor — VW

The following description deals with the New Beetle. Therefore differences must be considered, if necessary.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

VAS 6007 Air conditioner service station
V.A.G 1796 Leak tester
V.A.G 1331 Torque wrench (5...50 Nm)

Before starting repairs, read and comply with warnings and safety measures as ofpage 87-1 in Workshop manual.
Refrigerant must be evacuated with air conditioner service station V.A.G 6007 first.
The previously used service stations can still be used => Binder Volkswagen Workshop Equipment.
To prevent the ingress of humidity/moisture, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Warning!
Always disconnect battery earth strap before working on electrical system.
Notes:

When the battery is reconnected, please remember to check vehicle equipment (radio, clock, convenience electrics etc.) in accordance with Workshop manual and/or Owners manual.

Perform following work first:

Evacuate refrigerant.

Note:

Evacuating the refrigerant into the environment is a punishable offence.

Remove bolts -A- (torque setting: 22 Nm).
Remove O-rings -B- (10.8 mm; 1.8 mm) and -D- (14.3 mm; 2.4 mm).

Notes:

Refrigerant line -C- leads to condenser
Refrigerant line -E- comes from expansion valve
Ensure refrigerant lines are seated correctly over pins -F- when installing lines.

The rest of the assembly is basically in reverse order to the dismantling sequence.

The following work steps must be performed before initially operating system when a new compressor is installed, or fresh refrigerant oil is filled (e.g. after blowing refrigerant circuit through or draining compressor via oil drain plug).

After installing, turn compressor over approx. 10 rotations by hand.

Start engine with compressor switched off.
Wait until the idling speed has stabilised.
Then switch air conditioner compressor on and run at idling speed for at least 10 minutes.