Radiator Fan Issue (2.0T FSI)

[Fahrvernugen]

Hello, i need to help here...

...i have a 2006 Jetta 2.0T. Lately, one of my radiator fans (small one on passenger side) is not working, cause the bigger one to run like crazy every time i use the car.

What could it be?

Bad Thermoswitch?
Bad radiator fan?

I have also noticed (not sure if related) that my a/c isnt working well when i start up the car, and it takes a while to get to normal cooling temp. This new issue is recent, (not so the other), but i suspect i has to do with the same thing.

Anyone?

[iGen3]

search.

there is a decent likelihood the fan motor has seized. In my case, one of the motor brushes got hung up on some dust/grit. took it apart, cleaned it and that fixed it.

[iGen3]

search.

there is a decent likelihood the fan motor has seized. In my case, one of the motor brushes got hung up on some dust/grit. took it apart, cleaned it and that fixed it.

here: http://forums.vwvortex.com/showthrea...an-Replacement

[iGen3]

oh, and here is the rough idea for busting open and repairing the motor, if it is not too fried.
http://pics.tdiclub.com/data/517/Fan_Repair.pdf

[Fahrvernugen]

Thanks for the info! Very useful, specially that last fan fix.

[Fahrvernugen]

Bump.

[Alan_G_1.8T]

Did you find the issue, and figure out a fix?? My wifes 2006 Jetta is exhibiting the exact same issues, right down to the A/C not cooling as efficiently unless you turn it way down.

[jennythejetta]

Seems like a common issue...my 2005.5 slave died so the master was spinning like crazy to make up for it.

[black6MKV]

i have a 2006 Jetta 2.0T. Lately, one of my radiator fans (small one on passenger side) is not working, cause the bigger one to run like crazy every time i use the car.

Mine started doing the same thing a couple days ago.

[Alan_G_1.8T]

I've found a couple of other threads on this issue. Sounds like the dealership will bend us all over for about $1,000 to fix "their" prematurely failing fan units. Anyone know of a cheaper replacement parts source in North America, or is it off to the wreakers?

[CanadianJetta2.0T]

Alan_G_1.8T, how did you get a total of 1000$ ?... I changed the pass. fan for around 200$ with new and genuine VW fan and I'm not particularly good with a wrench.

[Alan_G_1.8T]

I read this in another thread. Another Vortex member said he got a quote from the dealership to replace both fans plus installation and it amounted to a roughly a grand.

Found it in this thread:
http://forums.vwvortex.com/showthrea...005-Jetta-2.5L

[Fahrvernugen]

I honeslty havent done anything related to this issue. I was hoping maybe to see how other's solved this issue so i can start moving in some direction.

Still, ill let u guys know if i find anything.

[jennythejetta]

Call VWoA...I'm seeing a trend in the failure rate. See what they can do for you...

[Alan_G_1.8T]

Many threads are now popping up on this subject, sounds like the fans are going the famous ignition coil route! Like the coils it will take years for the VAG group to admit they have a problem, the owners deal with the problems until it's an epidemic.
I don't think I am going to complain, VW's & Audi's are all subject to a multitude of electrical or sensor failures, it's common knowledge now. My past three vehicles have been Audi's or VW's (presently a TT, and two Jetta's, and my wife now has a Jetta) and all have electrical gremlins. Like I said in another post, it's very unlikely I'm going to by another VAG car which is a shame, other then the electrical bull crap, they are super nice cars and I will miss them.

[Fahrvernugen]

Alan_G_1.8T
Many threads are now popping up on this subject, sounds like the fans are going the famous ignition coil route! Like the coils it will take years for the VAG group to admit they have a problem, the owners deal with the problems until it's an epidemic.
I don't think I am going to complain, VW's & Audi's are all subject to a multitude of electrical or sensor failures, it's common knowledge now. My past three vehicles have been Audi's or VW's (presently a TT, and two Jetta's, and my wife now has a Jetta) and all have electrical gremlins. Like I said in another post, it's very unlikely I'm going to by another VAG car which is a shame, other then the electrical bull crap, they are super nice cars and I will miss them.

I agree with you...honestly, ive been thinking of moving to other brands for my next vehicle purchase...my VW Corrado hasnt been allmighty in terms of reliability, but DAMM, this Jetta sucks compared to it!

Im just 55k and its been issue over issue over issue...and not simple ones. At this moment, beside THIS fan issue, my throttle body is acting funny...and im not happy at all.


