VW/AUDI ENGINE/ RADIATOR COOLING FAN CONTROL MODULE

VW/AUDI ENGINE/ RADIATOR COOLING FAN & CONTROL MODULE

The radiator is an integral part of each and every VW, Audi, Skoda and Seat vehicle. Its main objective is to keep the engine oil cool which in turn keeps all the moving parts of the engine cool. Most cars have a radiator fan with a separate fan for the air conditioner however, VAG vehicles have an integrated Radiator and Condenser Fan Assembly,  as can be seen in the image below. Be that as it may, it is not a one size fits all situation. Virtually every VW, Audi, Seat and Skoda vehicle category has a slightly different fan which is very evident when looking at the different three character alphanumeric prefix and the alpha suffix in their part numbers. View the list below to see what I mean.

Radiator and Condenser Fan Assembly.  The fan on the right is 360mm in diameter
with a 4-pin main connector rated at 300W.  The fan on the left is 295mm  with a 2-pin
female connector, and rated at 200W. 

The flip side of the Radiator and Condenser Fan Assembly

Be aware that a VW Polo 9N and 6R have different fans, an Audi A3 and a Q7 have different fans, a Skoda Fabia and a Roomster have different fans, a Seat Ibiza and a Seat Leon have different fans and the same and the same goes for Passat, Golf, Beetle, Tiguan, Touran, Fox, Transporter, Jetta, etc...  Having said all that, suffice to say that all these fans are troublesome, they burn out, the fins disingrates, they go open circuit and I've even known a few to go short circuit and blow its 30 amp fuse.

VW THERMOSTATICALY CONTROLLED  RADIATOR FAN 

6Q0 959 455AF Engine type: BBX - VW POLO
6R0 959 455D  Engine Code: Polo Vento
6Q0 959 455AE Engine Code: BZG - Fabia,
6Q0 959 455AE Engine Code: BMS -  Fabia, Roomster
6Q0 959 455 N Engine Code: BNM, BAY, BNV, - VW Polo, Fox,
1K0 959 455P  Engine Code: BSE  - Audi A3
1K0 959 455N  Engine Code: BLR - Passat
1K0 959 455DH Engine Code: BMY - VW Touran
1K0 959 455P  Engine Code: BMY -VW Golf
1J0 959 455   Engine Code: AKQ - VW Golf
1K0 959 455ET Engine Code: CFG - VW Tiquan
1K0 959 455FR Engine Code  CFGB - VW Tiquan
6Q0 959 455AD Engine Code: CAYB -VW Polo
6R0 959 455   Engine Code: CFWA - Skoda
6Q0 959 455AD Engine Code: AMF - Polo, Skoda Fabia, Seat Ibiza
6E0 959 455A  Engine Code: AAA - VW Golf, Passat, Polo
7L0 959 455F  Engine Code: CBFA, CCTA - Audi Q7
8D0 959 455   Engine Code: AFB - Audi A6/A8, VW

This list is by no means complete and there are probably a few dozen more variations. These fans are made  by Brose 
(Puebla/Mexico),   Behr Hella Services GmbH (Germany), Wenzhou (Mainland China) and several other an OE manufacturer expressly for the Volkswagen Group with OEM replacement part numbers 1K0959455DT, 1K0959455CQ, 1K0959455N, 1K0959455DL, 1K0959455FE, 1K0959455FJ, etc.  These are predominantly the 300W, 4-pin main connector with 2-pin female secondary connector type, guaranteed to fit the following VW and Audi models. 

2006-2013 Audi A3

2008-2015 Audi TT

2009-2015 Audi TTS

2012-2014 Audi TTRS

2012-2012 Volkswagen Beetle (up to 3/4/2012, VIN specific)

2009-2015 Volkswagen CC

2007-2015 Volkswagen EOS

2006-2014 Volkswagen GTI

2010-2014 Volkswagen Golf

2005-2012 Volkswagen Jetta (up to 3/4/2012, VIN specific)

2006-2010 Volkswagen Passat

2012-2012 Volkswagen Passat (up to 3/4/2012, VIN specific)

2008-2008 Volkswagen R32

2006-2009 Volkswagen Rabbit

2009-2015 Volkswagen Tiguan

The 360mm Radiator fan, notice the four wires in the plug, two thick and two thin.

However, in order to avoid future problems, it is highly recommenced by the fan manufactures that the controller module should be replaced together with correct fan.  The list below are just a few of the radiator controller modules / relays that support the glut of VAG fans. These relays are  VIN specific, so please verify existing part number with the supplied part for correctness.  These contollers are manufactured in Hungary,  Brazil, and Germany. 

