A/C not working on my 05' Passat Wagon

05PassatWagonTDI

Well-known member
Joined
Jun 19, 2010
Location
Poulsbo, WA USA
TDI
2005 Passat Wagon TDI
I checked the 384 relay and found a soldered contact to be broken. I soldered it carefully back on and it "clicks" and engages the A/C compressor clutch now. Still no cold air is blowing. Everything is intact and stock under the hood. The car is an 05' that was originally purchased and owned in Arizona. I am the second owner. I can't imagine the car leaking out all the refrigerant in a climate where the A/C must have been used a lot. Anything obvious I should check/consider? Thanks.
 

Mikey2

Veteran Member
Joined
Aug 23, 2005
Location
Europe
TDI
Passat 2002 grey
Is there any condensate water visible underneath the car ? If the compressor works okay, there should be condensate, and then the problem would be in the temperature control:

- faulty outside temp gauge (visible in the instrument cluster)
- faulty inside temp gauge (try setting the temp request to LO)
- faulty temp regulation flap motor (no we're talking about big money)
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
Turn key on, turn A/C on, open hood and check to see if electric fan (passenger side, radiator) is on. If not, fan is dead, no A/C (or it will cycle).
 

05PassatWagonTDI

Well-known member
Joined
Jun 19, 2010
Location
Poulsbo, WA USA
TDI
2005 Passat Wagon TDI
Turn key on, turn A/C on, open hood and check to see if electric fan (passenger side, radiator) is on. If not, fan is dead, no A/C (or it will cycle).
Yup, this fan works perfect. I can get a little bit of cool air to pass out the vents, but it seems like the temp should be a lot colder. Maybe a recharge? Recharging kinda worries me because its a 2005 year and if the refrigerant is low, there is a leak someplace. I figured leaks was something not possible on a stock vehicle that is fairly "newer". I'd expect leaks from an older rig. Maybe I'm dead wrong. :confused:
 

blaz

Veteran Member
Joined
Apr 16, 2006
Location
Ontario Canada
TDI
05 Passat
Mine had to be recharged last year. They couldn't find any leaks. Fan was ok. Still seems to be working a year later ... :confused:
 

mr bill

New member
Joined
Feb 1, 2011
Location
central ok
TDI
05 passatt
ac not working on startup

just changed ac condenser fan fixed the problem 125$ 45 min to change :ma:)
 

rarmstrong

Veteran Member
Joined
Dec 5, 2006
Location
Charlotte
TDI
2004 Passat TDI
Mine had similar problem and leaked due to bolts that were loose allowing refrigerant to escape. NOt sure of what the part is called but it was up where the hoses are beside the battery. You may want to check there.
 

blaz

Veteran Member
Joined
Apr 16, 2006
Location
Ontario Canada
TDI
05 Passat
Mine had to be recharged last year. They couldn't find any leaks. Fan was ok. Still seems to be working a year later ... :confused:
OK. Spoke too soon. Just got the car back from my son and no cold air. Hottest day of the year and no AC. Anyway ...

384 relay working? Check. Pulled it apart and all the joints look good. I can feel a faint click when turning the AC on/off.

Electric fan (passenger side, radiator) working? Check.

Is the "ac condenser fan" working? Dunno. Is that the same as above?

Checked "bolts that were loose allowing refrigerant to escape. NOt sure of what the part is called but it was up where the hoses are beside the battery." and all the plumbing there looks tight and like new.

What else can I do before taking it to the stealer and have them recharge and test it, then tell me nothing's wrong (except somehow all the freon or whatever has miraculously disappeared?
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
These cars are not known for leaks, and if the compressor clutch engages and stays engaged (even if RPMs increase) that you have sufficient charge to at least make some pressure. So, if it STILL won't cool, then it is not making pressure, which means: A: the compressor is shot, or B: the expansion valve is stuck 'wide open'. But here is the deal, on these cars, even if the expansion valve was stuck wide open, there should still be some pressure drop across it... so the system will work, just not very well.

