2006 AC ISSUE

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Hello Folks, been a while since I have posted. I'm having a issue with my AC. i have
just recently replaced my Radiator in the old Girl. She has 217k on the clock. She was losing coolant.
Had a leaking hose clamp, but later realized I had a Radiator leak. Tried some stop leak crap but the
leak just got worse. Replaced the Radiator with a new one. What a major pain that turned out to be.
Ended taking the whole front bumper skin off the car. New radiator in and everything worked okay
for about two days. The AC quite working and the outside temp gauge on the dash quite working. the
led's doesn't show any numbers just blank dashes. I had a wiring harness hanging down by the battery box.
Now the button on the end is missing? I'm now guessing that that button was the temperature sensor. It
had been hanging down there for years, never found the location to plug it in. Now it's probably got ripped off
when I reinstalled the front facade. AC doesn't work. I had a similar problem several years ago and I had to replace
the pressure switch valve on the compressor. Dropped the compressor and replaced the switch with a new
pressure switch. She took some Freon but probably not the correct amount, don't think the compressor is actually
working. Going to check for voltage down on the plug going into the pressure valve. My question now does the
temperature sensor that is now missing talking to the ECM, and shutting down the actuating pressure valve on
the compressor. Kinda perplexed with this issue. As always you Folks are the best Best
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Haven't gotten any response. Maybe the question about if the non functioning ambient temperature is related to
my issue was too stupid of an idea to answer. Again, I replaced the actuating pressure valve on the compressor and
it doesn't appear to fix my problem like it did several years ago. The compressor seemed normal when I removed it to
replace the pressure valve. Don't think that's the issue. Anyway the AC has been intermittent for about a month. It wouldn't
work, then after stopping at the store or something it would start working again. Same issue I had several years ago. That's
why I assumed it was the valve again. Now with ambient air temp not working I'm asking if this is telling the ECU not to activate
the actuating pressure valve. I'm grasping at this point, it may have nothing to do with the missing temperature sensor.
I haven't yet checked for voltage at the plug going to the valve on the compressor. I probably need need to check the
fuse box and AC related fuses as well. Please, any help would be appreciated. I don't have a vagcom, actually I do just have
no idea where it went. lol
 

relumalutan

Veteran Member
Joined
Dec 6, 2012
Location
Michigan
TDI
06 Jetta TDI Special Edition
1. You did not have to remove the entire front end of the car to replace the radiator. All you you had to do was remove the 4 screws that hold the cooling fans assembly to the radiator, and carefully remove the fan assembly either by pulling it straight up from the engine bay (little clearance), or by lifting the front end of the car and sliding it down. Once that is done, there is enough clearance to remove the radiator straight up, once you unbolt the intercooler from it.
2. The AC will not work no matter what if the temperature sensor does not communicate with the ECU. If I correctly recall, it is connected to the lower left front end of the radiator, there should be a bracket that holds it. Start there, and make sure that you see the outside temperature in the instrument panel. If your AC still does not work after that, move on into replacing the RCV valve.

Keep in mind, there might be other issues causing the AC to not work: cooling fans defective (this one might be also related to a defective RCV valve, as the valve by opening/closing "tells" the fans to turn on). Also, if your car is equipped with the winter package (heated windshield nozzles): the harness that goes from the car to the hood (on the passenger side) is too short, causing the wires inside to break, causing an electric shortcut that for some reason is the root of an G65 high pressure valve error.

Long story short: fix the temperature sensor, and let me know if the AC still does not work, I'll try to guide you.
 
