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Giving a 405 Sport Wagon another chance

By diyauto

( 4 )

7 minute(s) of a 111 minute read

4-23-2016

I got my windows tinted few days ago,they are 25% all the way around.

On Monday I attempted to recharge A/C which end up working for only few minutes. Last year I did 134a retrofit so I used what I had left over to full it up and check for leaks. Not surprisingly I had one leak which end up being quick seal replacment fix. After I fully recharged it I left it idling for 10 minutes with me sitting inside the cabin enjoying cold air when all the sudden I noticed weird odor. I got out and noticed that it's coming front front of the car so I opened the hood and found that smoke is coming from A/C compressor clutch :-(

Quickly I turned engine off and started to clean up then all the sudden I heard this loud boom with green fluid leaking out,I told my self well this is great it looks like radiator has let go 10 minutes before I leave for work. Closer examination confirmed it was Freon leaking around A/C dryer. Last year A/C worked great on this car with out any problems...oooohhh well this is battle for another day.

On possitive note I know my A/C compressor wiring to GTI6 end up being correct as no information on this was available.

5-11-2016

I got A/C repaired today :-) I'll drive it for few weeks just to make sure that everything is OKay before I take it to a shop for proper A/C service with A/C machine.

I updated pressure switch to 91 and up style,replaced A/C receiver drier and compressor clutch coil. Problem was in 306 GTI coil,they do look identical however 12V+ and negative are on opposite sides to 405 unit. That caused my compressor clutch to smoke and lock up.

I also replaced crankshaft pulley as original has moved (rubber part failed) on these engine it is very important to have good crankshaft pulley as TDC hole is part of pulley. If you have one that's failed it may give you faulse TDC when you are changing timing belt which may result in valve to piston damage. If you look at my picture you can see that my TDC has moved for about 45*

5-15-2016

Today was heater core fun!

Also today I had to rewire A/C compressor ON input to ECU as when A/C compressor clutch is engaged idle would drop down and it would not increase as ECU is not aware of A/C compressor clutch command. Finding this information was tricky,all XU10J4RS swaps end up not using A/C system so there was zero information on this. If you remember I had to figure out fan control as well,at first I wired it in as 205 GTI guise did but with ignition on my fans were on at full speed do to missing Briton temperature sensor circuit. So pretty much once again I had to figure out this pice of puzzle my self.

I found ECU pin out diagram on Google however diagram shows A/C input at pin 26 and 50 which is not sufficient enough of information. On 405 those A/C inputs are at pin 41 and 40 where pin 41 is input from A/C switch and pin 40 is input from Trinary switch (A/C compressor 12V) so I end up getting small help from UK on this.

I made thread on 306 GTI forum about A/C schematic diagram with question specific about pin 26 and 50. One person gave me answer that 26 is A/C compressor on and 50 A/C select on.

The rest was simple! Using multi meter I found which pin these wires belog (to GTI6 pig tail that I used to mate 405 body harness) and they were next to each other. Next step was to connect 405 body side wires to GTI6 side and those were in MC3A (brown) connector.

MC3A Pin A2 A/C select input (A/C switch) wire 41 to GTI6 8pin (small connector) green wire (ECU pin 50)

MC3A Pin A5 A/C compressor ON ( from Trinary switch) wire 6A to GTI6 8 pin (small connector) white wire (ECU pin 26)

This 6A wire (MC3A connector pin# A5) needs to be spliced with brown wire in GTI6 small 8 pin connector pin #6.

Eureka!!!! With A/C compressor clutch engaged idle raises up and stays few RPMs higher,success gents!!!

And it's 23:15 and SavoSpec is very tired. Long day indeed.