Category Archives: Air Conditioning

Volkswagen Golf Mk7 Airconditioner Drain Hose Incorrectly Installed until June 2013 including Audi A3 and Seat Leon

Over 300,000 Volkswagen Golf Mk7 manufactured until June 2013 may have a problem with the Air Conditioner drainage hose being installed incorrectly which leads to water accumulating in the passenger foot-well. As of September 2013 only around 50 cases of this occurring have been identified.

Condensation that collects on the evaporator is normally discharged to the outside via a small hose on the firewall.

This problem also affects the Audi A3 and Seat Leon.

source: http://www.autobild.de/artikel/vw-golf-vii-skandal-im-dauertest-4362680.html

Volkswagen Golf, GTI, Passat, Jetta, EOS, Rabbit and Tiguan Air Conditioner Compressor Failure

Air conditioner does not work, noises from engine compartment

Volkswagen Technical Product Information # 2023580/1
Repair Operation # 87 34 01 99
Release Date: 29-Jun-2010

Problem

Air conditioning does not work.

Noises from the engine compartment.

Background

Pulley bolt works it’s way free from compressor shaft creating noise and eventually failure of the compressor.

Only Delphi Compressors are affected, optimised Delphi compressors fitted from August 2008.

The refrigerant circuit does not need to be flushed as the damage to the compressor is external.

Diagnosis

Check the connection between the pulley and the compressor shaft while they are fitted:

  • The cooling performance check shows no pressure increase, although the refrigerant circuit is correctly filled and the control valve current is about 0.8A.
  • The mounting bolt of the pulley has visibly wandered out of the compressor shaft (see photo above).
  • The pulley turns without transmitting power, because the teeth of the pulley are worn.

Repair

Replace the compressor.

Models affected

137 –
1F7 – EOS
1K1 – Golf V
1K2 – Jetta III
357 – Passat CC
3C – Passat / Passat Wagon
5K1 – Golf VI
5M1 – Golf V Plus
5N1 – Tiguan

Volkswagen Climatronic Diagnostics – Mark VI

volkswagen_climatronic_diagnosticsThe Climatronic display on the Mark VI Golfs (and others that use the same system) has a heap of information that can be accessed like the Mark V.

Golk Mark V Information is here – Volkswagen Climatronic Information – Mark V

To access the information follow the steps as shown on the image.

  1. Hold down the “AC” button and press the “Window Vent” button, release when the LED’s on both buttons start flashing alternatively.
  2. The left hand knob adjusts the Main Channel, the centre buttons (FAN) adjusts the Sub Channel.
  3. To exit press the “AC” button.

The left hand number indicates the Main Channel and the Second number indicates the Sub Channel.

Further details to follow.

Sanden PXE16 Air Conditioner Compressor Specifications (1K0820803)

sanden_pxe16_air_conditioner_compressor_volkswagen_golf_1k0820803_001Sanden’s PX series next generation swash plate compressors are variable controlled for maximum environmental benefit, these compressors replace the Zelex and Valeo compressors that are prone to early failures – Volkswagen Golf, GTI, Passat, Jetta and Eos Air Conditioner Compressor Failure.

The PXE16 has a minimum displacement of 4.9cc, a maximum displacement of 163cc,  maximum speed of 8500RPM and 7 pistons. The displacement control is external and varies the compressor displacement without the use of an electromagnetic clutch. The unit runs all the time and varies output from 2% through to 100% as required.

Refrigerant used is R-134A and the oil used is SP-10.

