V871518 2038368

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Golf/GTI,Golf
SportWagen
2015-2016
All
All
All
All
Condition
87 15 18 December 16, 2015 2038368 Supersedes Technical Bulletin V871517 dated November 24, 2015 to
update the vehicle model years applicable and to add N280 valve inspection R.O. documentation.
Air Conditioning Does Not Cool and or Compressor is Noisy
One or more of the following conditions are exhibited:
 The air conditioning does not cool, or the cooling performance is very weak.
 The air conditioning system cools, but the compressor is noisy. The noise is characterized as a grinding or
groaning noise.
 Either symptom may be intermittent.
 No DTCs are stored.
Technical Background
The condition may be caused by a faulty A/C compressor regulator valve N280 (Sanden). The internal
components of the valve can be obstructed and incapable of full function. This loss of refrigerant regulation from
N280 can cause noise from the air conditioning compressor and/or affect the HVAC cooling.
The condition may be caused by a faulty N280
valve (Figure 1). The internal components of
the valve can be obstructed and incapable of
full function. This loss of refrigerant regulation
from N280 can cause noise from the A/C
compressor and/or affect the HVAC cooling.
Figure 1 N280 Refrigerant Regulating Valve
5Q0260839A
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Technical Bulletin
Note:
This bulletin applies to vehicle built with Sanden 5Q0820803C, 5Q0820803E and 5Q0820803G compressors
only. The replacement N280 valve is not compatible with other Sanden compressors. The N280 valve is not
compatible with any Denso compressors.
If a Denso compressor is installed on the vehicle this bulletin does not apply. Further diagnosis is
required.
Production Solution
Improved N280 valve for the Sanden A/C compressor CW36/15.
Service
Since either symptom may be intermittent, the diagnostic process can affect the reproducibility of the
condition. Begin the diagnosis by isolating the cause before performing the basic checks.
Connect both the refrigerant service station (Figure
4) and the diagnostic tester to the vehicle.
Figure 4. Robinair A/C Service Unit.
Cases of noise:
When diagnosing cases of noise, use chassis ears or a technician’s stethoscope to make sure that the root cause
of the noise is from the air conditioning compressor. The noise can change or may be absent depending on the
setting on the HVAC control unit. In many cases, the noise is more pronounced with the system switched OFF.
Page 2 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Cases of low or no cooling performance:
Rule out a refrigerant circuit leak as the root cause. Evacuate the refrigerant circuit to determine the refrigerant
volume. The refrigerant volume will likely be in specification. Should the refrigerant volume be too low, investigate
a potential refrigerant leak in the circuit. It is not likely that the refrigerant level will be too high because if it is, a
DTC will be stored. If no system leak is determined, recharge the circuit with the specified amount of refrigerant
before proceeding.
Perform the following diagnostic steps:
With the engine at idle, switch the climate control unit to full cold and full fan.
Turn recirculation mode on and close all windows.
Using the diagnostic tester, go to Guided Functions.
Monitor the measuring value for the air
conditioner compressor regulating valve N280
signal (Figure 5).
The actual and specified values will be plausible
and will show a normal regulating range of current
for cooling request (0.400 A – 0.820 A).
Figure 5. Checking N280 signal value Measuring
Value Block.
After verifying the compressor should be on and
operating. Check the gauge readings on the
Robinair service station to verify equalized
pressure readings on the high and low sides of
the circuit (no pressure generation from the
compressor) (Figure 6).
Note: If the gauge readings are showing
normal compressor operation per the Elsa
Repair Manual, this bulletin does not apply
and further diagnosis is required.
Figure 6. Equalized pressure condition.
Page 3 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Check that the compressor torque limiter has not
been activated (Figure 7b).
Note: If the torque limiter has been released
the N280 regulating valve is not at fault. The
compressor needs to be replaced.
Figure 7a. Example of torque limiter over load
protection activated.
Figure 7b. Example of torque limiter over load
protection still intact.
Page 4 of 17
© 2015 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Shut off the engine. Connect the breakout harness
VAS 5256 (Figure 8) between the N280 valve and
its connector.
Figure 8. VAS 5256 breakout harness.
Go to Operating Mode “Measurements” to check
the N280 signal from the control module.
Select Measurements.
Select oscilloscope.
Change time division to 2ms/Div (Figure 9).
Figure 9. Select Measurements from operating
mode menu”.
Select the correct DSO channel according the
test leads hooked to the vehicle (Figure 10).
Figure 10. Setting up DSO channel”.
Page 5 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Change the voltage to 5VDiv.
Check the signal wave form (Figure 11). The
square wave signal should be between 75% and
100%.
If the wave form signal is good, the mechanical
integrity of the N280 valve needs to be inspected.