55k = 2 new Turbo's, 1 repaired turbo (by myself, not warranty), 1 knock sensor, this fan issue, the Throttle body issue, 4 ignition coils (replaced under recall), 2 DV's (can complain, im chipped), 1 roof liner, 1 chipped CD unit, 1 chipped power mirror switch, 1 trunk latch, 1 belt tensioner + belt, 1 mildly worn Cam Follower...too much for 2006 55k mile vehicle.

[trane]

Same thing just started for me recently. Dealer service says that the little fan should signal the computer if it isn't working and without a computer code they can't determine that anything should be done. Just put $800 into the turbo a month ago. This car could cost more per month in repairs than it did in payments if it keeps this up.

[bwoodahl]

Same thing just started for me recently. Dealer service says that the little fan should signal the computer if it isn't working and without a computer code they can't determine that anything should be done. Just put $800 into the turbo a month ago. This car could cost more per month in repairs than it did in payments if it keeps this up.

B.S. there is no stored code on only a failed secondary fan. If both fans (primary and secondary) fail, then a code will be stored.

[trane]

I just installed the Bentley repair manual on my computer to try to find out how the fans are supposed to work, but alas all I can find is information on what to connect and not how things should work. Pardon my being an engineer, but it always bugs me to have instructions without having theory of operation to support interpretation of the instructions. Does anybody know if proper fan function is documented in the manual somewhere?

Do any of you know the electrical relationship between the two fans to know if the little one not spinning while the big one is spinning is a sure sign of problems vs normal operation? Maybe if I had a second GLI I could compare them.....

Thanks!
Mark

[Fahrvernugen]

B.S. there is no stored code on only a failed secondary fan. If both fans (primary and secondary) fail, then a code will be stored.

True..i got no code, and only my small fan aint working.

Do any of you know the electrical relationship between the two fans to know if the little one not spinning while the big one is spinning is a sure sign of problems vs normal operation? Maybe if I had a second GLI I could compare them.....

I think (not sure though) that small fan operates only when a/c is on...which makes sense, since large fan goes like crazy ONLY when i turn a/c on.

[jennythejetta]

True..i got no code, and only my small fan aint working.

I kinda second that comment: no MIL but the dealer did pull a code saying the fan was fried. They initially thought it was both fans (based on the code they got back), but once the little guy was replaced the code cleared itself.

On a related note, 2 months after the small fan is replaced, I get a MIL. Its the coolant temperature sensor this time...great...but such a curious coincidence that its related to the engine's cooling system.

[trane]

Talked to the dealer service rep today. It would be a little over $1000 to replace both fans. $660 to replace the little one. Parts are something like $350 and $250 for the fans. He said it should be fine to just let the big one pick up the slack and not worry about the little. Also, he said there's a controller for the fans mounted on the motor of the big fan on the 2.0T, which would make sense since the cable runs on to the fan board, up to the big fan, and from there to the little fan. On the 2.5 it looks like it splits before going to the fans. Guess I'll just have to put up with feeling the vibrations of the fan in my steering wheel.

[iGen3]

Talked to the dealer service rep today. It would be a little over $1000 to replace both fans. $660 to replace the little one. Parts are something like $350 and $250 for the fans. He said it should be fine to just let the big one pick up the slack and not worry about the little. Also, he said there's a controller for the fans mounted on the motor of the big fan on the 2.0T, which would make sense since the cable runs on to the fan board, up to the big fan, and from there to the little fan. On the 2.5 it looks like it splits before going to the fans. Guess I'll just have to put up with feeling the vibrations of the fan in my steering wheel.

dude. take the fan off. open up the back of it with dremel. If it is just stuck brushes, FIX IT. or just buy just the fan online and replace it. Don't pay those insane prices.

[Fahrvernugen]

Update:

Finally took the fans out today, pretty easy task (even more thanks to DIY provided by IGen3). Gave the small fan to my brother who can basicly can fix anything, so he can check it out by busting it apart. Fingers crossed hoping that fan just needs some TLC...but we will see in a few days.

In the meantime, i also took out and replace my throttle body for one i bought here on Vortex...also somewhat easy task due to added clearance by not having the fan's assembly. Currently, my car is acting up, and it stalls or misfires like hell whenever it feels like doing so...and VAGCOM throws some Throttle Body codes. Will have a chance to test the car as soon as i get my fan back in place.

[Fahrvernugen]

Update #2

Fan was fixed by my brother...exact same problem as described by IGen3...hence, same solution!!

Looking forward to put everything back together within the next two days. Lets see if everything works well!

If so, cost for fan repair: $4!!! Yay! hehehe.

[Fahrvernugen]

Final Outcome:

The fan was repairable...hell, it wasnt even bad, just dirty!