This all sounds to me like your compressor is just plain shot. Which is not super common, but it does happen (it is Japanese, after all :p ). Do NOT get a Chinesium no-name compressor! Only get a genuine VW unit or an aftermarket Denso or Sanden compressor (I am pretty sure the BHWs use a Denso... but I would have to look to be sure... it will be on the tag). I think VW list price is around $550, and the part number is 8D0-260-805-R but do not take that as fact until verified by VIN and the tag.

Keep in mind, this is a best guess without actually seeing the car and placing gauges on it. I'd also replace the receiver/drier, part number 3B0-820-193. Not sure who supplies these on the B5s, but Parker is a possibity, or Hella. I'd only get that from Volkswagen, too.
 

thundershorts

Top Post Dawg
Joined
Jul 15, 2010
Location
west chester pa
TDI
2015 passat tdi sel premium 2015 golf s tdi gls tdi b5.5, 2002 eurovan,Peugeot 505 td,Citroen cx25 prestige
if in fact the compressor is bad, receiver/drier should always be changed as it is the filter downstream.
 

blaz

Veteran Member
Joined
Apr 16, 2006
Location
Ontario Canada
TDI
05 Passat
Take it to a good shop that specializes in A/C work
hmmm, we've got a lot of shops around here specializing in rust-proofing but none in A/C. Texas vs Ontario maybe?

So took it to a different (less convenient) VW shop that had worked well before. (Currently too far away from a Toronto guru, and we really needed a/c in this heat wave).

And yes the R134 was low again; clutch, pressures and electrical all checked ok. But these guys knew enough to put some dye in the system and tell me to come back after 1000km, and use the A/C meanwhile ... no problem there. Driving back from the shop was a relief.

Like all dealers though, not cheap. Especially that R134A.

Thinking that leaks like this may be more common up north where they put a lot of salt on the roads. I've had to replace brake lines, transmission fluid lines and all sorts of stuff because of corrosion on older cars.
 

tditom49

Member
Joined
May 24, 2011
Location
Mo
TDI
99 Beetle TDI, 05 Passat TDI, 05 Beetle TDI
I ordered a compressor from this company. Recieved new Sanden compresser for 99 NB for about $200, has worked flawlessly since.
TechChoice Parts
3051 FM 663
Midlothian TX 76065

Phone: (972)723-0112
Toll Free: (877)723-0112
Fax: (972)723-0513

sales@techchoiceparts.com
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
hmmm, we've got a lot of shops around here specializing in rust-proofing but none in A/C. Texas vs Ontario maybe?
Sorry :eek:, forgot you live in Canada where A/C shops are not on every block like they are around here. The dye test should help pinpoint a leak.
 

Kbleguy

New member
Joined
Jan 13, 2011
Location
AJAX
TDI
05 Passat wagon
Glad you got yours fixed I had asimuler issue withmy 05 wagon. we changed the high presure switch recharged it several times the relay clicked etc, it turned out to be a bad relay go figure. FYI in canada we use A LOT less salt than the northern states. I was in GA (Brunswick) and had a major prob and they had mine so far apart it was scarry no rust any where. They were shocked. They said northern cars ALWAYS have some rust. mine NONE. FYI my oil pump failed on my way to FLA last november. In Brunswick GA a shop Called boatwrights (Steve) was the owner and Josh works there too. I needed a turbo and then they found the motor was cooked too. Josh had me andmy lady stay with him and his wife and 3 kids. These guys fixed me up and were very fair with the price. All new parts, I wish I knew before the turbo went on it I would of got a better one.
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
Glad you got yours fixed I had asimuler issue withmy 05 wagon. we changed the high presure switch recharged it several times the relay clicked etc, it turned out to be a bad relay go figure. FYI in canada we use A LOT less salt than the northern states. I was in GA (Brunswick) and had a major prob and they had mine so far apart it was scarry no rust any where. They were shocked. They said northern cars ALWAYS have some rust. mine NONE. FYI my oil pump failed on my way to FLA last november. In Brunswick GA a shop Called boatwrights (Steve) was the owner and Josh works there too. I needed a turbo and then they found the motor was cooked too. Josh had me andmy lady stay with him and his wife and 3 kids. These guys fixed me up and were very fair with the price. All new parts, I wish I knew before the turbo went on it I would of got a better one.
You mean your chain drive for the balance shaft and oil pump failed? How many miles on the car when that happened, may I ask?
 

delaware_doug

Member
Joined
Jul 14, 2011
Location
Delaware USA
TDI
Passat B5.5 GLS
I had poor cooling 2 years ago and found the power steering cooler in front of the condenser had rubbed a hole in it. I removed it and had i welded, but ended up replacing the condenser with a used one, now just had to replace relay 384. So far, ice cold even with black/black leather! (I do have dark tinted windows, though). I will always replace the o rings and drier whenever I open a system that's a few years old.
 