GO TO: Removing/Installing the N280
Regulating valve.
Figure 11. Checking the N280 signal wave form.
Removing/Installing the N280 Regulating valve.
Recover the refrigerant from the system. Remove the N280 valve using the following procedure.
WARNING:
With the refrigerant circuit charged the N280 valve is under pressure. Be certain that the refrigerant
circuit is completely discharged before removing the N280 valve.
Remove one of the A/C lines from the compressor to assure the pressure in the compressor is the same
as ambient pressure.
1. Remove circlip-A- carefully.
Note:
Circlip must be reused.
2. Carefully remove the A/C Compressor Regulator Valve N280- -B- from the A/C compressor mount -C-, using a
suitable screwdriver -D-, for example (Figure 12).
Figure 12. Circlip / N280 removal
Page 6 of 17
© 2015 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Assess the condition of the N280 valve bore and
the valve filter screen (Figure 13). If severe
contamination is found in valve bore there is a risk
of damaging the replacement valve on installation
In these cases the A/C compressor must be
replaced.
Note:
A slight amount of debris or corrosion does
not present a risk and does not justify
replacement of the AC compressor.
Figure 13. Corrosion in the N280 valve bore.
Should severe contamination be found at the
valve filter screen (Figure 14) and A/C
compressor replacement becomes necessary,
ensure that the refrigerant circuit is flushed in the
course of repair.
Note:
Small random particles on the filter screen
does not constitute “severe” contamination
and does not justify replacement of the A/C
Figure 14: Severe contamination at the N280 valve compressor.
filter screen.
 If little or no corrosion or contamination is found perform Repair Procedure A: Replacing the N280 regulating
valve.
 If corrosion and contamination is found, perform Repair Procedure B: A/C compressor replacement.
 Document the all workshop findings of this procedure on the repair order.
Page 7 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Repair Procedure A: Replacing the N280 regulating valve
1. Check the A/C compressor mount -C- and the
circlip groove for dirt, and if necessary, clean them
carefully and thoroughly with a clean, lint-free cloth
(Figure 15).
Figure 15: Prepare mount for N280 installation.
Note:
Risk of damaging another N280 Valve or compressor may result due to dirt contamination or damage to the
sealing surfaces in the mount.
 If necessary, carefully clean the A/C compressor mount -C- using only a clean, lint-free cloth (do not use
compressed air).
 Make sure while cleaning the mount -C- that no dirt gets into the area underneath the O-ring sealing surface F- or the existing channels and none of the mount sealing surfaces become damaged.
1. Check the O-rings -F-, -G- ,-H- and -E- (if
applicable) of the A/C Compressor Regulator
Valve -N280- -B- for damage.
2. Coat the O-rings -F-, -G-, -H- and -E- (if
applicable) of the A/C Compressor Regulator
Valve -N280- -B- lightly with refrigerant oil and
check for proper seating (Figure 16).
Figure 16. Check and prepare N280 o-rings
3. Insert the A/C Compressor Regulator Valve -N280- -B- until the stop in the A/C compressor mount -C-.
Page 8 of 17
© 2015 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
4. Re install circlip -A-.
5. Install the removed parts in the opposite order.
6. Evacuate and refill the refrigerant circuit.
Repair Procedure B: Air conditioning compressor replacement.
Note:
The refrigerant circuit must be flushed every time the A/C compressor is replaced. The replacement A/C
compressor comes with a full charge of oil for the entire refrigerant system. Therefore the A/C circuit
must be flushed of all original oil form the entire refrigerant circuit.
For this procedure always replace the receiver drier and expansion valve after flushing the refrigerant
circuit.
The flushing procedure can be found in Elsa at: Heating, Ventilation & Air Conditioning>>Refrigerant
R134a Servicing >>00 General Technical Data>> Refrigerant circuit removing contaminates>>Refrigerant
Circuit, Cleaning (Flushing), with Refrigerant R134a. The procedure is also described in Technical Service
Bulletin 2019947.
The correct adapters for the 2015 Golf/GTI can be found in Elsa at: Ventilation & Air
Conditioning>>Refrigerant R134a Servicing >>00 General Technical Data>> Refrigerant circuit removing
contaminates>>Refrigerant Circuit, Cleaning (Flushing), with Refrigerant R134a >>Adapter for
Assembling Flushing Circuit.
MY2015 GTI/Golf, SportWagen production have Sanden
compressors 5Q0820803C, 5Q0820803E and 5Q0820803G.
The replacement compressor is Denso 5Q0820803F
Figure 14: Denso compressor
5Q0820803F
Page 9 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
When installing a new compressor transfer the compressor
shipping caps to the original compressor as shown in Fig 15.
Figure 15
The replacement Denso compressor will come with the
specified type of PAG oil G 052 300 A2 (Figure 16).
