AC-HEATER SYSTEM - MANUAL.pdf - VW - groundsin

A/C-HEATER SYSTEM - MANUAL

Article Text

1996 Volkswagen Golf

For Volkswagen Technical Site

Thursday, August 19, 1999 11:25PM

ARTICLE BEGINNING

1995-96 MANUAL A/C-HEATER SYSTEMS

Volkswagen

Cabrio, Golf, Golf III, GTI, Jetta & Jetta III

* PLEASE READ THIS FIRST *

WARNING: To avoid injury from accidental air bag deployment,

read and carefully follow all SERVICE PRECAUTIONS and

DISABLING & ACTIVATING AIR BAG SYSTEM procedures in the

AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY

EQUIPMENT section.

CAUTION: When battery is disconnected, radio will go into anti-theft

protection mode. Obtain radio anti-theft protection code

from owner prior to servicing vehicle.

A/C SYSTEM SPECIFICATIONS

SPECIFICATIONS

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Application Specification

Compressor Type ................ Sanden SD7-V16/SD7-V16L 7-Cyl.

Compressor Belt Tension (1)

System Oil Capacity .................................. 3.9 ozs.

Refrigerant (R-134a) Capacity (2) .............. 28.0-29.8 ozs.

System Operating Pressures (3)

High Side ............................. 203 psi (14.27 kg/cmý)

Low Side .............................. 17.4 psi (1.22 kg/cmý)

(1) - Serpentine belt tension is automatically adjusted by

tensioner pulley.

(2) - Use SP-10 PAG Compressor Oil (Part No. G 052 154 A2).

(3) - Measured at 68-86øF (20-30øC) ambient temperature.

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DESCRIPTION & OPERATION

REFRIGERANT SYSTEM

System uses R-134a refrigerant. Variable displacement

compressor increases or decreases pressure as necessary to maintain

evaporator temperature near 32øF (0øC). Expansion valve restricts

refrigerant flow, causing pressure differential. See Fig. 1.

A/C-HEATER SYSTEM - MANUAL

Article Text (p. 2)

1996 Volkswagen Golf

For Volkswagen Technical Site

Thursday, August 19, 1999 11:25PM

Fig. 1: A/C-Heater System Component ID (Engine Compartment)

Courtesy of Volkswagen United States, Inc.

COMPRESSOR CLUTCH CONTROL

Evaporator Temperature Switch

Although compressor clutch does not normally cycle on and

off, an evaporator temperature switch turns off the compressor clutch

if evaporator temperature decreases to 32øF (0øC). This prevents

evaporator icing. See Fig. 6.

A/C Pressure Switch

A/C pressure switch is a triple-pressure switch, which

monitors high side pressure. See Fig. 1. If pressure decreases to less

than 17.4 psi (1.2 kg/cmý), A/C pressure switch interrupts power to

compressor clutch (low-pressure cutout). Switch closes when pressure

increases to more than 34.8 psi (2.4 kg/cmý).

If pressure increases to more than 464 psi (32.6 kg/cmý),

A/C pressure switch interrupts power to compressor clutch (high-

A/C-HEATER SYSTEM - MANUAL

Article Text (p. 3)

1996 Volkswagen Golf

For Volkswagen Technical Site

Thursday, August 19, 1999 11:25PM

pressure cutout). Switch closes when pressure decreases to less than

348 psi (24.5 kg/cmý).

A/C pressure switch also controls cooling fan high speed

operation. If pressure increases to more than 232 psi (16.3 kg/cmý),

switch contacts close, causing cooling fan to operate at high speed.

When pressure decreases to less than 181 psi (12.7 kg/cmý), switch

contacts open.

Ambient Temperature Switch

If ambient temperature decreases to less than 36øF (2øC),

ambient temperature switch interrupts power to compressor clutch. When

ambient temperature increases to more than 45øF (7øC), ambient

temperature switch restores power to compressor clutch. See Fig. 1.

