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T5 130 Caravelle 2004 Fans Stuck on No Air Con
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cdpdml View Drop Down
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    Posted: 05 Jun 16 at 18:11
Hi I have a a 2004 Caravelle with Climatronic air con and I've just finished a trip after which the aircon has stopped working and the fans are always on. I've changed the outside air temp sensor (£5) and have checked connections on Fan Control Relay in engine bay and the temp sensor at the bottom of the Rad. Connections look ok, no corrosion etc and no broken wires. I've not got a vag-com but have checked OBD II and no codes present. Had a number of air con issues last year but all fixed and system reliable since then.

Am I right in assuming the best bet is to get the codes checked due to the complexity of the system or just go and change the Fan Control relay. Also if I do so will I still need to get potential error codes reset or will turning off and changing the controller complete the reset?

Any help gratefully received.

Colin
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jun 16 at 18:06
Ok so I got the fault codes off the car today and they were: 353,819,1292, 249. The 819 is the air con HP sensor so that will be changed but this has failed in the past and all the fans never came on so I'm not sure that's the actual cause of the fan issue. I cannot find and info on the other codes 353,1292 & 249 so am at a loss. That said if the 1292 code should have a P this could relate to the "mapped control engine cooling thermostat F265". 

If it does relate to the F265, there appears to be nothing wrong with the thermostat's actual operation as even under heavy loads  the temp guage maintains a rock steady 90 degree C but clearly if it's sending the wrong signals to the ECU the fans could fail safe. Thing is I cannot find any reference when googling to the 2.5 130hp engine having and f265. Can any one confirm if it does?

Thanks Colin.
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cdpdml View Drop Down
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jun 16 at 19:00
Found what looks like the answer via:


Really useful resource if correct :)

This shows:

00249 - Function Return Message for Recirculating Air Regulator

00353 - Function Return Message from Fresh Air Blower Regulator

00819 - High Pressure Sensor (G65)

01292 - Right Rear Side Airbag Shut-Off Key Switch (E298)

Struggle to see why these switch the fans on all the time, i'll do more digging...
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cdpdml View Drop Down
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Oh and another useful source of fault code info:
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I'm not an A/C specialist but the high pressure sensor code looks like the most important one to me. 

 As far as I know any fault that the A/C controller sees that means it can't fully control the A/C will result in the fans being on all the time as a precaution.  This happens if the air temp sensor behind the bumper fails for example.  Have you seen this?  http://wiki.ross-tech.com/wiki/index.php/00819
2004 2.5 174
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cdpdml View Drop Down
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jun 16 at 13:25
Hi T5 TDI, thanks for you reply, Yes I've come to that conclusion too and the van is booked in to get the HP sensor replaced. Apparently a failed sensor does turn the fans on to try and reduce the refrigerant temp and pressure. Thing is the same sensor was replaced with a genuine part less than a year ago so I'm not sure what makes them fail...
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They need to check the wiring first.  The other codes sound like the bus system is working in a limited fashion. 
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HP sensor checked no issues, fuses "C 22" blown. Fuse replaced blew again then replaced a second time and now all working so it does appear to be an intermittent cable fault. Both the HP sensor and G238 Air Quality Sensor fed from this 7.5A fuse.

I know where the HP sensor is located so can track from there but no idea of the location of the G238 Air Quality Sensor. Can anyone help?
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It's under the heater air intake cover on the drivers side.  
 
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cdpdml View Drop Down
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 10 Jul 16 at 13:06
Sorry T5 TDI I must be missing something as I still can't find it. Can you be a bit more specific please i.e.

1. Am I looking under the bonnet or inside the car?
2. I can see the heater air intake on my car is behind the battery on the passenger side in the bulkhead. But I can't find anything that looks like an air quality sensor in that area.
3. when I look at the blower/pollen filter assembly can't see anything there either

Thanks, any help appreciated!

Colin
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It's under the bonnet.  But first you have to take the wiper arms and bonnet seal off.  Then take the plastic plenum cover off.
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 13 Jul 16 at 21:43
Sensor found and on inspection one of the pins was showing signs of burning which probably explains why the fuse had blown in the first place (assuming that when the fuse was replaced the sensor finally completed it's burn out process before failing open circuit).

New air quality sensor bought from VW, £71 plus VAT :( interestingly part number has changed from original 7L0 907 643 to 7E0 907 643 assuming VW gave me the correct part. Next step to get the codes reset then hopefully I'll have a "cool" car again. Only other potential issue is the sound the aircon makes. Pump replaced last year so should be fine but it sounds like the pump/system is cycling on/off somehow (every 2 seconds) I'll keep posting and will upload photos of sensor location shortly...
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Points: -998266 		Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 14 Jul 16 at 04:07
Thanks for the update, hopefully the new sensor will fix the issues for you.

Re the aircon noise, did you replace the freewheel mechanism when you replaced the pump ?  These T5 freewheel thingies are known to wear out and cause trouble. I had a vague idea that the aircon runs all the time, but pumps more or less as required.


Edited by gregozedobe - 14 Jul 16 at 04:08
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Hi gregozedobe, thanks for your posting. Yes the freewheel/gates coupling was replaced. Thing is the cycling noise is quite regular but not related specifically to engine speed or pump speed. It's like the system is calling for cooling then after a second or two decides to change it's mind! The other context is that it has made similar noises when the aircon has been operational but only since the pump as changed.
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There shouldn't be any noises out of the compressor on the 2.5.  Even the engine note stays virtually unchanged on mine when switching on because of the lack of a conventional clutch.  It sounds like the new compressor could be faulty or possibly out of line.
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gregozedobe View Drop Down
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The freewheel is a separate part  to the gates coupling, were both replaced ?  In a normal service only the gates coupling (black rubbery cylinder with internal teeth) would be replaced.

Also maybe check the aircon system is fully charged with refrigerant ?  If it is low it might be going into 0% duty cycle to protect the pump, then trying again ?
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 16 at 10:20

T5 TDI I agree; prior to the pump change this noise was not heard and the switch between 0% and cooling was almost silent save for the old pump rumbling a little which was why it was replaced. 

I think gregozedobe may be right in terms of the source of the noise (the pump cycling between 0% and duty) but I expect the system to be correctly charged as this was checked when the HP sensor was replaced. Question is what is triggering it to cycle? Next step I think to take it to VW for a Aircon check. they've quoted me £65 which isn't too bad. 

Have to say, the guy's I've used to replace the pump etc are excellent but the sheer complexity of the system/Can Bus etc. means if I had my time again I'd do to the main dealer. 

On a separate note gregozedobe, yes the free wheel and coupling where replaced with the pump. 

The new Air Quality Sensor appears to be working correctly as you can hear the system changing to recirculation mode from time to time so that was definitely the cause of the C22 fuse failure/fans coming on all the time.

Thanks for the support provided I think this is close to resolution. Once completed It will be time to look at the Webasto which I’m not convinced is currently working correctly when it’s cold…
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Points: 12 		Post Options Post Options   Thanks (0) Thanks(0)   Quote cdpdml Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jul 16 at 14:11
Ok got hold of a VCDS and checked/cleared the codes. All now working as expected and "noise" no longer there. Will review once it's had a decent drive but for now aircon working again :)
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Fingers crossed it is OK now Thumbs Up
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