Specified Values

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High-pressure side:

Increasing from initial pressure (when connecting the pressure gauges) to a maximum of 20 bar.

Low-pressure side:

Decreasing from initial pressure (when connecting pressure gauges) to the value in the graph.

Fig 1: Identifying Permissible Tolerance Range Graph

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

High pressure in bar

B -

Low pressure in bar

C -

Permissible tolerance range

Possible deviation from specification	Possible cause of fault	Corrective action
High pressure remains constant or increases only slightly (above pressure with engine stopped), Low pressure quickly drops to value in graph or below Required cooling output is not attained	Not enough refrigerant in circuit or expansion valve malfunctioning.	-- Extract refrigerant from the refrigerant circuit If quantity of refrigerant extracted roughly corresponds to specified capacity: -- Replace expansion valve-- Charge the refrigerant circuit.-- Repeat the test.
High pressure normal Low pressure in line with value in graph Required cooling output is not attained		If quantity of refrigerant extracted is substantially less than specified capacity: -- Localize the leak with leak detector and eliminate-- Charge the refrigerant circuit.-- Repeat the test.

NOTE:

If no malfunction can be found and the function of the A/C system is not correct after repeating the test, flush (clean) refrigerant circuit with refrigerant R134a, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A . If that is not possible in this workshop, flush the refrigerant circuit with compressed air and remove moisture with nitrogen, refer to REFRIGERANT CIRCUIT, FLUSHING WITH COMPRESSED AIR AND NITROGEN .

Possible deviation from specification	Possible cause of fault	Corrective action
High pressure increases above specification Low pressure quickly drops to value in graph or below Required cooling output is not attained	Constriction or obstruction in refrigerant circuit Expansion valve faulty	-- Run hand over refrigerant circuit to check for differences in temperature If difference in temperature is found at one component: -- Replace the hose or pipe if kinked or constricted.-- If there is an obstruction, flush refrigerant circuit with compressed air and nitrogen and replace expansion valve. If no malfunction can be found. -- Flush (clean) refrigerant circuit, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A .-- Repeat the test.

Possible deviation from specification

Possible cause of fault

Corrective action

High pressure increases above specification
Low pressure quickly drops to value in graph or below
Required cooling output is not attained

Constriction or obstruction in refrigerant circuit
Expansion valve faulty

-- Run hand over refrigerant circuit to check for differences in temperature

If difference in temperature is found at one component:

-- Replace the hose or pipe if kinked or constricted.-- If there is an obstruction, flush refrigerant circuit with compressed air and nitrogen and replace expansion valve.

If no malfunction can be found.

-- Flush (clean) refrigerant circuit, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A .-- Repeat the test.

NOTE:

If the function is not correct after flushing the refrigerant circuit, the expansion valve must be replaced.

Possible deviation from specification	Possible cause of fault	Corrective action
High and low pressure normal at first After some time, high pressure increases above specification and low pressure drops to value in graph or below Required cooling output is no longer attained.	Expansion valve faulty Moisture in refrigerant circuit	-- Examine expansion valve for dirt or corrosion; replace if necessary.-- Flush refrigerant circuit with compressed air and nitrogen.-- Replace receiver/dryer.-- Repeat test if function is not OK.-- Flush (clean) refrigerant circuit, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A .-- Charge the refrigerant circuit.-- Repeat the test.

NOTE:

Always replace receiver/dryer in case of this malfunction.

Possible deviation from specification	Possible cause of fault	Corrective action
High pressure normal or too high (see diagram), Required cooling output is not attained A/C compressor noise (particularly after switch-on)	Too much refrigerant in the circuit. Expansion valve or A/C compressor faulty.	-- Extract refrigerant from the refrigerant circuit If quantity of refrigerant extracted roughly corresponds to specified capacity: -- Replace expansion valve-- Charge the refrigerant circuit.-- Repeat test If quantity of refrigerant extracted is substantially greater than specified capacity: -- Charge the refrigerant circuit.-- Repeat the test.

Possible deviation from specification

Possible cause of fault

Corrective action

High pressure normal or too high (see diagram),
Required cooling output is not attained
A/C compressor noise (particularly after switch-on)

Too much refrigerant in the circuit.
Expansion valve or A/C compressor faulty.

-- Extract refrigerant from the refrigerant circuit

If quantity of refrigerant extracted roughly corresponds to specified capacity:

-- Replace expansion valve-- Charge the refrigerant circuit.-- Repeat test

If quantity of refrigerant extracted is substantially greater than specified capacity:

-- Charge the refrigerant circuit.-- Repeat the test.

NOTE:

If the function of the A/C system is not correct when the test is repeated, re-install old expansion valve and flush refrigerant circuit with compressed air and nitrogen. Then replace A/C compressor and receiver/dryer.

Possible deviation from specification	Possible cause of fault	Corrective action
High pressure only increases slightly above pressure with engine stopped Low pressure drops only slightly Required cooling output is not attained	A/C compressor faulty.	-- Flush (clean) refrigerant circuit, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A .-- Replace A/C compressor and receiver/dryer.

Possible deviation from specification	Possible cause of fault	Corrective action
High pressure normal Low pressure too low (see graph) The required cooling performance is obtained	Expansion valve or A/C compressor faulty	-- Replace expansion valve-- Charge the refrigerant circuit.-- Repeat the test.

NOTE:

If A/C system function is not OK when the test is repeated, flush (clean) refrigerant circuit, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A . Then replace A/C compressor and receiver/dryer.

With this malfunction, evaporator may ice up although quantity of refrigerant in circuit is OK.

Possible deviation from specification	Possible cause of fault	Corrective action
High and low pressure normal Required cooling output is not attained	To much refrigerant oil in the circuit.	-- Discharge the refrigerant circuit.-- Flush (clean) refrigerant circuit, refer to REFRIGERANT CIRCUIT, FLUSHING (CLEANING) WITH REFRIGERANT R134A .
High and low pressure normal A/C compressor noise (particularly after switch-on) The required cooling performance is obtained

NOTE:

Overfilling with refrigerant oil can occur in the event, for example, the compressor has been replaced without adjusting the quantity of refrigerant oil.

If the A/C compressor is not replaced, the refrigerant oil should be drained from the A/C compressor via the oil drain plug. Out of the entire quantity of refrigerant oil (refer to vehicle-specific Repair Information), 50 grams should be put in the A/C compressor and the rest in the refrigerant circuit.