Thermo fans....help!

[dubbed]

Is there anything that I could have done to make that easier for you?

ie, extra holes, trimmed differently or something?

Preeny, you did a great job If anything the diagram I sent you needs tweaking on a case-by-case basis because I think there are subtle differences between models and/or chassis'. I mentioned it was a pain in the arse because you have to lay on your back and try and squeeze your hands into awkward angles to secure the plate.

For anyone else wishing to do this** I would suggest getting a blank plate made up from Preeny and then measure and drill holes yourself. Mine has a bunch of extra holes in it now but it's only aesthetics which you don't see anyway. And I may have put it around the wrong way...! I'd buy another plate to do it again a bit neater (I'm pedantic) but to be honest 1) I can't be bothered getting metal fragments in my eye again lol and 2) like I said, you don't see it anyway

**I recommend EVERY Mk 4 owner do this mod because your fans will fail. Chances are they already have and are currently not working as they should - run the test which is mentioned in the links in this thread.

[Back Door Shenanigans.]

Haha, As i said its about 10x easier if you take the front bumper off.

[dubbed]

Hmm may do that this weekend because the panel beater didn't align it very well anyway.. Cheers mate.

[Preen59]

If you need another blank.. I can send you one. Just buy me a beer some time or something.

[dubbed]

Okay, good and bad news.

Good:

• Fans now work
• Air con is cold again
• Discovered why my bumper isn't aligned properly (broken mount)
• Car isn't on fire

Bad:

• Job isn't the neatest so I will redo now I know what I'm doing
• Broke a clip that secures the wiring to the fans
• Temp doesn't sit on 90 degrees Celsius, seems to sit around 80
• Found out my fan(s) squeal when I first start the car. I always thought the squeal was the serp belt so that leads me to believe the brushes in the fan(s) are rooted and maybe the reason the fuse blew (30A on top of battery). Can you buy replacement parts or will the fans need replacing?

Thanks again for all those that helped, couldn't have done it without everyone.

PS: removing the bumper is easy and gives you heaps of access. Would highly recommend removing it if you do this job. http://forums.vwvortex.com/showthread.php?3871619

[rhyno]

So given the weather is getting warmer again, I thought it's about time I got my fans going which crapped out late last summer. I bought the resistors online a few weeks ago, made up the plate, then threw it in the boot in waiting for a delivery of motivation.
That motivation came this afternoon, and I promptly pulled off the bumper, decoupled the connectors, and proceeded to test the fans before I cut anything.....The bloody things work, both high and low....
Two things:
1. Does anyone want a pre made plate, with resistors mounted?
2. What would you recommend my next fault finding step would be? Are the only fuses for the fans on top of the battery? Where is the relay to turn them off and on?

This car has been an electrical nightmare since I bought it; the previous owner had wired in a few too many/overpowered accessories and created a small fire in the fuse compartment, the clear is starting to come off of the boot, roof and bonnet, and the front end is knocking with despite replacing pretty much everything.... it's a constant battle with this car. I think I have to admit, I bought a lemon.

[JustCruisn]

Fans are controlled via the fan control unit which is mounted below the rail under the battery.
It has a 14pin connector with all sorts of signals - ac pressure, throttle open, coolant temp, ac button signal, compressor.....
And a big 4 pin connector which controls both the fans for high and low speed.
I'm trying to work out why my ac does not work and this control unit has been the centre of this whole debug process.

[Jmac]

Fans are controlled via the fan control unit which is mounted below the rail under the battery.
It has a 14pin connector with all sorts of signals - ac pressure, throttle open, coolant temp, ac button signal, compressor.....
And a big 4 pin connector which controls both the fans for high and low speed.
I'm trying to work out why my ac does not work and this control unit has been the centre of this whole debug process.

Not that hard to diagnose the control unit, bypass it and check the fans actually work, they have to cool the condensor, and of course when its cool the pressures come down and the high pressure switch doesnt switch the system off.
Fans dont work the compressor clutch wont kick in.
Jmac

[rhyno]

So that may be why my aircon isn't cool either!

Is there a guide to testing the control unit anywhere that you know of?
edit: found one! http://pics.tdiclub.com/data/516/A4_...ting_Rev_7.pdf

If I need to replace it....
http://www.germanautoparts.com/Volks...ectrical/336/1 (ouch!)

[JustCruisn]

The fan controller can be had for about $36 delivered [ebay]130585665559[/ebay]