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 Zelex/Valeo compressor can be identified by the photo on the right, the part number will be 1K0 820 803 L (1K0820803L) or 1K0 820 803 N (1K0820803N). The failure can be identified in two ways;
- 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
Models affected
Eos – 2007
Jetta – 2005 – 2007
Golf, Rabbit, GTI, Passat – 2006 – 2007
Volkswagen Technical Bulletin # 2013314
it seems that seat installs the same compressors in it’s cars. i have a seat toledo 2005 2,0 pdtdi dsg and my ac went dead on monday. sadly nobody here in hungary seems to know anything about this replacement program. i hope extends here as well…
estoy interesado por favor enviar mas fotos
I have the same problem I believe, now require new compressor and condenser at great expense – is there any news that this 5 year extension will be sent to UK customers or should I call VW direct and risk listening to the standard ‘we have no issue’ response?
I also have the same problem on a Mark V 2006 Golf Gti. Dealers have just replaced condenser, the parts were given as a good will gesture, however, £500 labour costs and still doesn’t work. Awaiting VW UK to investigate as it appears metal fragments are still in the system and they can’t solve it. Quite clearly there is a major problem with these condensors.
Hi Maverick,
Thanks for posting this; I am looking at a late ’06 MY07 Jetta and would like to check this out, too.
I hope this is covered fully by the VWA extended warranty in Oz.
Cheers,
Bizi
Its really good.keep up the good work.
The air conditioning in my seat altea stopped working due to the same problem. Out of warranty – quote of £1400 to fix. Very unhappy.
I recently took over ownership of a used Golf Gti MkV 2005 and the air cond stopped working about a month ago. I then took it into my local service centre in Sydney, Australia. VW Aus came back offering a good will replacement and fix based on the regularity of the car being serviced and aged of the car. Unfortunately I will still be $400 AUD out of pocket and VW will chip in the rest of the cost.
My air con stopped working on my 2007 GTI last week lost all pressure in system, VW replaced compressor and condenser under warranty. Car only done 37k, had all the coils replaced last month. cost very expensive.
Is there any help being offered in the US? Mine just went out and I am at 59K. Thanks
I’m at 56K miles and a quote of $1700 for the compressor, condenser, and expansion valve and my dealership wouldnt goodwill it. Called VW USA and they said they were aware of the compressor failures but they do not determine it is a problem and will not offer any assistance. I was told if a recall is issued within the next 6 months I can get everything replaced free of charge. So, wait for the possibility of a recall (probably not gonna happen) or shell out the $1700 to get everything replaced.
I had my compressor replaced not more than a year ago. I took it in for a service this morning with complaints about the a/c playing up again. Well, the friendly people at this particular VW dealership in Sydney, say that the compressor needs to be replaced – AGAIN.
This Valeo compressor is building a terrible reputation here in Egypt especially in the Jetta since it was released 4 the first time & also in the Skoda Octavia as both have almost the same components. I was about 2 buy a brand new Jetta until I discovered this disaster…it’s a serious disaster especially when 1 tackles a country that reaches over 40 degrees celcuis in the summer months of July & August…just imagine yourself in such temperature with no AC…!!!!! I bet death is easier…;)
Since the faulty compressors were fitted until June 2007, then VW should do the right thing and issue a recall for the affected cars made up until that date. Why wait until the compressor fails when it’s a known problem that it will fail.
It’s not a known problem that will fail but rather a higher rate of failure compared to the newer compressors. Every compressor will fail at some point but this needs to be viewed in the context of the life of the car.
You can’t defend VW in this…I am at 78K miles and my compressor just failed for the second time. Every 40k miles is a problem that needs to be addressed.
mine went out in the winter- noticed because defrost wouldn’t do it’s job. Compressor replaced under warranty for my 07 eos. Hope this isn’t a recurring problem
Picked a new mk6 GTI, on 10 December 2009, ac stopped working after 2 days, ac compressor was replaced.
Did that fix it for you Michael? Just had to use my AC this past weekend on my mk6 GTI and no cold air!!!!!
