Help me find the correct AC clutch

[JustCruisn]

I need a new AC clutch.
VW want between $680 and $757 for the part. 2 dealers gave me different part numbers.

Newstead VW say part number 1J0820811M
I found VW JETTA AC Compressor CLUTCH ASSEMBLY 98 99 00 2000 A/C City Bora | eBay
I asked the seller to confirm and says it is for a Sanden compressor and will not fit 1J0820803G compressor.


Springwood VW say 1J0820811F
Springwood guy took the time to read the notes and said the M was for Sanden compressor, and the F was for Zexel. Zexel compressor was fitted for VIN 1JY onward, mine is 1JZ so it is covered.

I definitely have a Zexel, it is written on the compressor and it is part 1J0820803G.
So I found this part AUDI A3 VW GOLF MK4 AIR CON BELT PULLEY - 1J0 820 811 F | eBay
Now this seller says that it wont fit my VIN even though his listing says it fits compressor 1J0820803G.
My clutch looks just like his pic, it has the round things on it not the bars like the M clutch.

I'm leaning toward the F variant and just tell the guy to ship it and I'll wear it if it does not fit.
But I don't want to waste $110 + shipping. And I just cant stomach paying $600+ from the dealer.

The vehicle VIN is WVWZZZ1JZ1P550905 Engine AGU 1.8T.
These pics are from my car.




So anyone with knowledge on these things please chime in.

[Shadow_Rusty]

I'd have to agree with you... The 'F' looks correct...

[JustCruisn]

Top marks for you. Where did you get that table ?

I asked the seller to check again and got another message from the seller, they also want £54.02 via FedEx

Hi Chris,
Sorry ignore my colleague Adam's message. This is the pulley for that compressor p/n as per listing description.
Kind regards
Ben
Parts Depot

[Shadow_Rusty]

It's a screenshot from ETKA (VAG Parts Catalog)...

[Jmac]

Im missing something but you are looking for an AC clutch, these can be bought seperate from the compressor as you know, you need to shop at an AC parts supplier and not VW as they wont miss you with prices.
Price you are quoting seems seriously dear, seems like it is for a complete AC compressor. A whole compressor isnt that much more than that
Call Bob at Brisbane Auto Air and tell him i sent you on 32522398
Jmac

[JustCruisn]

Full compressor with clutch is around the $900 from VW.
I don't want to replace the compressor as that will require regas, drier expansion valve etc.

I spent many hours trouble shooting, and have had help from Gavin (h100vw) then spent $220 getting diagnosed by an auto electrician.
I also need the fan controller, $260 for that part via the Auto Electrician + labour to replace that sucker. I ordered the part for $36 online and know it is a 5 min swap.
I made a few calls to AC places and they all wanted to repair it not just supply parts.

I ordered the clutch online tonight, about 1hour before you told me about the guy in Brisbane. I might call tomorrow just to see if I spent too much online, maybe I don't want to know. I've had no AC for over a month now and just want it sorted without spending a grand or more.

[JustCruisn]

I got the F model pulley and field coil and installed on my compressor over the weekend. It was fairly big job and each stage presented a new problem.
I put in a new fan control module as it was burnt out.
After all this their is still no signal to activate the clutch
I have followed every troubleshooting guide I could find and everything looks fine.
I can only guess there is some wiring issue someplace.

I'm fresh out of ideas, off to find a good AC shop.

[craig_the_german]

If it was me, first stop would be the guy Jmac recommended

[grtuned]

Get someone to look at it if you were told this was the problem from the first person you went to forget him. Also you sure you got gas in the system???

[JustCruisn]

I can confirm that if I manually power the coil the clutch engages and I get cold air. The fans also work at low speed if I power them manually. So something in the system is saying STOP for some reason.

System full of gas. 2 ac people checked this and confirmed.
I called 5 AC places today, none of them were interested in even having a look.
Called the guy Jmac suggested. He was a nice bloke to talk too, gave me some advice and told me that under no circumstances was he going to touch my car. He said crapwagons are too complicated for their own good, best bet was to pay through the nose and take it to the stealer. He also mentioned that if there is a fault logged the system may be locked out. I'll get the codes cleared tomorrow arvo and go from there.