Last edited:

Quest4TDI

Well-known member
Joined
Apr 22, 2005
TDI
Passat, '05, Candy White
I'm having similar symptoms as the original poster.

AC seemed to suddenly quit working from one day to the next, based upon what my wife has described to me (I rarely drive the Passat).

1) I pulled the 384 relay, and a quick visual didn't show any obvious signs of problems. May need to pull it again and check with a magnifying glass (middle-age eyesight sucks).

2) Check for operation of the passenger-side electric fan, and it comes on with the AC on.

3) Checked the AC fuse (fuse #25 if I recall correctly) and that fuse is fine.

4) Inside temperature display is operational

Any other diagnostics I should perform before I either decide to buy a replacement relay and easter-egg it to see if it does the trick, or before I go to an AC specialist to have the whole system checked? I don't believe we've ever had the freon recharged, but the sudden change would lead me to believe that it's not the freon unless there was a catastrophic failure.

If the compressor turns out bad, it looks like I should have the following replaced:
- the compressor (Sanden or Denso) (is a Sanden-Behr compressor the same brand?)
- the drier

- is there an orifice tube to replace?
- is there an expansion valve to replace?


thanks,
Herb
 

JETSLED

Member
Joined
Aug 24, 2005
Location
Levittown, PA
TDI
05 Passat TDI
NO AC in 05 Passat TDI

I too am in the same issue. 05 Passat TDI with AC failure just this past week. Started researching (search) on here & did the above checks. I will remove relay 384 again & double check. Passenger side fan works, AC fuse (25) good & inside temp display is operational/normal.

I do NOT have any drips on the ground.

what's next?

thanks,

jetsled
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
Can anyone follow up on these A/c issues? Our other Passat is going through the same drill: everything obvious works - fan, 384 relay, etc and the A/C cools for a day then stops.

I don't think it would have anything to do with the outside temps being 110F.....:confused:
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
110F temps should not cause the system to not work at all, no. Certainly won't work as well as it would on a 90F day, but it should still work.

I guess the question is, when it "stops cooling", does the compressor stop working? Does the ECU A/C request remain 'on'? Does the auxilliary fan continue to run?

I've never seen one of these have any issue beyond the retarder relay or a compressor.
 

thundershorts

Top Post Dawg
Joined
Jul 15, 2010
Location
west chester pa
TDI
2015 passat tdi sel premium 2015 golf s tdi gls tdi b5.5, 2002 eurovan,Peugeot 505 td,Citroen cx25 prestige
could be lots of things, including possible overcharge, triggering high pressure cut out. maybe its time to get out the gauges.
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
110F temps should not cause the system to not work at all, no. Certainly won't work as well as it would on a 90F day, but it should still work.

I guess the question is, when it "stops cooling", does the compressor stop working? Does the ECU A/C request remain 'on'? Does the auxilliary fan continue to run?

I've never seen one of these have any issue beyond the retarder relay or a compressor.
I'll have to check the car out closer this weekend as the daughter is driving it. I did put a new 384 relay in last week and that fixed it for a few days. Then she called me yesterday saying the A/C is out (again). The A/C aux fan is 3 months old. I'll report back Saturday.

I'm just kidding about the 110F :D, it's just been punishing here. No rain in literally months, also. Not only are we on water rationing, but now there is warnings about power brownouts. I'm surprised it took this long for power poblems.
 

sirpuddingfoot

Veteran Member
Joined
May 14, 2010
Location
Seattle, WA
TDI
05 Passat, 05 Jetta
I'd say check the relay again. Mine had an itty bitty hairline crack all around the pin in the solder: seen here circled.

I got my $5 POS soldering iron hot, got the smallest bit of solder on the tip of the iron and just went around the pin to touch it up. Flawless since.
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
I'd say check the relay again. Mine had an itty bitty hairline crack all around the pin in the solder: seen here circled.