Last edited:

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Okay my Friend, I think you answered my question. The outside ambient temperature must show up on the cluster. Mine doesn't any more
I'm thinking I broke the sensor off the harness. Damn, It was hanging down below the battery box, thinking when I put the front back on
the harness must have gotten caught on the wheel or something. Its gone now. Wonder where to get one of those? Again, I'm assuming that was the temp sensor? Shoot me now! lol Yes I replaced the valve on the compressor with a new one, it was about 35$. I'm also suspicious about the high pressure switch on the the high pressure line. Thanks very much! will get the ambient temp working and proceed. It's hot down here in Texas
 

Rx7145

Veteran Member
Joined
May 21, 2017
Location
Ohio
TDI
2006 Jetta BRM
You might be able to put a resistor between the wires to trick the computer into working. Just get a variable one off Amazon.
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Fantastic Folks, I was just speculating about the ambient temp being the problem. Really guessing! Seems like everything is computer controlled
I ordered a part and Amazon already got it to me. Don't see the sensor per say, just the plug with a wire pig tail . Let you know what happens.
You TDI GUYS are always the best. Let you know what happens,
 

John Wesley Hardin

Veteran Member
Joined
Aug 28, 2022
Location
Rockport Texas
TDI
2003 VW Jetta 1.9 Diesel GLS , Five Speed Standard Shift
1. You did not have to remove the entire front end of the car to replace the radiator. All you you had to do was remove the 4 screws that hold the cooling fan assembly to the radiator, and carefuly remove the fan assembly either by pulling it straight up from the engine bay (little clearance), or by lifting the front end of the car and sliding it down. Once that is done, there is enough clearance to remove the radiator straight up, once you unbolt the intercooler from it.
2. The AC will not work no matter what if the temperature sensor does not communicate with the ECU. If I correctly recall, it is connected to the lower left front end of the radiator, there should be a bracket that holds it. Start there, and make sure that you see the outside temperature in the instrument panel. If your AC still does not work after that, move on into replacing the RCV valve.

Keep in mind, there might be other issues causing the AC to not work: cooling fans defective (this one might be also related to a defective RCV valve, as the valve by opening/closing"tells" the fans to turn on). Also, if your car is equipped with the winter package (heated windshield nozzles): the harness that goes from the car to the hood (on the passenger side) is too short, causing the wires inside to break, causing an electric shortcut that for some reason is the root of an G65 high pressure valve error.

Long story short: fix the temperature sensor, and let me know if the AC still does not work, I'll try to guide you.
Does a 2003 Jetta have an outside temp in the instrument panel ?
 

John Wesley Hardin

Veteran Member
Joined
Aug 28, 2022
Location
Rockport Texas
TDI
2003 VW Jetta 1.9 Diesel GLS , Five Speed Standard Shift
I have an A/C problem myself. Temps down hee...r South Texas way 114-120. Have to wear my Leopard Skin Speedo when I drive around , the little wifeys not cool with that when I show up where she works. Not sure why. The Quickie Mart locks the door and makes me use the drive -thru. Whats up with that? I believe my compressor went out . When I first noticed the A/C would work briefly about 10- 15 minutes then start fading out till it stopped blowing cold air for a couple of weeks. Then it just stopped blowing cold air. I didnt realize it at the time but I believe my Radiator and A/C were not working at the time. Took it to a A/C guy he put the gauges to it and said I had a bad compressor. Compressor kicks on but you cant really hear it engage or notice any drop in rpm. Cooling fans are working, inside fan blowing , compressor turning just no cold air. Oh yeah this is a 2003 Jetta 1.9 TDI. Any comments appreciated before I take further action like replacing the whole system or changing my attire
 

John Wesley Hardin

Veteran Member
Joined
Aug 28, 2022
Location
Rockport Texas
TDI
2003 VW Jetta 1.9 Diesel GLS , Five Speed Standard Shift
I have an A/C problem myself. Temps down hee...r South Texas way 114-120. Have to wear my Leopard Skin Speedo when I drive around , the little wifeys not cool with that when I show up where she works. Not sure why. The Quickie Mart locks the door and makes me use the drive -thru. Whats up with that? I believe my compressor went out . When I first noticed the A/C would work briefly about 10- 15 minutes then start fading out till it stopped blowing cold air for a couple of weeks. Then it just stopped blowing cold air. I didnt realize it at the time but I believe my Radiator and A/C were not working at the time. Took it to a A/C guy he put the gauges to it and said I had a bad compressor. Compressor kicks on but you cant really hear it engage or notice any drop in rpm. Cooling fans are working, inside fan blowing , compressor turning just no cold air. Oh yeah this is a 2003 Jetta 1.9 TDI. Any comments appreciated before I take further action like replacing the whole system or changing my attire
Meant to say Radiator and A/C Fans
 

Rx7145

Veteran Member
Joined
May 21, 2017
Location
Ohio
TDI
2006 Jetta BRM
I think the 2003s have a clutch, if so, I would put a meter on the clutch wires to make sure it’s actually getting voltage.
 