Note:
The compressor comes with a full charge of oil for the
entire refrigerant circuit. However the amount of PAG oil
supplied with the replacement compressor may not be
the exact amount to replenish the refrigerant circuit.
Drain and measure the PAG oil in the replacement
compressor to determine the required amount. If the
amount needs to be adjusted, do so using the correct
type of PAG oil specified in ETKA. Refer to Elsa for the
correct oil capacity for the compressor being installed.
Figure 16: Denso compressor
manufacturer PAG oil G 052 300 A2.
Page 10 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Warranty
Note:
Document and attach all workshop findings of this procedure on the repair order.
All replaced compressors must have the shipping caps re-installed before being returned to the WPRC.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
Golf/GTI,Golf
SportWagen
2015-2016
All
All
VIN Range From
VIN Range To
All
All
SAGA Coding
Claim Type:
Use applicable Claim Type 1)
Damage
Service Number:
Code
8734
0010
Parts Manufacturer
HST
Damage Location
(Depends on Service No.)
--
Use applicable when
indicated in Elsa (L/R)
Golf/GTI, Golf SportWagen
SYP
Repair Procedure A:
Labor Operation 3) : Refrigerant drain and fill
87031700 = 60 TU
Labor Operation 3) : N280 valve remove and install
87371950 = 20 TU
Labor Operation 3) : Noise dampening pan remove
and reinstall
10821900 = 40 TU
-OR-Repair Procedure B: (if A/C compressor is necessary)
Labor Operation 3) : Refrigerant drain and fill
87031700 = 60 TU
Labor Operation 3) : Noise dampening pan remove
and reinstall
10821900 = 40 TU
Page 11 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Labor Operation 3) : N280 valve remove and install
(with debris on filter screen found)
87371950 = 20 TU
Labor Operation 3) : A/C compressor remove and
87341970 = 50 TU (1.8/2.0 TFSI)
reinstall
87341955 = 40 TU (2.0 TDI)
Labor Operation 3) : Expansion valve remove and
reinstall
87701970 = 50 TU (1.8/2.0 TFSI)
Labor Operation 3) : Radiator grill remove and
reinstall
66051900 = 20 TU
Labor Operation 3) : Receiver drier replace (nonModine)
87555550 = 30 TU
Labor Operation 3) : Receiver drier replace (Modine)
87555552 = 40 TU
Labor Operation 3) : Air conditioner clean
87012999 = 140 TU
87701955 = 60 TU (2.0 TDI)
Outside Material: A/C Flush Machine Behr filter, Part $4.25 total per A/C System Flush which
No. BA1783400103
accompanies a repair (this amount equals ¼ of the
cost of the A/C flush machine filter)
OR
Outside Material: A/C Flush Machine Bosch filter,
Part No. 17707-6
$17.88 total per A/C System Flush which
Causal Part:
5Q0260839A
accompanies a repair (this amount equals ¼ of the
cost of the A/C flush machine filter)
Diagnostic Time 4)
GFF Time expenditure
01500000 = 55 TU max.
Road Test
01210002 = 10 TU
01210004 = 10 TU
Technical Diagnosis
01320000 = 20 TU max.
YES
YES
YES
Claim Comment: Input “As per Technical Bulletin 2038368” in comment section of Warranty Claim.
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Code per warranty vendor code policy.
Page 12 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policy Procedures Manual.
Page 13 of 17
© 2015 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Required Parts and Tools
Part Description
Part No:
Quantity
N280 Regulating Valve (Sandan)
5Q0260839A
1
-OR—
(if A/C compressor is necessary)
Oil for refrigerant compressor
(Denso)
G 052300A2
0.2 (Max if required)
Air conditioner compressor
(Denso)
5Q0820803F
1
Seal ring
4D0260749B
1
Seal ring
4E0260749B
1
Seal ring
4E0260749A
1
Seal ring
8E0260749C
1
Drier insert with mounting parts
5Q0298403A
1
5Q0820679C
1
5Q0898850A
1
Expansion Valve
(With Compressor replacement
only)
Set of round seals
Page 14 of 17
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Tool Description
Tool No:
ROB134APF
Robinair A/C Service Unit
VAS 6337/1A
Air Conditioning Flush Tool
Air Conditioning System Flushing Device Filter
Behr - BAI783400103
OR
Page 15 of 17
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No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Air Conditioning System Flushing Device Filter
Bosch – 17707-6
VAS 6338/3
Refrigerant Circuit Adapter 3
VAS 6338/12
Refrigerant Circuit Adapter 12
VAS 6338/38
Refrigerant Circuit Adapter 38
Page 16 of 17
© 2015 Volkswagen Group of America, Inc.
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No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 17 of 17
© 2015 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.