Fan is installed and working like a charm. So did the "new" used throttle body. It did the adaptation like in 5 seconds LOL.

[ponchoboy]

Officially resurrecting this thread...

Back story: I've got an '09 TSI (~8K miles) that was hit in the front. The donor car was an '06 FSI (~40K miles), which is where the radiator fans/shroud came from. Unfortunately, I needed to splice the plug from the FSI onto the TSI harness. In retrospect, I probably should have spliced the fan/shroud side, but here we are (why the heck do they have to change connectors?!).

Anyway... big fan works fine, temperature is right at 190 all the time, but I'm 99% sure the little fan never spins. Turn on the A/C when the car is parked, and only the big fan spins. Also, I've noticed that the big fan runs after I park and shut off the car (noticed this more recently, but maybe that's due to the summer heat?). It starts slow and then ramps up for a minute or two.

What are the symptoms of a stuck/dirty little fan? Mine spins freely when you push it by hand, but could the motor still be seized? I kept both fans from the TSI (the fins are borked but the motors should be good). Will they work in an FSI shroud? I saw some discussion about different part numbers... but maybe that's due to the connector change.

Thanks for the help!

[Fahrvernugen]

OP is back.

Small fan simply wouldnt move even if i tried to "help" to start moving it by myself. It felt loosed and easy to spin.

After being fixed, felt the same way, but with the difference that it worked.

[ponchoboy]

OK, so it sounds like I've got a weekend project coming up. Hooray (sarcasm).

Thank goodness for DIYs in this forum!

[Cnyman]

on another thread this guy shows a step by step on how to repair the fan if it is only the brush holders. (if it is not working, what have you got to lose?)

http://pics.tdiclub.com/data/517/Fan_Repair.pdf

The forum is awesome for folks that have taken the time to help others.

I just got the 800 quote from the dealer for the the two fans (parts and labor) The numbnuts parts manager insists on charging more than list price for OEM parts and I have attempted to get them to understand how much business that drives away but hey, they can run their business they way they want. They are the one of two dealers in Raliegh that charge over list. Gotta love it.

[crashnburn987]

Had the same issue. Passenger fan would no longer turn on. After removing the fan, I was able to cut the back off with a dremel. Once opened, I hit it with a can of compressed air and a ton of dirt, sand, and pebbles came out. Also cleaned it up with some contact cleaner. JB Welded the back back on the fan and it is now working perfectly. I suggest trying this first before you go out and buy a new one.

[grink]

I had both replaced in 2008 (under warranty on my 2006 Jetta). The smaller fan died.

Now fast forward to now. Both fans work but do not come on when I turn on the AC. The fans only run when the car hits 190F. I'm going to guess that I need to replace the bigger fan based on the codes below. I honestly want to fight VW to get this done for free. I find this rediculous.

Could it also be the AC High Pressure Switch? I'm going to run the output tests later today for the fans.

UPDATE: I ran the output tests and both fans come on...

01-Engine -- Status: Malfunction 0010

3 Faults Found:
008343 - Post-Catalyst Oxygen (Lambda) Sensor Correction; Bank 1: Too Rich
P2097 - 001 - Upper Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 2
Mileage: 112430 km
Time Indication: 0
Date: 2000.00.00
Time: 21:31:56

Freeze Frame:
RPM: 847 /min
Load: 29.8 %
Speed: 13.0 km/h
Temperature: 84.0°C
Temperature: 51.0°C
Absolute Pres.: 1020.0 mbar
Voltage: 13.462 V

006470 - Control Module 1 for Coolant Fan: Defective
P1946 - 004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 0
Fault Frequency: 3
Mileage: 112854 km
Time Indication: 0
Date: 2000.00.00
Time: 20:41:17

Freeze Frame:
RPM: 1018 /min
Load: 18.4 %
Speed: 15.0 km/h
Temperature: 88.0°C
Temperature: 39.0°C
Absolute Pres.: 1010.0 mbar
Voltage: 13.843 V

001152 - Coolant Fan Control Circuit 1: Electrical Malfunction
P0480 - 004 - No Signal/Communication - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100100
Fault Priority: 0
Fault Frequency: 2
Mileage: 113030 km
Time Indication: 0
Date: 2000.00.00
Time: 21:40:47

Freeze Frame:
RPM: 721 /min
Load: 18.8 %
Speed: 6.0 km/h
Temperature: 86.0°C
Temperature: 42.0°C
Absolute Pres.: 1010.0 mbar
Voltage: 13.970 V

Readiness: 0000 0000