Had the same issue with Jetta 08 DSG Turbo. The A/C just stopped blowing cold air – that in the middle of Oz summer. Let’s hope it’s covered under warranty coz it sounds expensive to fix!!!
I also have the same problem with my 2006 Golf V GTI…
Air-con stopped working, I took it in and I was told that my compressor is busted. Now i’m told I have to replace the whole unit at a cost of +-R20000… I hope VW South Africa Does something about this…
Hi Quentin. My Caddy aircon has also gone. Can get the whole lot replaced aftermarket in Krugersdorp for R8500. Still not acceptable. VW need to look at this plus their turbo problems on 1.9TDI
Mk 5 2.0 GT Tdi, Five years and two weeks old, thought it just needed a re-gas but the compressor and valves are stuffed. Local dealer quotes 700gpb. Very annoyed, shocking attitude that VW won’t recall the part. The dealer even wanted to bill for the re-gas and ‘knocked a bit off’. I expected VW to be more reliable than this. Most of the Koreans are throwing in warranties that make the total cost of ownership very, very attractive compared to this mobile money pit.
My 1.9Tdi VW Caddys aircon and also a friends both gave in at just over 90 000km.Both cars are just under 4years old. I approached Tavcor,the vw agent in George,they deny that there is a problem.They quoted me R22400 to replace it. When shopping around for a better price 2 different companies told me that they get in a lot of the newer vw as the airconpumps dont disengage with a clutch like the older models.They turn all the time while the motor turn and have a solenoid operated valve that open and closes to operate it, and BECAUSE THEY TURN ALL THE TIME THEY DONT LAST.
My caddy one was done 2 yrs ago and our ’07 Eos is no longer blowing cold air
It’s a major pain in the butt but at lease it’s covered under warranty
This happened to my 2006 Golf 5 GTI at 30,000 miles back in December of 2007. A/C unit was replaced 3 times and the car was at the dealer for over a month. Volkswagen gave me a new .:R32 and kept me happy.
Hey people,
Just to let you know this happened to me 2 weeks ago. I have an ’06 MKV GTI. I’m in Melbourne and took the car to the good folk at Barloworld Glen Waverley (expecting them to tell me that it’s going to cost me (as the car is 14 months out of warranty). But instead they called me up and told me my car was ready and that it will not be any charge to me.
When I went in to pick me up they told me again that the condenser and valve had been replaced, the system flushed and re-gassed.
On the free invoice it said that it was done under good faith with the charges going to VW Aus. With that I’m very happy and cannot wait till I can go an buy the MKVI Golf R when it’s available.
Hope next time , DELPHI will be the new supplier of these compressors, at least are more reliable.. mine is still running and in good shape!!!!
[...] is a five year warranty with 50% labour covered in the fourth year and none in the fifth year. Volkswagen Golf, GTI, Passat, Jetta and Eos Air Conditioner Compressor Failure website: http://www.my-gti.com Reply With Quote Promote to Article [...]
Just had this happen to our ’06 Passat in Ohio, USA. It is almost 4 yrs old with about 65K miles. Our dealer talked with VW who is covering around 50% of the cost. Still US$800 but better than nothing. Glad to hear this compressor is gone now
Todd
I live in Ohio and I have an 06 Passat, Dealer quoted me $2K + tax & shop supplies to fix this problem. What dealer did you take Passat to, I live in Cleveland area.
[...] in 2007 and whilst they can still fail like any moving part the incidences are much lower. Volkswagen Golf, GTI, Passat, Jetta and Eos Air Conditioner Compressor Failure Major car manufacturers including VW have training and drive days ( hard to believe I know). [...]
We have been running volkswagen golfs as a second car for the last 7 years, but this will be our last. After a catalogue of faults on all cars,some serious, the latest being the air con to pack in. The quality and reliability of volkswagen is shocking, they could not even be rated with Bmw and Mercedes, our main cars. I am glad “everything in life is” not ” as reliable as a volkswagen”, because the world would be at a standstill!
