www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums TDIFAQ Articles Links Meets
Orders TDI Club Cards TDIFest 2014 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You



Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

Reply
 
Thread Tools
Old June 30th, 2010, 13:34   #1
Joester
 
Joester's Avatar
 
Join Date: Aug 2009
Location: St. Louis
Fuel Economy: 52/42/28
Default A4 radiator fan removal and replacement

okay, this is my first tutorial, so bear with me.

This is to replace or repair a radiator fan that is not working. it is easy to test this. put the key in the ignition and turn it to the on position, the car itself does not have to be running. push the A/c button and turn the blower fan on 1. now open the hood and both the fans should be spinning in unison. read more about the subject and possible causes here: http://forums.tdiclub.com/showthread...t=radiator+fan

and here is the fan repair PDF: http://pics.tdiclub.com/data/517/Fan_Repair.pdf

the car this is being performed on is a 2002 golf tdi. the process is defintitely the same for all ALH golfs and jettas, and might also apply to the PD jetta/golf and all NBs, im not sure about those.

the process is pretty much the same. the passenger side fan comes out the bottom and the drivers side can slide out the top. this tutorial demonstrates the drivers side fan being removed.

tools:
T-27 Torx
10mm socket
ratchet and various extensions

First, put the car up on jack stand and remove the engine cover and belly pan. dont forget to unhook the vacuum line from the engine cover before pulling it if you own a jetta or golf! now remove the battery cover. it may also be wise to remove the battery if you have big hands. my small hands plus a bit of patience and i was able to get the the torx by the battery.

belly pan off, engine cover waiting for removal


heres a picture of the things your trying to get to.




go underneath. bring your T-27 Torx you will see one of the torx bolts and the plug for the fan.



you may have to pull the fan wire out of the housing to see and get to the bottom torx.



heres what kind of plug it is. it comes off if you pull hard enough, but i suggest doing it the right way.



undo the top 2 torx and the fans ready to come out.

heres the path out. you may need to bend and push some hoses out of the way, but it will come out.



now the fan only comes into 2 pieces. undoing the 3 10mm nuts on the back of the housing allows it to come off for removal/ installation of your new fan, or just to fix the old one.







reinstallation is the same thing backwards. the 3 pronged housing IS directional in how it fits over the motor. theres a notch where the wires go through. start to finish for this was 30 minutes. it was my 3rd time.

be careful when supporting the car. if you break anything its not my fault. use common sense and dont force anything
__________________
2002 Golf 4dr 5spd TDI ---- Malone stage 4 - Borg Warner BV-39 - PP520 Nozzles - South Bend Stage II Daily Clutch - TacoTaco Intercooler - Bilstein Sport Shocks and Struts on H&R Sport Springs - 17x7 Long Beach Wheels with Bridgestone S0-4 Summers - General Altimax Arctic on Stock 15s for Winter

Last edited by Joester; June 30th, 2010 at 13:39.
Joester is online now   Reply With Quote
Old June 30th, 2010, 13:38   #2
Joester
 
Joester's Avatar
 
Join Date: Aug 2009
Location: St. Louis
Fuel Economy: 52/42/28
Default

here are some macros of the motor housing and the backing plate and how the tabs are bent. the pictures in the fan repair PDF are kinda blurry.







and heres the notch that the housing has to be orientated to to fit around the motor propery.

__________________
2002 Golf 4dr 5spd TDI ---- Malone stage 4 - Borg Warner BV-39 - PP520 Nozzles - South Bend Stage II Daily Clutch - TacoTaco Intercooler - Bilstein Sport Shocks and Struts on H&R Sport Springs - 17x7 Long Beach Wheels with Bridgestone S0-4 Summers - General Altimax Arctic on Stock 15s for Winter
Joester is online now   Reply With Quote
Old June 30th, 2010, 13:53   #3
Mass. Wine Guy
Veteran Member
 
Mass. Wine Guy's Avatar
 
Join Date: May 2001
Location: NW of Southeast Dipstick, MA
Default

Very cool and helpful. thank you very much for taking the time to prepare and post this.
Mass. Wine Guy is offline   Reply With Quote
Old June 30th, 2010, 18:18   #4
Joester
 
Joester's Avatar
 
Join Date: Aug 2009
Location: St. Louis
Fuel Economy: 52/42/28
Default

no problem. thats what forums are for right?
__________________
2002 Golf 4dr 5spd TDI ---- Malone stage 4 - Borg Warner BV-39 - PP520 Nozzles - South Bend Stage II Daily Clutch - TacoTaco Intercooler - Bilstein Sport Shocks and Struts on H&R Sport Springs - 17x7 Long Beach Wheels with Bridgestone S0-4 Summers - General Altimax Arctic on Stock 15s for Winter
Joester is online now   Reply With Quote
Old July 2nd, 2010, 20:17   #5
thermographer
Veteran Member
 
thermographer's Avatar
 
Join Date: May 2004
Location: Maryville, Tennessee
Fuel Economy: 51.7/46.06/39.66 800 mile club 3 times.
Default

I replaced the drivers side fan today on my PD and it's pretty much the same.