View a video of the operation of the PXE compressor here (Internet Explorer required)

Climatronic Air Quality Sensor Operation and Location

The air quality sensor detects noxious substances in the ambient air (primarily petrol and/or diesel fumes).
t   The Climatronic control unit -J255- evaluates the signal from the air quality sensor -G238-. The air conditioning system is actuated depending on the degree and manner of ambient air pollution.
At an ambient temperature higher than approx. +2° C, air recirculation is actuated even when there is a minimal increase in noxious substances in the ambient air.
At an ambient temperature between approx. +2° C and approx. -5° C, air recirculation is not actuated until there is a strong increase in noxious substances in the ambient air. The compressor is also switched on at the same time.
At an ambient temperature less than approx. -5° C, air recirculation is not actuated until there is a strong increase in noxious substances in the outside air, but only for approx. 15 seconds, and the compressor is not started. When the concentration decreases, the air conditioning system is switched back to fresh air mode.
t   The “automatic air recirculation” function can be switched off at any time. If the function is active, the compressor will be switched on even at an ambient temperature below +2° C when “automatic air recirculation” is required. However, even with this function, it is not possible to operate the compressor at temperatures below -5° C.
t   On vehicles with “automatic air recirculation”, the air conditioner compressor can also be switched on at temperatures down to approx. -5° C even if the recirculated air function has been activated manually.
t   So that the air conditioning system does not operate continually in air recirculation mode in areas with consistently high levels of pollutants, the “intelligent” sensor adapts its sensitivity to the prevailing environmental pollution.
t   If the level of noxious substances in the ambient air remains relatively high over a long period of time, the intelligent sensor starts to adapt to the change in environmental conditions so that, generally, the demand for recirculated air lasts less than 12 minutes in areas where the ambient air exhibits a constant level of pollution. If a series of pollution peaks occur, the air conditioning system may operate over a longer period of time in air recirculation mode.
t   A certain amount of time is required for repositioning of the air conditioning system flaps. To prevent noxious substances from entering the passenger compartment while the flaps are closing (e.g. when driving through a cloud of diesel smoke), a dust and pollen filter with an activated charcoal layer is installed. A saturated filter cannot perform this task and should be renewed.
t   To prevent too frequent operation of the recirculation/fresh air flap, the flap is not actuated immediately if there is a minimal increase in noxious substances in the ambient air (the sensor does not send a request to the Climatronic control unit -J255-). The effect of the activated charcoal filter in the dust and pollen filter is adequate for this.
t   To prevent the air recirculation/fresh air flap from switching too frequently, the sensor’s request for “automatic air recirculation” continues for at least 25 seconds (minimum waiting period) even if the air pollutants decrease to a level that no longer requires air recirculation.
t   If the air conditioner compressor is switched off (e.g. in ECON mode), the maximum period of “automatic air recirculation” is limited to approx. 15 seconds by the Climatronic control unit -J255- so that condensation does not develop on the windows.
t   To clear condensation from windows as quickly as possible, the Climatronic control unit -J255- does not permit air recirculation in the “defrost” mode.
t   The air quality sensor -G238- requires approx. 30 seconds to become operational once the ignition has been switched on (warm-up time). During this time, the sensor can send no request for “automatic air recirculation” to the Climatronic control unit -J255-.
t   The air quality sensor -G238- is a highly sensitive electronic component which direct contact with solvents, fuels and certain chemical compositions could damage beyond repair. For this reason, do not install sensors that may have come into contact with these substances.
  • The air quality sensor detects noxious substances in the ambient air (primarily petrol and/or diesel fumes).
  • The Climatronic control unit -J255- evaluates the signal from the air quality sensor -G238-. The air conditioning system is actuated depending on the degree and manner of ambient air pollution.

At an ambient temperature higher than approx. +2° C, air recirculation is actuated even when there is a minimal increase in noxious substances in the ambient air.

At an ambient temperature between approx. +2° C and approx. -5° C, air recirculation is not actuated until there is a strong increase in noxious substances in the ambient air. The compressor is also switched on at the same time.

At an ambient temperature less than approx. -5° C, air recirculation is not actuated until there is a strong increase in noxious substances in the outside air, but only for approx. 15 seconds, and the compressor is not started. When the concentration decreases, the air conditioning system is switched back to fresh air mode.