John Wesley Hardin

Veteran Member
Joined
Aug 28, 2022
Location
Rockport Texas
TDI
2003 VW Jetta 1.9 Diesel GLS , Five Speed Standard Shift
I think the 2003s have a clutch, if so, I would put a meter on the clutch wires to make sure it’s actually getting voltage.
Thanks for the reply. I am going to order the GDP A/C kit on Rockauto, w/ condenser and a drier( sold Separate) compressor is a Sanden which is the original on my car. My TDI has 300'000 plus. Dont know if the A/C was ever serviced. Have a mechanic guy at my work , says he'll put it in for me . I think that may be the most economical way Kit and labor around $ 700.00. I'll give him a hand . He said six hours . I think thats about right maybe a little longer in my opinion.
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Just a update. Sounds like this is more of a common issue than I thought. Thanks, everybody . YES, it's hot down here south of Houston. I don't
even bother to ware shorts anymore just go naked. Have the same issue with the local Quick Mart, these folks don't seem to appreciate a true well endowed
Cowboy in the Buff. Lol! You Folks made my day! Anyway, it appear the sensor got twisted off, I found the wiring harness, two wires. A brown(may be yellow) and a blue/brown wires. They had twisted together and obviously had completed the circuit, bare wire was twisted together probably from the incident that caused this whole issue. Changing out the Radiator. It was a Bear trying to change it out. Didn't appear to me it would slip out with just removing those four torix screws off the Fans. Hence, I took the front Facade off. Yeah, probably went too far. It's done now! I cut back the wires and removed the short. I was expecting the dash digits to go to 000 or something on the ambient temp gauge. They stayed as dashes ---. No change! Now what, these wires came off a larger harness and bifurcate down near the bottom of the radiator into a separate smaller harness with the two wires . These wires the brown/blue and brown(actually may be yellow) that i assume go to the missing temp sensor. I bought what i assumed I needed, it's a plug with a 2 wire pig tail but there is no sensor. The plan was to splice the wires into the pig-tail. This will not work because I still don't have the sensor. I'm very hesitant about metering the two wires. I don't want to potential burn out my ECU. I pulled the air-box out and battery for clear vision.
Convinced these are the correct wire pair, maybe? Going to research the sensor and try to figure out exactly what I need.
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Just bought the sensor I think, should work with the harness set up I already bought. They sell them as a package. Maybe this is the beginning of the solution. Still concerned of why I didn't see a display change on the ambient temp monitor when i opened up the circuit?
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Thinking that Lottery Pencil is still cleaner than the Door Handle on your local Star Bucks. lol Buddy, you crack me up!
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
I got the sensor, now just need to figure out it all goes together. I bought the harness and the sensor not sure how this works?
 

p930man

Veteran Member
Joined
May 15, 2007
Location
Rosharon, Tx
TDI
2013, 2002 jetta, 06 tdi jetta
Thanks everybody for the help. Could only use a part of the harness. Ended up splicing the wires from the pig tail into the old wires that had been left over from the original. These wires ran into another bigger harness so I just did a splice. The ambient temperature display now works. It showed 86*, probably real close to the actual temperature today. I was able to add Freon and put in close to the proper amount. She is now blowing good and cold. Very happy if she keeps functioning. I replaced the expansion tank with a new one and seem to maintain proper coolant level now. I have managed to pick up a engine code now, don't know what it is yet. Hopefully I will figure that out tomorrow. I truly appreciate the TDI forum Brain Trust. You Folks always amaze me. THANKS!!!!
 
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