I would add that the plug was easier to get to from underneath the car. Remove the skid plate for the bottom torx and fan plug. (May be PD specific).

My $40 investment on ramps has paid for themselves many times over.

Great write up, thanks for posting.
__________________
2004 Jetta Sedan with Auto Trans @ 250K miles. It's not just wheat beige, it's pure gold.
thermographer is offline   Reply With Quote
Old July 3rd, 2010, 11:23   #6
poor1
Veteran Member
 
Join Date: May 2003
Location: UK
TDI(s): MK4
Fuel Economy: 56mpg (UK gallons)
Default

Changing a Radiator Mk4 TDI European

Should anyone want to just remove the radiator here is an old post of mine dating back to 2007.

Looks like the radiator on a Mk c4 Golf TDI is an expendable item. Mine is 8 years old and has only done 50000 miles. Seepages on both side of radiator indicated only staining by red coolant at the edges of the radiator. No noticeable drop in level in the coolant reservoir.

Changing a radiator is quite straight forward, but quite a lengthy process, principally because the front bumper need to be removed to gain access to the four Torx headed screws which hold the four rubber radiator mountings in place.
The bumper must be removed but the headlamps can remain in place. Removing the battery gives good access for the business side of the radiator itself.
Remove the fan and mounting in situ.
Don’t even bother starting without jacking the front of the car up sufficiently to raise the front wheel off the ground. It mades life much easier by removing the engine under shield at the start. This is also fastened with Torx headed self tapper.
Removing and replacing the bumper is easy enough for one person to handle. There are four Torx self tappers on the inside edge of the front wing and five special setscrews, (including two underneath each headlight unit)which can be only be accessed by removing the two grills on either side.
The hose outlets which are retained by stainless steel clips can be stubborn to remove from the radiator. Light taps with a delicate hammer will easily remove them once the stainless steel clips have been sprung into their resting position.
The bonnet release catch can be awkward to spread open without the chance of breaking it. The most controlled method of spreading it is a pair of outside circlip pliers.
The top and bottom rubber mountings are different. It is important to note that whilst the two lower radiator rubber mountings are not handed the top two, can only be fitted with the “notch” at the top. This is quite obvious if they are inserted in the mounting on the car before attaching them to the radiator.
Essential tools
Appropriate sized Torx drivers and hose clip spreaders and a 30mm deep socket of ring spanner to remove the temperate sensor.
Other parts which must be renewed as a matter of course are the two O rings inside the top and bottom hose outlets.
The only other matter is replacing the coolant. The most important thing is to put the coolant in very slowly otherwise you will create air locks. The TDI capacity is 6 litres and VW recommend at leady 40% of their own anti additive. The problem with the TDI is getting the coolant in and getting rid of the air locks. Ensure that the heater is fully on, fill the reservoir and try removing some air by squeezing the large hoses. It is quite obvious when these hoses become full of coolant because of the added resistance when squeezing them. Removing the overflow pipe and blowing hard down the pipe helps in the initial stages. When a reasonable quantity has been put into the system drive the vehicle for a mile, instead of letting it tick over and then top up. This accelerates the process of getting up to normal operating temperature. Keep an eye on the level for a few days and top up if necessary.
Hope it might be of assistance to someone.

As regards ramps suggested in the post immediately preceeding this one I find that two pieces of wood about two inches thick with a leading edge and about eigth inches wide are extremely useful for gaining quick access to the underneath for removing the undershield and draining the sump.
.

Last edited by poor1; July 3rd, 2010 at 11:27.
poor1 is offline   Reply With Quote
Old January 15th, 2011, 06:43   #7
sschwein
Newbie
 
Join Date: Dec 2010
Location: Newmarket, Ontario
Default

I have looked for information on how to replace the A5 (2006 TDI BRM) Radiator fans (I am told the large fan needs replacing). Is there a thread on how to do this change?
sschwein is offline   Reply With Quote
Old July 15th, 2012, 12:41   #8
Idahokevin
Newbie
 
Join Date: Jun 2012
Location: Idaho Falls. ID
TDI(s): 2003 JETTA
Default big thank you

After a very warm trip to the auto parts store, only to find that I "should" buy both fans and wait a week for them to arrive. I succesfully repaired my fan in a few hours. Biggest challenge of the project was unplugging the darn thing.
Many thanks
Kevin
Idahokevin is offline   Reply With Quote
Old July 15th, 2012, 18:28   #9
freakwithracket
 
Join Date: Oct 2010
Location: Columbus, OH
TDI(s): 2003
Fuel Economy: 50.57mpg
Default

Question not related to the fan: how on earth did you get your engine to look so clean? Everything looks borderline brand new.
freakwithracket is online now   Reply With Quote
Old July 17th, 2012, 09:53   #10
zhouge
Veteran Member
 
Join Date: Mar 2007
Location: Mississauga, Canada
Fuel Economy: 5.4L/100km
Default about the connectors

Would anybody show or explain a little more details how to unplug the electrical connectors?
__________________
2003 Silver Golf TDI, Automatic
zhouge is offline   Reply With Quote
Old July 17th, 2012, 10:42   #11
Genesis
Veteran Member
 
Join Date: Feb 2003
Location: Niceville, FL
Fuel Economy: 53/48/42
Default

1. Put car on ramps or stands, remove belly pan. Plugs are right under the driver-side fan toward the fenderwell.

2. Get under the car, remove passenger side (rear-most) plug from the clip it is in. If that's the one you want depress lock and unplug. You're done. If not...