[Jmac]

Sounds like only thing missing here is to have a VW tech look at it. Pm sent
Jmac

[Shadow_Rusty]

Been looking through the circuit diagrams, and everything leads back to the "Control Unit For Radiator Fan"

Looks like this is the central point for Fans / Water Pump / Aircon Compressor...
Still looking further, as I'm in a similar boat to you...

[Update]

Looks like there are 4 main parts... (With most likely cause being 2/3)
1. Climatronic (About a billion wires and connections going everywhere...)
2. F129 - Air Con Pressure Switch
3. F163 - Air Con Shut Off Thermo Switch
4. J293 - Control Unit For Radiator Fan


J293 (Control Unit For Radiator Fan) (T10B)
Pin 2 - Input from F129 Pin 3 and climatronic
Pin 5/8 - Input from F163 Pin 2
Pin 6 - Compressor Ground (Shared with thermo fans)
Pin 10 - Compressor Activate

F163 (Air Con Shut Off Thermo Switch) (Should be Closed Circuit To Enable the AirCon)
Pin 1 - F129 Pin 1
Pin 2 - J293 Pin 5/8

F129 (Air Con Pressure Switch)
Pin 1 - Climatronic Control J255 (T16B / Pin 2) and F163 (Pin 1)
Pin 2 - Climatronic Control J255 (T12 / Pin 2)
Pin 3 - Climatronic Control J255 (T16B / Pin 10) and J293 (Pin 2)
Pin 4 - A20 Conection (15a) in dash panel wiring harness (Assuming fuse box, but not sure)

[JustCruisn]

I don't have the F129 - I have G65 3 pin variable signal pressure sensor. It sends a duty cycle value to the J293 Fan control unit. under 20% is low pressure cut out, 90% is high pressure cut out.
Also pin 3 on the J293 Fan control box (T14/3) is not used, it is plugged on the connector.
The G65 runs to pin 2 (T14/2) white line, on the fan control unit.

There is a fault logged for this sensor. I've replaced the sensor and the control box and the fault keeps coming back.
An auto sparky diagnosed that the signal line from G65 was going to ground in the J293 Fan control unit. I'm suspecting it is still going to ground but not in the J293 fan control unit but rather in the harness. The line also goes to the J220 Engine control module, maybe it is grounded on its way there.
I'm going to try to diagnose it further this weekend. I'll have to test the sensor directly without the harness connected to see what is actually coming out of the thing.

---------- Post added at 08:21 AM ---------- Previous post was at 07:43 AM ----------

I'll have a look at that F163 cut out switch too, that sounds like a good hunt.

Here are some resources I've found helpful.

Good discussion
AC doesn't work - Page 3 - TDIClub Forums

Fan control module pinout

http://pics.tdiclub.com/data/529/J293-a4_fancontrol_module.pdf

Guide to diagnosing the Fan control module
Fault diagnosis in the Fan Control Module - Gtivr6wiki

---------- Post added at 04:08 PM ---------- Previous post was at 08:21 AM ----------

UPDATE - SOLVED

I tried a few more things today and got nowhere. Then I decided to try the old pressure sensor I'd replaced. Turns out the old one was not faulty at all, this was suspected after finding the fan control unit fried and grounding the pressure signal.
The new one was the dud, I had trouble believing that, its always possible that the a replacement part it faulty but is a hard thing to believe.

Thanks to everyone who took time to help me with this. Especially Gavin (h100vw) who drove all the way out to Kenmore for me.

[Jmac]

Good result, i remember calling the pressure switch early in the piece when you called me at the airport, what a bummer the new one was a dud, does make it hard when the new one should be good, see that heaps with air mass meters and can really waste time, thinking you have nailed the bad parts, and then keep looking to find yourself back at the bloody thing.
Result is the main thing
Jmac

[h100vw]

You're dead right Jimmy, calling time on an already replaced part is hard but as you have said sometimes you have to stop and start over again. It makes more sense, when you stop trying to figure the new part in the troubleshooting.

No worries on the trip for me Chris, I got some precious beer! Lucky you got it fixed with all the hot, dry weather we are having?

Gavin