  • The “automatic air recirculation” function can be switched off at any time. If the function is active, the compressor will be switched on even at an ambient temperature below +2° C when “automatic air recirculation” is required. However, even with this function, it is not possible to operate the compressor at temperatures below -5° C.
  • On vehicles with “automatic air recirculation”, the air conditioner compressor can also be switched on at temperatures down to approx. -5° C even if the recirculated air function has been activated manually.
  • So that the air conditioning system does not operate continually in air recirculation mode in areas with consistently high levels of pollutants, the “intelligent” sensor adapts its sensitivity to the prevailing environmental pollution.
  • If the level of noxious substances in the ambient air remains relatively high over a long period of time, the intelligent sensor starts to adapt to the change in environmental conditions so that, generally, the demand for recirculated air lasts less than 12 minutes in areas where the ambient air exhibits a constant level of pollution. If a series of pollution peaks occur, the air conditioning system may operate over a longer period of time in air recirculation mode.
  • A certain amount of time is required for repositioning of the air conditioning system flaps. To prevent noxious substances from entering the passenger compartment while the flaps are closing (e.g. when driving through a cloud of diesel smoke), a dust and pollen filter with an activated charcoal layer is installed. A saturated filter cannot perform this task and should be renewed.
  • To prevent too frequent operation of the recirculation/fresh air flap, the flap is not actuated immediately if there is a minimal increase in noxious substances in the ambient air (the sensor does not send a request to the Climatronic control unit -J255-). The effect of the activated charcoal filter in the dust and pollen filter is adequate for this
  • To prevent the air recirculation/fresh air flap from switching too frequently, the sensor’s request for “automatic air recirculation” continues for at least 25 seconds (minimum waiting period) even if the air pollutants decrease to a level that no longer requires air recirculation.
  • If the air conditioner compressor is switched off (e.g. in ECON mode), the maximum period of “automatic air recirculation” is limited to approx. 15 seconds by the Climatronic control unit -J255- so that condensation does not develop on the windows.
  • To clear condensation from windows as quickly as possible, the Climatronic control unit -J255- does not permit air recirculation in the “defrost” mode.
  • The air quality sensor -G238- requires approx. 30 seconds to become operational once the ignition has been switched on (warm-up time). During this time, the sensor can send no request for “automatic air recirculation” to the Climatronic control unit -J255-.
  • The air quality sensor -G238- is a highly sensitive electronic component which direct contact with solvents, fuels and certain chemical compositions could damage beyond repair. For this reason, do not install sensors that may have come into contact with these substances.

Removing and installing air quality sensor.

  • The air quality sensor -G238- is installed on the air intake grille in the front right (from the driver’s perspective) of the plenum chamber.
  • The air quality sensor -G238- is a highly sensitive electronic component which direct contact with solvents, fuels and certain chemical compositions could damage beyond repair.
  • Do not install a sensor that has been kept, for example, in a tool box.
  • Do not place a removed sensor in an area where it can come into contact with solvents, fuels and certain chemical compounds (fluids or vapours).

Removing

  1. Remove plenum chamber cover.
  2. Remove cover -1- from plenium chamber (see picture 1).
  3. Seperate connector on air quality sensor -G238- (see picture 2).
  4. Release air quality sensor -G238- and turn out of retainer on air intake grille (see picture 2).

Installing

  • Installing is a reverse of the removing order.

Volkswagen Golf, GTI, Passat, Jetta and Eos Air Conditioner Compressor Failure

vw_compressor_zelex_valeo_1K0820803Early 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.

vw_compressor_limiter_1K0820803The 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;

  1. The limiter (indicated by 1 on the photo) is broken or is missing
  2. 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

Volkswagen Climatronic Diagnostics – Mark V

Climatronic Diagnostics
Climatronic Diagnostics

The Climatronic display on the Mark V Golfs has a wealth of information that can be easily accessed. The information below has been put together from bits and pieces, the original document was translated into another language and I’ve attempted to translate from that, as I find errors I’ll clean them up.

Golf Mark VI Information is here – Volkswagen Climatronic Diagnostics – Mark VI

To access the information follow the steps as shown on the image.

  1. Hold down the “ECON or AC” button and press the “Window Vent” button, release when both displays change to indicate zeros.
  2. The left hand knob (Left Temperature) adjusts the Main Channel, the centre knob (FAN) adjusts the Sub Channel.
  3. To exit press the “ECON or AC” button.
The left hand number below indicates the Main Channel, the second number indicates the Sub Channel.