AIRFLOW CONTROL

Fresh/Recirculated Air Flap

Fresh/recirculated air flap (door) above blower motor

controls air entering ducting system. Flap is controlled by a vacuum

servo. See Fig. 6. Vacuum supply to servo is controlled by a 2-way

valve (electric solenoid), located between vacuum reservoir and vacuum

servo. When voltage signal from A/C-heater control panel is applied to

the 2-way valve, the valve opens, allowing vacuum supply to vacuum

servo.

Temperature Flap

Temperature flap (door) diverts air through or around heater

core. Flap is controlled by a cable connected to the A/C-heater

control panel.

Central Flap

Central flap (door) diverts air to face vents or to footwell

and defrost vents (or a combination of all 3). Flap is controlled by a

cable connected to the A/C-heater control panel.

Footwell/Defrost Flap

Footwell/defrost flap (door) diverts air to footwell or

defrost vents (or a combination of both). Flap is controlled by a

cable connected to the A/C-heater control panel.

ADJUSTMENTS

TEMPERATURE FLAP CABLE

Ensure cable is connected to A/C-heater control panel and

panel is installed. Remove cable sleeve retaining clip (cable sleeve

is Blue). See Fig. 2. Disconnect cable from temperature flap lever.

Adjust temperature control knob to maximum cold position. Connect

cable to temperature flap lever. Push lever in direction of arrow

until it stops. Hold lever in position, and install cable retaining

clip.

A/C-HEATER SYSTEM - MANUAL

Article Text (p. 4)

1996 Volkswagen Golf

For Volkswagen Technical Site

Thursday, August 19, 1999 11:25PM

Fig. 2: Adjusting Temperature Flap Cable

Courtesy of Volkswagen United States, Inc.

CENTRAL FLAP CABLE

Ensure cable is connected to A/C-heater control panel and

panel is installed. Remove cable sleeve retaining clip (cable sleeve

is Black). See Fig. 3. Disconnect cable from central flap lever.

Adjust airflow distribution knob to defrost position. Connect cable to

central flap lever. Push lever in direction of arrow until it stops.

Hold lever in position, and install cable retaining clip.

Fig. 3: Adjusting Central Flap Cable

Courtesy of Volkswagen United States, Inc.

FOOTWELL/DEFROST FLAP CABLE

Ensure cable is connected to A/C-heater control panel and

panel is installed. Remove cable sleeve retaining clip (cable sleeve

is Black). See Fig. 4. Disconnect cable from footwell/defrost flap

lever. Adjust airflow distribution knob to defrost position. Connect

A/C-HEATER SYSTEM - MANUAL

Article Text (p. 5)

1996 Volkswagen Golf

For Volkswagen Technical Site

Thursday, August 19, 1999 11:25PM

cable to footwell/defrost flap lever. Push lever in direction of arrow

until it stops. Hold lever in position and install cable retaining

clip.

Fig. 4: Adjusting Footwell/Defrost Flap Cable

Courtesy of Volkswagen United States, Inc.

TESTING

WARNING: To avoid injury from accidental air bag deployment,

read and carefully follow all SERVICE PRECAUTIONS and

DISABLING & ACTIVATING AIR BAG SYSTEM procedures in the

AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY

EQUIPMENT section.

A/C SYSTEM PERFORMANCE

1) Ensure no bubbles are present in sight glass. See Fig. 1.

Connect manifold gauge set to service valves. Run engine at 1500 RPM.

Set air distribution knob to face vent position. Set temperature

control knob to full cold position.

2) Press A/C NORM button. Set blower motor on 2nd speed.

System is okay if air temperature at center vent is less than 50øF

(10øC) after one minute and system operating pressures are within

specification. See SPECIFICATIONS table at beginning of article.

A/C PRESSURE SWITCH

NOTE: A/C pressure switch may be removed without discharging A/C

system.

Connect manifold gauge set to service valves. Disconnect A/C

pressure switch connector. Check continuity between specified A/C

pressure switch terminals. See A/C PRESSURE SWITCH CONTINUITY table.

See Fig. 5. Replace A/C pressure switch if continuity is not as

specified.

AC-HEATER SYSTEM - MANUAL.pdf

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