Thread: Aftermarket A/C - 300Tdi dual cab

So I've decided to get my condenser fan working. The Tdi has been running a tad hot these summer days, especially on the highway with the A/C on so I'm working on doing what I can to improve air flow.

A quick test of the fan showed it was working fine so I wired it in from the feed to the compressor relay from the pressure switch, meaning that it shares the fuse and relay with the compressor. It was working wonderfully and the engine temperature was probably a little cooler, but alas it was short lived. The 15A fuse blew.

I checked the wiring (4 mm) and there is no sign of damage to the insulation so would anyone like to hazard a guess as to whether I should go to a 20A fuse? goingbush measured the current draw on his fan as over 10A and he used a 30A fuse in this location. I also haven't used diodes as he did. I'm just being extra cautious because electrics aren't my strongest skill and I'd rather not have to discharge my fire extinguisher .

James.

P.S. I have made some progress on the ducting in the past few days and am hoping to start upholstering it this week end so will have some pictures up shortly.

If you check out the standard wiring diagram the fan will likely have its own circuit with appropriately rated fuse.

Steve

Originally Posted by steveG

If you check out the standard wiring diagram the fan will likely have its own circuit with appropriately rated fuse.

Thanks Steve. Yeah - logical stuff that one should have thought of himself. I'm not sure if the A/C is in the diagram because it was an Australian dealer fitment on the Tdi, but I will certainly have a look.

James.

Originally Posted by rainman

Thanks Steve. Yeah - logical stuff that one should have though of himself. I'm not sure if the A/C is in the diagram because it was an Australian dealer fitment on the Tdi, but I will certainly have a look.

James.

If not, I'd think the D1 300tdi fan would be the similar (if not exactly the same), and they were factory fit.

Steve

After blowing a 20A fuse I have gone to a 30A. With only one 10 minute test so far I have managed to not burn the vehicle to the ground so all is well. I checked the wiring immediately afterwards and there was no heat detectable. As my knowledgeable father-in-law has pointed out, perhaps the compressor clutch kicking in gives a spike in load on the circuit rather than a continuous draw. I'll keep a close eye (and nose) on it in the near future.

On the ducting - good progress was make on the week end and I am finally trimming it. Typically, I am going to have to install the sound system at the same time because I won't be able to slide the head unit into position with the ducting in place, so I'm madly trying to piece together the schematics for that. Anyway, all good fun.

The three sections dummy mounted (yes - rather imposing in bare aluminium):


The front section foam covered. I'm re-using packaging foam (waste not want not ):


The front section complete


James.

Nice work

Have you had a chance to test the demisting capabilities, particularly with the current weather up here?

Originally Posted by Ranga

Nice work

Have you had a chance to test the demisting capabilities, particularly with the current weather up here?

Hi Ranga,

The demisting was excellent without the ducting in place because the air was blown across the roof straight at the windscreen. I haven't really had the chance to try it out with the ducting in place because I guess when demisting would have been required lately I would have already had the A/C on. I'd say it won't be as effective though because you can't direct the air at the windscreen with the positioning of the diffusers.

But! You have just given me an idea. I could put another diffuser in the middle at the front, angled forward toward the windscreen. Thanks Ranga!.

James.

P.S. I should have the final speaker mounts at the rear done over the next few days so I will get some photos up of the finished product.

I'm really sorry it has taken so long to get the final shots up. I wanted to have the stereo in so it looks complete, rather than having speaker holes everywhere.

Since the compressor rebuild the system has run flawlessly. The only issue I have now is that the thermofan has stopped working again which is probably because it has died of old age. It's no big deal, and I'll get around to replacing it soon (or maybe later).

So here it is:

Inside the ducting. The vents on the sides at the rear are for air intake. The vertical pieces directly in front on them divide the "intake side" and "output side", to prevent and possible recirculation inside the ducting.



Complete and installed.

(I am working on covering the hoses, but other jobs prevail at this point.)





Thank you, thank you, thank you everyone who followed and gave their advice and opinions

James.