For example 19 – 0 is your digital speedometer in KPH, 19 – 1 is your digital speedometer in MPH. The type column indicates the type of data that is expected.

0. System Data Type
0 – 0 Program number Digital
0 – 1 ERL Left Digital
0 – 2 ERL Right Digital
0 – 3 Point being used Digital
0 – 4 Recirculating Automatic Digital
0 – 5 Stationary Heating Active Digital
0 – 6 Air Quality (7 = Fresh Air) Digital
0 – 7 Derived Digital
0 – 8 Country Acronym Digital
0 – 9 Sensor Zone Head °C
1. UIF
1 – 0 Internal Temperature °C
1 – 1 External Temperature °C
1 – 2 Temperatura? Piastrine? In? Platino? °C
1 – 3 Correttore? Piastrine? In? Platino? °C
1 – 4 Uif-Sonnenint? Digital
1 – 5 Sun Intensity Corrected °C
1 – 6 Correttore? Dinamico? °C
1 – 7 Correttore? ricircolo? °C
1 – 8 correttore? termico? °C
1 – 9 Compensazione accensione UIF? °C
2. Sun Intensity Sensor Left
2 – 0 Sun Intensity Not Corrected W/m2
2 – 1 Sun Intensity Corrected W/m2
2 – 2 Fan Correction W/m2
2 – 3 Value Digital
3. Sun Intensity Sensor Right
3 – 0 Sun Intensity Not Corrected W/m2
3 – 1 Sun Intensity Corrected W/m2
3 – 2 Fan Correction W/m2
3 – 3 Value Digital
4 . External Temperature
4 – 0 Temperature External °C
4 – 1 Temperature External CANBUS °C
4 – 2 Temperature Intake °C
5. Temperature Left Setpoint
5 – 0 Temperature Output °C
5 – 1 Difference between temp and temp setpoint °C
5 – 2 Regulator Setting (½%)
5 – 3 Pi-Stell-Max? (½%)
5 – 4 Defrost Digital
6. Temperature Left Actual
6 – 0 Temperature °C
6 – 1 Footwell °C
6 – 2 Vents °C
7. Temperature Right Setpoint
7 – 0 Temperature Output °C
7 – 1 Difference between temp and temp setpoint °C
7 – 2 Regulator Setting (½%)
7 – 3 Pi-Stell-Max? (½%)
7 – 4 Defrost Digital
8. Temperature Right Actual
8 – 0 Temperature °C
8 – 1 Footwell °C
8 – 2 Vents °C
9. Evaporator Temperature Setpoint
9 – 0 Evaporator temperature °C
9 – 1 Difference between temp actual and temp Setpoint °C
9 – 2 Evaporator value settings 5mA/Dig
9 – 3 Sensor Sight
10. Evaporator Temperature Actual
10 – 0 Evaporator Temperature °C
10 – 1 Liquid refigerant pressure bar
10 – 2 Liquid refigerant temperature °C
11. AC Compressor
11 – 0 Power setpoint mA
11 – 1 Power actual mA
11 – 2 Power maximum mA
11 – 3 Compressor PWM Digital (0-200)
11 – 4 Power offset compressor
11 – 5 Power value Digital
11 – 6 Compressor code
12. Climate Control Fan
12 – 0 Fan Setpoint Voltage V
12 – 1 Manual regulation
12 – 2 Code anomaly
12 – 3 Reduction impeller V
12 – 4 Impeller offset 0.1V
13. Temperature Air Vent Left
13 – 0 Setpoint value %
13 – 1 Setpoint temperature Digital
13 – 2 Actual Temperature Digital
13 – 3 Maximum Temperature Digital
13 – 4 Minimum Temperature Digital
14. Temperature Air Vent Right
14 – 0 Setpoint value %
14 – 1 Setpoint temperature Digital
14 – 2 Actual Temperature Digital
14 – 3 Maximum Temperature Digital
14 – 4 Minimum Temperature Digital
15. Temperature Air Vent Diffuser
15 – 0 Setpoint value %
