A/C quit working

[Dave K.]

Hello. Yesterday the A/C quit blowing cold in our 2004 Jetta TDI (it has a BEW if that matters). We were a 1/2 hour into a 3 day road trip. Completely fouled up my weekend. Trip got canceled. We lost $250 for the 1st nite at the hotel. What was the icing on the cake you might ask? Yesterday was my birthday. Happy #($*%&^ Birthday to me!

Anyway I've done a little research but would greatly appreciate any help fixing this thing with as little pain as possible. The condenser/radiator fan does turn ON when the A/C in ON, so that eliminates many potential culprits.

With a test lite, I probed the compressor clutch plug. I don't have a wiring diagram for this car, so I'm kind of flying blind here. One of the terminals did nothing, I assume this is the ground. The other terminal flashed the lite ON for a 1/2 second, OFF for 3 seconds repeatedly. OK. Weird. So what does that mean to somebody that knows how this system works?

Thanks,
Dave

 

[P2B]

Compressor clutch coil failure is not uncommon on these, should read a few ohms. If it's open circuit you found the problem. You need to drop the compressor to change the coil, but it doesn't require opening the system.

Do both fans run with key on AC on?

 

[Zak99b5]

ohm out the clutch coil. Mine was bad on my car when I bought it, so I replaced it. Also, the coil was bad on my daughters 05 Golf. Replaced it today.

 

[mikearvan]

I had a similar situation/symptoms and it was a bad wire coming out of a plug to the fan control module under the battery tray. In my experience it is more likely bad connections or wires than parts. First try reconnecting all the plugs and wiggling harnesses associated with fans and sensors associated with a/c before changing parts

 

[Dave K.]

Compressor clutch coil failure is not uncommon on these, should read a few ohms. If it's open circuit you found the problem. You need to drop the compressor to change the coil, but it doesn't require opening the system.

Do both fans run with key on AC on?

Only the passenger side fan turns on with key on, A/C on. That is with the engine not up to temperature, so I assume that's why the driver side fan was not on.

Compressor clutch tested open circuit. To double check the clutch, I jumper'd it right to the battery......nothing. Guess I found the problem.

Next question: Which clutch removal tool works on a VW? I'll have to buy one. It's a Sanden SD7V16.

 

[Zak99b5]

You need regular hand tools and snap ring pliers. Kansascitytdi has a how to video and sells the parts you need.

 

[P2B]

Only the passenger side fan turns on with key on, A/C on. That is with the engine not up to temperature, so I assume that's why the driver side fan was not on.

Both fans should run on low speed regardless of coolant temperature. You need to replace the driver's side fan or you will cook the compressor.

 

[Genesis]

Yep. The common failure is the driver side fan stops working. You don't detect it and over time you cook the compressor and what was a $100 to $200 problem becomes a $1,000+ problem.

 

[csstevej]

For me common hand tools and a deep 90 degree snap ring pliers .

 

[Dave K.]

Before buying a new fan, I want to make sure it's bad. (Or the control module or wire or ??). Is this wiring diagram correct for my car?

COOLING FAN – Volkswagen Jetta GL 2004 – SYSTEM WIRING DIAGRAMS – Wiring diagrams for cars

COOLING FAN Cooling Fan Wiring Diagram, Auto A/C 1.8L TURBO 1.8L Turbo, Cooling Fan Wiring Diagram, Manual A/C 1.9L TURBO DIESEL 1.9L Turbo Diesel, Cooling Fan Wiring Diagram, Manual A/C 2.0L 2.0L, Cooling Fan Wiring Diagram, Engine Code BBW with Manual A/C 2.0L, Cooling Fan Wiring Diagram...

portal-diagnostov.com

Thanks.

 

[BobnOH]

Temporarily put 12v to the fan.
If the colors and connections match your car, it's likely correct.

 

[oilhammer]

Gotta check those fans.... one isn't enough when it is warm, and the A/C pressure gets too high, so it starts turning the compressor clutch off, then back on, then back off... which it is not supposed to do, and it overheats the coil and it dies.

Your fan has been dead for a while, it likely didn't just happen. I get cars in here all the time with a dead fan, and the owner never knew.

 

[Genesis]

The interesting thing is that of all the fans I've seen fail (several ALH cars) its ~3-4:1 driver-side. One (mine) lunched TWO driver-side fans, the pax side is OE and still working fine at ~300k miles.

 

[Dave K.]

