Early Air Conditioner compressors manufacturered by Zelex/Valeo and installed in the Golf, Passat, Jetta and Eos until June 2007 have a reasonably good chance of early failure due to a lubrication problem inside the compressor. This causes metal fatigue and eventually the breakage of the compresser shaft which distributes metal particles around the system.
Volkswagen are covering replacements out of warranty, in Germany the parts are covered for five years and 150,000 km with Volkswagen covering 50% of the labour costs in the fourth year and none in the fifth year. In Australia cars have been covered 6 months out of warranty.
The fix requires a new compressor manufactured by Sanden part number 1K0 820 803 (1K0820803) and index S or greater 1K0 820 803 S (1K0820803S), the replacement of the expansion valve along with a new condenser. To clean out the metal particles the system has to be flushed for 4+ hours.
- The limiter (indicated by 1 on the photo) is broken or is missing
- The compressor control valve is restricted by metal particles and the compressor does not build up pressure.
The compressor replacement, expansion valve, condensor and labour cost around AUD$3000. A new compressor is around AUD$1200.
Details of the Sanden Compressor are here – Sanden PXE16 Air Conditioner Compressor Specifications (1K0820803)
Some information (in German) is available at Autobild.de
Eos – 2007
Jetta – 2005 – 2007
Golf, Rabbit, GTI, Passat – 2006 – 2007
Volkswagen Technical Bulletin # 2013314