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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old July 21st, 2011, 07:26   #16
aja8888
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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?
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Old July 21st, 2011, 20:10   #17
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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.

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Old July 26th, 2011, 18:35   #18
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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
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Old August 2nd, 2011, 11:24   #19
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Default 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
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Old August 3rd, 2011, 14:42   #20
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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.....
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Old August 4th, 2011, 04:27   #21
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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.
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Old August 4th, 2011, 05:06   #22
thundershorts
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could be lots of things, including possible overcharge, triggering high pressure cut out. maybe its time to get out the gauges.
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Old August 4th, 2011, 07:33   #23
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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 , 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.
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Old August 5th, 2011, 08:38   #24
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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.
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Old August 5th, 2011, 09:18   #25
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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.
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Old August 7th, 2011, 16:47   #26
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Thumbs up fixed relay 384

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Originally Posted by JETSLED View Post
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
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Old August 9th, 2011, 10:00   #27
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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.
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Old August 14th, 2011, 16:38   #28
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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...
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Old August 21st, 2011, 15:26   #29
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Default 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.
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Old August 21st, 2011, 16:06   #30
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I believe there are also two relays for the cooling fan on the relay panel
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