Thermo fans....help!

[4mo]

Hey All,

I have been lurking for a few weeks and thought it was about time i joined this community....

My Bora after years of not missing a beat is playing up and thought that the experts here might be able to assist/recommend a mechanic.

I need two new thermo fans as mine are shot, also in the need for control arm bushes.

Any help is appreciated.

I am located on the Nth Shore of Syd if that is any help.

4Mo

[Bora Sport]

Read through this. You may find that your fans are not buggered at all and that just the internal resistor is broken.

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=4197

The link to the site that I got the info from is here.

http://website.lineone.net/~alan.james.lorely/fan%20mod/Repair.html

I don't know if this will help you. I did this modification about 9 months ago and so far both the original fans are operating perfectly.

This site was accessed from the vortex thread here:

http://uk-mkivs.net/forums/p/59897/488123.aspx#488123

[dubbed]

My fans stopped working as the above. Can I just replace both fans? I don't have the knowledge to make aluminium boards, resistors etc unless someone in Melbourne wants to make a few bucks or slab of beer??

[Back Door Shenanigans.]

My fans stopped working as the above. Can I just replace both fans? I don't have the knowledge to make aluminium boards, resistors etc unless someone in Melbourne wants to make a few bucks or slab of beer??

You can, But the new one will most likely have the same exact problem. Making up the resistor plate aint exactly hard thought. Just sketch it out onto the plate drill and cut, screw on resistors and join cables

[goodfella]

I got mine repairer under the BS used car warranty from the dealer... it was fixed by Barloworld Five Dock for about $1200ish (inc 2xfans + fuses)

I'll PM you with more details..

[dubbed]

lol $1,200! Wow...

Back Door Shen, where can I get the parts locally?

[Back Door Shenanigans.]

lol $1,200! Wow...

Back Door Shen, where can I get the parts locally?

Aluminium sheets and nuts and bolts would be from bunnings or metal place i imagine.
Resistors are here
Arcol | Passives | Resistors | High Power | Aluminium Housed, Wirewound - 5 to 600W |HS100 1R J
And cables from what ever your favourite electrics shop is.

Heres a bit more info if you need it

http://www.vwwatercooled.org.au/f14/diy-external-resistor-fix-fan-problem-bora-43843.html

This fan repair modification was developed for a 2002 model V5 Golf, it will probably be OK for other Golf models especially the V6

[dubbed]

Hmm well I am comfortable I can do that sort of thing as long as I have all the correct parts. How many amps is the fuse on top of the battery?

Just ordered the resistors, now to get the plate made up. The rest should be fairly easy... I'm kind of excited about doing the fix given how much I hate MkIV Golfs now

[dubbed]

Half way through doing this fix. Can someone please clarify the instructions for me?

I am confused about what to do with the wiring and the in-line fuse(s). What I want to know is, according to the diagram it looks like red/white goes to one resistor, then from the other side of the resistor the new wiring goes through an in-line 30A fuse and then gets 'spliced' into the red/black wiring (you don't physically cut this one). Is that right?

This fan repair modification was developed for a 2002 model V5 Golf, it will probably be OK for other Golf models especially the V6

http://website.lineone.net/~alan.james.lorely/fan%20mod/fancircuit.jpg

[graeme86]

Correct.

Exactly as per the diagram you linked.

The red/white wire on the stock fan harness is the low speed circuit supply which runs into the fan motor (which has an internal resistor inside it).

So you are bypassing the low speed supply going through the original internal resistor and adding your own external resistor.

[dubbed]

Thanks mate. Thought so - it just seemed odd to me tapping into the different coloured wire. Any suggestions for an easy way to tap into the red/black wire? Should I get one of those connectors that bite into the other wire when you clip it down?

[Golf Loon]

Clip lock connectors are horrid amte. Use solder and heatshrink from Jaycar for a proper job.

[dubbed]

Thanks Loon. That was what I was going to do but thought there might be a better alternative.

Will finish the job one night this week or the weekend and let you know how I go.

[dubbed]

Okay chaps, I'm going to be a pain here because I have more questions

The wiring I got was 10/15A but the instructions mention a 30A inline fuse. Wouldn't the wiring melt before the fuse blows? I just got a fuse holder that can take 30A but the wiring is pretty damn thick - 5AG I think - much thicker than the wiring for the resistors. Should I be adding an inline fuse for each resistor circuit?

[Back Door Shenanigans.]

Okay chaps, I'm going to be a pain here because I have more questions

The wiring I got was 10/15A but the instructions mention a 30A inline fuse. Wouldn't the wiring melt before the fuse blows? I just got a fuse holder that can take 30A but the wiring is pretty damn thick - 5AG I think - much thicker than the wiring for the resistors. Should I be adding an inline fuse for each resistor circuit?

Where does it mention that? If you mean " I used a 30A terminal block ("chocolate block") for this." he doesn't mean a fuse for that.

He mentions the wire has to carry 7.5A "(4) Solder approx 30 inches of wire to each resistor termination and cover the bare termination with heatshrink to provide some protect against the elements and accidental shorts. The wire has to carry approx 7.5A and I used some 1.5mm² wire I had lying around." So a 10A fuse will do, I think thats what i put in mine, that or 15A fuses. I put one on each as there is one resistor for each fan.

Also as been said by many people the only stupid question is the one you don't ask. Better to get it right than cause more problems heh.