Fan Relay

[BrianT]

I have been fighting a problem with my cooling fans and at the same time tring to get my A/C working. Both turned out to be the same problem, my fan relay had gone bad, or I thought. I cleaned the contacts on the old one and plugged it into the socket and it still did not work. I knew I had all the right voltages and it should work. I plugged it in without the cover and worked it manually and both fans came on but when it worked with out my help just one or none would work. I found the coil lead on the relay was pushing back when I would plug it into the socket and just left the cover off and used a screw driver to help it in until my new one came in. Well the new one came in and today I thought I would switch it out. I had a hard time getting the old one out and when I got it out one leg had melted plastic on it. I pulled the fuse/relay panel out fearing the worse and found just one leg (output to the right fan) had melted but the socket was gone, melted. I was surprised to see that the top row of relays are just add ons and can be replaced easy. I thought they were all one unit. Does anyone know where to get this part. The markings has VW/Audi #135937501A. I took the connectors out of the socket, cleaned them and have them plugged onto the relay without the socket, I wonder if it is even worth replacing as it is working fine this away. Should I?

Also I had to remove the secondary fuse panel, I found someone had used a wire with spade connectors and crossed over the fuses for the power windows and fuel pump. The wire to the fuel pump had burnt and was very brittle, would anyone know why someone would go behind the panel where it has spade lugs and cross over the fuse, this sounds like a fire waiting to happen. I removed them and everything seems to work OK. I cleaned all the connections to the panel and the fuse contacts while I was their. The A/C connections on the back of the panel were getting a little hot. After I ran everything for an hour and nothing got really hot, the A/C connections got warm but not hot. It is suppressing what you will find when you dig into things. I might have prevented a fire.

[SoCal Driver]

Early 944 electrical diagrams:

http://www.pelicanparts.com/944/electrical/944_electrical_diagrams.htm

[BrianT]

SoCal, These diagrams were the things that helped me find the bad relay, and how everything was routed. I could not have done it without them. I have them saved on my computer and printing them out one at a time and splicing them together to make one big digram. I am also enlarging them some from one page to two. I am also tring to convert them to a digital format (having trouble with program, looking for better program) so I enlarge them without distorting them. If I can do that I can splice them together in a computer program, then I can enlarge it as a unit and plott it out 4ft. X 6ft. or what ever size makes sense. This would be nice to have in one piece so you are not going from page to page. Also I can put some color in it to make tracing wires easyer. When I get time and get it avalible I will make several copys and if someone wants a copy they can have it.

[toolboy62]

I an guessing that the diagrams in the FSM were actually fanfolded large sheets, if anyone has ever pieced them back together I'd be interested in the files, I have access to a large format laser plotter at work.

nate