3. Remove driver-side (front-most) plug from clip IT is in.

4. Depress lock, unplug.

Note that there isn't much slack in the wire and the plugs interfere with the ones coming out of the FCM so you have to be a bit creative maneuvering them out of the clip, but it's not particularly difficult.
Genesis is offline   Reply With Quote
Old September 3rd, 2013, 10:35   #12
Dave_D
Veteran Member
 
Join Date: Jun 2003
Location: Gaithersburg, MD, USA
Default

A word of warning to others, I recently found that my driver's side fan had died and given that my blower fan died last year figured it would make sense to replace the smaller fan as well. Given this, I bought a complete set from Advance Auto with limited lifetime warranty that included the radiator shroud with the fans installed.

I started the job with the expectation I would be able to remove the shroud, which is only attached with 4 T27 bolts, and replace this as a unit. With difficulty I managed to get them out and disconnect the fan cables, only to find that there appears to be no way to get the shroud out or in with the engine and radiator in the car! I managed to get the bolts back into the shroud and then removed and replaced the fans individually.

So let this be a warning to others who think they might be able to replace both fans as a unit.

I should also note that you should be careful working around the lower radiator hose. It appears that I was not careful enough and now I am waiting for a replacment to arrive at the local dealer. This hose is original equipment, so after 14 years and almost 300k miles it did not appreciate being bothered and started leaking in the middle where I was playing with the fans.

Dave
__________________
1999.5 (A4) Tornado Red Jetta GL TDI,5 speed,4 door, RC 2+, Old Navy CCV mod, ventectomy, CAT filter
Dave_D is offline   Reply With Quote
Old September 5th, 2013, 21:59   #13
cgates30
Member
 
Join Date: Oct 2009
Location: Oregon
Fuel Economy: Jetta: 46.1-50.2
Default

I got home tonight to notice the smell of burning rubber and a little smoke coming from under the hood. Turns out the small fan motor was burning. Spun the big fan and noticed it doesn't turn smoothly, so it probably needs to be replaced too. Glad you mentioned the shroud kit isn't the right way to go.

Quote:
Originally Posted by Dave_D View Post
A word of warning to others, I recently found that my driver's side fan had died and given that my blower fan died last year figured it would make sense to replace the smaller fan as well. Given this, I bought a complete set from Advance Auto with limited lifetime warranty that included the radiator shroud with the fans installed.

I started the job with the expectation I would be able to remove the shroud, which is only attached with 4 T27 bolts, and replace this as a unit. With difficulty I managed to get them out and disconnect the fan cables, only to find that there appears to be no way to get the shroud out or in with the engine and radiator in the car! I managed to get the bolts back into the shroud and then removed and replaced the fans individually.

So let this be a warning to others who think they might be able to replace both fans as a unit.

I should also note that you should be careful working around the lower radiator hose. It appears that I was not careful enough and now I am waiting for a replacment to arrive at the local dealer. This hose is original equipment, so after 14 years and almost 300k miles it did not appreciate being bothered and started leaking in the middle where I was playing with the fans.

Dave
__________________
'02 Jetta, (July'13, 244k), (Apr'14, 272K), loads of goodies...

'00 nb bought Oct'09 211K, 100K TB deluxe kit Nov'09, Clutch conversion kit Dec'09, relay 109, replaced instrument cluster 153,934
cgates30 is offline   Reply With Quote
Old September 6th, 2013, 11:57   #14
Dave_D
Veteran Member
 
Join Date: Jun 2003
Location: Gaithersburg, MD, USA
Default

Quote:
Originally Posted by cgates30 View Post
I got home tonight to notice the smell of burning rubber and a little smoke coming from under the hood. Turns out the small fan motor was burning. Spun the big fan and noticed it doesn't turn smoothly, so it probably needs to be replaced too. Glad you mentioned the shroud kit isn't the right way to go.
It might still make sense to buy it, just don't plan to install it as a unit. In my case it was on sale, so I got both fans with a limited lifetime warranty and have a new shroud that perhaps I can sell to someone who could use it.

Dave
__________________
1999.5 (A4) Tornado Red Jetta GL TDI,5 speed,4 door, RC 2+, Old Navy CCV mod, ventectomy, CAT filter
Dave_D is offline   Reply With Quote
Old October 26th, 2013, 10:56   #15
LeBude
Newbie
 
LeBude's Avatar
Default

Just changed the large fan in an 03 Wagon. thanks for the post.
LeBude is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 13:50.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2014
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2013, All Rights Reserved
Page generated in 0.24930 seconds with 11 queries
[Output: 131.06 Kb. compressed to 109.90 Kb. by saving 21.17 Kb. (16.15%)]