Update on my previous comment. I telephoned Volkswagen to be told, they would look favourably with regard to financial assistance on repair, IF it was the compressor and IF I used a franchised dealer. Our franchised dealer, Inch Engineering at Bathgate, told me they would be unable to diagnose the fault themselves and required me to pay them for outside assistance. The grand total would amount to £785. I took the car to Hunters of Linlithgow, an independent shop with an excellent reputation for price and knowledge, (an opinion not shared by our local franchised dealer). The result was a faulty Valeo compressor with the part numbers as above, and a total repair bill of £367, with a spotless working vehicle returned to us. Volkswagen can keep their possible assistance, along with their extortionate franchised dealers.
I’m based in the UK and have an ’06 plate Golf (now out of warranty) — the air conditioning started blowing warm last week and a trip to Kwik Fit for a regassing didn’t fix it (which incidentally meant I didn’t have to pay for it!)
Crewe Volkswagen today diagnosed the problem as a faulty compressor, for which I had to pay their standard £46 diagnosis charge. Their initial assessment was a £750 bill to replace the compressor — ouch. Thankfully since I have a full VW service history they spoke to Volkswagen UK to see if there was any good will. The outcome of this is that VW have agreed to fund 100% of the cost of the compressor and 50% of the labour, leaving me with a bill for a grand total of £130 — even the initial diagnosis charge was rescinded.
The only downside is that the parts are on backorder so I’ll have to wait until they come back in to stock but overall I’d say that was a big win. Just goes to show that not all franchised dealers are out to rip you off, you just have to find one you can trust — thanks again Crewe VW.
Hi
Have they said how long the part is on back order for?
Not long! My car went back in on 29th June and I now have fully working air-con… result!
Do you know if you have to have full VW service history
If you’re still under warranty then it shouldn’t matter — if you’re out of warranty then you’ll only get good will if you have a full vw service history.
My 2000 Golf lost its compressor clutch assembly (burnt up) and also wiring harness in 2003 at 29,000 miles; and AC control module also replaced at the time (both under extended Toyota !! warranty). In June 2008 (64,000 mi) car A/C checked out OK before driving trip. Just 7,000 miles later, June 09, the AC ran once OK with AC on for 1+ hours; and a week or so later, stopped giving cold air when we were on the road. Here’s the deal: We just do not use the AC system enough to justify what has happened here. No one can specifically identify what is wrong without doing an evac and recharge test ($180), and already had one diagnostic ($108) that indicated it could be clutch (and compressor) so impossible to know whether compressor, clutch, consenser or whatever. Is this a LEMON ? (had a VW rabbit for 7 years and know all about lemons). Way past warranty, but VW is renowned for bad elec systems.
My car is a VW Golf GTI 2.008. The compressor of the A/C it was broken. It is possible that VW change this part by warranty?? What can I do??
Thanks,
I have a mark IV from 2001. Compressor was repaired in 2006 for €500 and has just gone again. What with all the other parts that have collapsed: electric windows, boot locking, turbo, on-board computer, oil-gauge, etc. which have gone wrong, I will never buy a VW again. They’re about as reliable as the England football team.
I took my 2006 VW Jetta GLI in for A/C service yesterday and they told me that my compressor and condensor have failed and required replacement. Total cost = $2500 USD. Unbelievable. I told them no, and considering my options for trading it in for something more reliable. I was warned about buying a VW and all went pretty well (despite oil consumption problems) for nearly 4 years but this is unacceptable and will never buy VW again. Too bad, really liked the car too.
My 07 rabbit had the compressor go out just out of warranty. I called up VW and they contacted my local dealer. I pay 20% they pay the balance. Ended up costing a bit over $250. My advice is to get a part quote then talk to VW direct. All in all VW has been a great company to deal with. This is my 1st issue in 3 new vw’s. Good luck to all
Our 2006 GLI just experienced the same problem and we called VW coporate and they assigned a claims oerson to look into it (because we are 9k miles out of warranty) to see what they would be willing to do. They agreed to pay for the parts ($824) and we would pay for Labor ($440) so that’s better then nothing…..