I got my $5 POS soldering iron hot, got the smallest bit of solder on the tip of the iron and just went around the pin to touch it up. Flawless since.
I have looked at the joint, re-soldered it and it looks just fine (but looks isn't everything). I have a second relay and it has been repaired also. I will try that tonight. I have lots of years of soldering experience on circuit boards and know what I am doing. Wonder if it could be something else with this controller? It does have a logic chip in it also.
 

JETSLED

Member
Joined
Aug 24, 2005
Location
Levittown, PA
TDI
05 Passat TDI
fixed relay 384

I too am in the same issue. 05 Passat TDI with AC failure just this past week. Started researching (search) on here & did the above checks. I will remove relay 384 again & double check. Passenger side fan works, AC fuse (25) good & inside temp display is operational/normal.

I do NOT have any drips on the ground.

what's next?

thanks,

jetsled

after double checking the relay over very closely, i saw the hair line crack in the solder point. Plus some research off passat_world dot com with some excellent pictures, i just got done re-soldering the point & tested with cold AC in the car. Got to love the internet!

thanks everyone!

jetsled
 

blaz

Veteran Member
Joined
Apr 16, 2006
Location
Ontario Canada
TDI
05 Passat
And yes the R134 was low again; clutch, pressures and electrical all checked ok. But these guys knew enough to put some dye in the system and tell me to come back after 1000km, and use the A/C meanwhile ... no problem there. Driving back from the shop was a relief.
So now we know. They used UV light to check for fluorescent dye leaking outside the A/C system, and apparently the leak is in the high pressure hose going from expansion valve to condenser.

Charged half an hour labour for the evaluation. But fixing it will be over $500can what with the new hose and recharge with R134, 2.5hrs labour and taxes. VW service is not cheap.

Think we'll wait until next spring. It's still working ok now. And I might get it done cheaper elsewhere.
 

delaware_doug

Member
Joined
Jul 14, 2011
Location
Delaware USA
TDI
Passat B5.5 GLS
Just an update, I have an '05 w/ 132K on it, I'm the 2nd owner & bought it 3/07 w/ 47.7K and the very next fall (2008) I noticed if not cooling very well on a nice warm fall day. I just "let it go" until spring of '09 and discovered the power steering cooler pipe in from the of the condensor was installed so the "loop" of the steel pipe wore a hole in the lower tube of the consensor. I removed it, had it welded & reinstalled it w/ a new drier/Orings & dye. The shop that weled it does cooling coils for refridge units and DIDN'T WELD IT RIGHT so it still leaked. I threw it the towel (and my wallet) and bought a used factory condensor off eBay. (the aftermarket units didn't fit, too narrow) After I had the now sealed system charged up, the a/c was great, but delayed. Found out it was relay 384, thanks to the great folks here! Now everything works, ice cold & instant relief finally...
 

swacapt

Member
Joined
Aug 14, 2011
Location
Apison, TN
TDI
2005 Passat wagon
Cooling fan won't work

Help! 05 Passat TDI wagon. I have read all of the above posts and many other threads but none guide me to a fix for my problem. I had a bad cooling fan (electric passenger side) and replaced it. The fan still does not come on with the key in the on position, A/C button on, and cabin fan on. The A/C lite is illuminated in the button. Here is what I have done.
1. Replaced electric cooling fan. It checks good with direct wired power.
2. Checked fuse #25 and 5
3. Checked relay 384, there are no visible cold solder or cracks in the solder.
4. Jumped relay 384 socket corresponding to pins 30 and 87 (still nothing)
5. Checked A/C coolant pressure.

Any ideas what to check next to determine why my electric cooling fan does not work. By jumping the relay 384, socket pins 30 and 87 should this confirm that it is not a relay issue?

Any help would be appreciated. :confused:
 

thundershorts

Top Post Dawg
Joined
Jul 15, 2010
Location
west chester pa
TDI
2015 passat tdi sel premium 2015 golf s tdi gls tdi b5.5, 2002 eurovan,Peugeot 505 td,Citroen cx25 prestige
I believe there are also two relays for the cooling fan on the relay panel
 
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