15 – 1 Setpoint temperature Digital
15 – 2 Actual Temperature Digital
15 – 3 Maximum Temperature Digital
15 – 4 Minimum Temperature Digital
16. Temperature Air Vent Defrost
16 – 0 Setpoint Value %
16 – 1 Setpoint temperature Digital
16 – 2 Actual Temperature Digital
16 – 3 Maximum Temperature Digital
16 – 4 Minimum Temperature Digital
17. Temperature Internal Recirculation
17 – 0 Setpoint Value %
17 – 1 Setpoint temperature Digital
17 – 2 Actual Temperature Digital
17 – 3 Maximum Temperature Digital
17 – 4 Minimum Temperature Digital
18. Temperature External Air
18 – 0 Setpoint Value %
18 – 1 Setpoint temperature Digital
18 – 2 Actual Temperature Digital
18 – 3 Maximum Temperature Digital
18 – 4 Minimum Temperature Digital
19. Engine Data
19 – 0 Vehicle Speed (kph) kph
19 – 1 Vehicle Speed (mph) mph
19 – 2 Engine Temperature °C
19 – 3 Engine speed RPM
19 – 4 AC compress speed RPM
20. CANBUS Data
20 – 0 Additional Heating 1=on
20 – 1 PTC Confirmation 1=on
20 – 2 Effective Power PTC A
20 – 3 Air requested from external %
20 – 4 External air percentage cooler %
20 – 5 Performance heating 1=no external provision
21. Air Distribution
21 – 0 Defrost %
21 – 1 Face %
21 – 2 Feet %
21 – 3 Air Vent Diffuser %
21 – 4 Recirculated %
21 – 5 Air Sensor %
22. Time
22 – 0 Engine Off Time minutes
22 – 1 Engine Operating Time seconds
22 – 2 Operating Time with Ignition On seconds
22 – 3 ?
22 – 4 ?
22 – 5 ?
23. Special. Channel
23 – 0 Inner Lighting Sensor Digital
23 – 1 Air Quality Sensor
24. Software Version
24 – 0 Development State
24 – 1 Software Version
24 – 2 Type of Software
24 – 3 Keep Frozen 0/1 – Diagnosis
24 – 4 Version K Matrix
24 – 5 EEP – Testflags
24 – 6 Encryption Vag (2)
25. Test Channels
25 – 0 Channel 0
25 – 1 Channel 1
25 – 2 Channel 2
25 – 3 Channel 3
25 – 4 Channel 4
25 – 5 Channel 5
25 – 6 Channel 6
25 – 7 Channel 7
25 – 8 Channel 8
25 – 9 Channel 9
26. Parameters for inventory on crystals
26 – 0 Delay seconds
26 – 1 Step/udm? (Digital) Digital
26 – 2 Minimal Limit (Digital) Digital
26 – 3 Maximum Limit (Digital) Digital
26 – 4 Step/udm? HellaKit? 1=connected
27. Direct Ventalation
27 – 0 Setpoint Value %
27 – 1 Setpoint temperature Digital
27 – 2 Actual Temperature Digital
27 – 3 Maximum Temperature Digital
27 – 4 Minimum Temperature Digital
28. Humdity
28 – 0 Setpoint Humdity %
28 – 1 Relative Humdity %
28 – 2 Temperatur Crystal WSS °C
28 – 3 Dewpoint temperature °C
28 – 4 Melting point °C
29. Raw Humdity
29 – 0 Tempertaure crystals corrected °C
29 – 1 Tempertaure crystals uncorrected °C
29 – 2 Humdity Sensor %
29 – 3 Temperature sensor °C
29 – 4 Dewpoint temperature (measurement test) °C
29 – 5 Code anomaly
30. Humdity Values
30 – 0 Thermophilic sensor value Digital
30 – 1 Thermophilic sensor reference Digital
30 – 2 Moisture duration 10 to the power of -4 sec
30 – 3 Humdity reference temperature Digital
30 – 4 Humdity sensor %
30 – 5 Temperature sensor °C
30 – 6 Temperature sensor (uncorrected) °C