Help so far is much appreciated. I bought a new Febi Bilstein fan but I'm not having much luck finding a decent A/C clutch without paying stupid money. VW wants $500+ for the clutch & coil. IMHO that's just ripping off the customer. And it's discontinued.

I bought what I thought might be a decent clutch from Amazon....it wasn't. Snap rings were to thick & didn't even fit in the grooves so I used the original snap rings. Then I tried to set the air gap.....with all the shims installed, there was still insufficient gap. Plus the I/D of the shims was .080" bigger then the original Sanden shim, were a poor fit, & would have failed. At that point I gave up & removed the Amazon clutch.

So now the VW is laid up and it's hot & humid. Wife needs her car & I need my truck back (which doesn't have air). There's nothing wrong with the original clutch. It's only the coil that failed. I wish I could find an genuine Sanden coil but after hours on the internet, I can't find anything. At this point I'd rather have a good, used Sanden coil than another Chinese piece of junk.

Any advice?

 

[Brett San Diego]

Pick-a-part salvage yard. Bring your clutch removal tools to the yard. Take just the coil, and swap it over to your compressor. Probably $10-15.

Brett

 

[J_dude]

Help so far is much appreciated. I bought a new Febi Bilstein fan but I'm not having much luck finding a decent A/C clutch without paying stupid money. VW wants $500+ for the clutch & coil. IMHO that's just ripping off the customer. And it's discontinued.

I bought what I thought might be a decent clutch from Amazon....it wasn't. Snap rings were to thick & didn't even fit in the grooves so I used the original snap rings. Then I tried to set the air gap.....with all the shims installed, there was still insufficient gap. Plus the I/D of the shims was .080" bigger then the original Sanden shim, were a poor fit, & would have failed. At that point I gave up & removed the Amazon clutch.

So now the VW is laid up and it's hot & humid. Wife needs her car & I need my truck back (which doesn't have air). There's nothing wrong with the original clutch. It's only the coil that failed. I wish I could find an genuine Sanden coil but after hours on the internet, I can't find anything. At this point I'd rather have a good, used Sanden coil than another Chinese piece of junk.

Any advice?

Well this is really weird, I know I just saw a clutch coil on Roseland’s site recently, but now I cannot find it anywhere. I guess find a used one like Brett suggested?

 

[mlemorie]

Let me know if you find a good replacement clutch. Mine died a couple years ago and my discounted employee price st the dealer was not worth it lol. I'd love to get my AC back in the jetta...

 

[csstevej]

Try a different vender on Amazon, I’ve done 4 clutch replacements from them and never had an issue with it.

 

[Black00Jetta]

I had the same issue and it was the magnetic coil. Bought a compressor at the salvage yard for $50. Bought a good snap ring pliers, dropped the a/c on the Jetta and had the coil replaced and back running in 2 hours with good results,

 

[Dave K.]

Car is back together and cooling as it should. I can't thank you guys enough. Below are some notes that I hope somebody will find helpful.

Clutch that did not met minimal standards: https://www.amazon.com/dp/B088WHV4WP?psc=1&ref=ppx_yo2ov_dt_b_product_details . Seller refunded the cost.

In the interest of time & my sanity, I bought an aftermarket (made in China) coil. https://www.amazon.com/dp/B071GQ7FLL?psc=1&ref=ppx_yo2ov_dt_b_product_details I hope it last. Going to a You-Pull-It when it's 90 degrees outside with 95% humidity is no longer an option for me. Many years ago when I was 20 that was an option, not so much anymore.

New Febi Bilstein cooling fan came from FCPEuro. I did an autopsy on the old fan motor excepting to find worn out brushes/commutator. That wasn't the case. Brushes had plenty of life left in them and the commutator was good. The brush holder, however, was not good. It had melted causing the brushes to seize in the holder. The front bearing, although not seized, was not smooth and the outer race was loose in the housing. I'm thinking the front bearing caused excess load on the motor, amp draw goes up causing excessive heat, brush holder melts, brushes seize, end of motor.

Having some other problems with the car and I have a tech article I'd like to submit. I'll be posting more very soon. Until then, take care.

 

[AndyBees]

I've used eBay for the coil/clutch assemblies with no problems. I've installed the China made compressors for a couple of folks... actually done it several years ago. Last I heard they were doing fine.

The brushes hanging-up in the slots is very common. Road debris is generally the culprit. The fan motor has a resistor that burns off 12 volts for the "slow" speed. Sometimes that resistor burns-out, leaving the slow speed dead.