1H0 919 506 A -VW Golf MK2 MK3, GTI 8V
1H0 919 506 B - VW Golf MK2 / MK3 GTI 8V
1J0 919 506 G - VW Golf, Lupo, caddy, Audi A3
1J0 919 506 K - Seat Arosa, Leon, Toledo, Skoda Octavia
1J0 919 506 L -  VW, Audi, Skoda & Seat
1J0 919 506 M - Polo, etc
1J0 919 506 P -Golf MK4 , etc,
1J0 919 506 Q - Golf Mk4 GTI, etc

4 and 14 Pin radiator controller module

4 and 10 pin radiator controller module

As mentioned earlier, the fans and controllers are troublesome but the German manufactured version is a lot better and thus last much longer but it is also pricier.  Notice that the main part number on both the above images are the same except for its prefix. The real difference is that the top module has 14 contacts on its right side connector whereas the middle module has only 10 and the bottom module has only 6.  The 2 images below gives you  good idea of the variations in modules. The final image shows how these modules burn.

Main and secondary connectors with 4 and 10 pins respectively.

The secondary plug has 14 pins

This is what happens to the modules made in Hungary and Brazil.

What is an EPC light? What is an EPC warning light? What is an EPC light on Volkswagen? What Is the VW EPC Warning Light? What is the EPC light on a Volkswagen Jetta? What is EPC on a Volkswagen? What does it mean if the EPC warning light comes on in a Volkswagen? Volkswagen - EPC Warning Light, What does an EPC light on the dash of a Polo match car mean? EPC light came on and lost all power.  The EPC warning symbol came on today while driving. EPC Light and stalling. EPC light came on and can't start the engine. EPC light on, what does it mean ? EPC light and engine check light. EPC warning light. Epc light. EPC + power loss/no boost.  Do not exceed 4000 rpm  EPC light.   EPC error where the car shakes terribly.  ESP EPC & Engine Light ON.  EPC Light and Stalling. Polo bluemotion 58 plate and a yellow engine light came on. I read the manual but still not sure something to do with the exhaust?? A little help as my wife needs the car for work.2002 1.6L GOLF, EPC light on. POWER LOSS An EPC light will appear on the dash randomly whilst driving. Once it is on, there is a noticeable loss in power and it stays this way until the... volkswagon polo epc warning.step by step guide to turn light off please, preferably without visiting expensive vw garage. Have diagnostic computer to see code! EPC light came on and engine will not rev higher. I have a vw polo and the EPC warning light has come on what should i do? Orange light 03 vw polo. VW Polo Map sensor fault code idling poorly. EPC light on my dashboard 2001 vw polo. It has something to do with the engine management, retarding the power of the engine.

VW BREAKDOWNS

VW BREAKDOWNS

Virtually everyday I see at least a half a dozen of brand new cars hitching a lift to some service center. Rollsbacks are becoming pervasive and are thus trending because the days when you could manage a quick repair along the roadside is long gone. Whether you drive an older well used or brand new vehicle, breakdowns are inevitably and will happen at the most inopportune moments or at the worst possible time. Having a roadside assistance service like the AA (Automobile Association) can provide some peace of mind, especially to female drivers with infants or aging parents / grandparents on board. Somehow breakdowns seem to happen when you are smartly dressed enroute to a function of sorts or when you are late for an appointment. That's Murphy's Law for you.

VW Golf GTI with a engine sensor issue

VW Golf GTI going nowhere slowly

The most common road side problem today seems to be  cars running out of fuel, because of erroneous assumptions. Due to the recent rapid rise in fuel prices everyone is still topping up their fuel tanks based on note value rather than on litre value.  For example, R100.00 worth of fuel (8.2 litres) is not the same as asking for 20 litres of LPR fuel (R250.00). Hence drivers are judging driving distance based on the Rand value, often ignoring the fuel guage and getting stuck without fuel as a consequence, though expecting the rand value of the fuel they bought should have taken them a lot further than it actually did. 

A dead battery is another common issue, which is most susceptible in winter, especially relevant to delivery vehicles that drive short distances, starting their engine often, thus not giving the battery sufficient opportunity to charge fully. Persistent battery problems are more often than not caused by a faulty alternator regulator and is not normally repairable at the road side. I've had my alternator die on me at night while driving home from movies, and I was actually watching my headlights getting dimmer by the meter, as I drove. Fortunately I made it home before my battery ran down completely.

Then there is the clutch cable that snaps under stress,  which is normally a deal breaker because it inhibits changing gears. Once when this happened to me, I started my car whilest the transmission was in 3rd gear causing the car to lunge forward as the starter rotates. It's kinda like using the starter to propel the car forward until it starts. When my car's engine started, I managed to drive all the way home in third gear without incident.

VW Polo with a ESP and EPC issue

VW Polo enroute service centre.

A flat tyre / blowout is another roadside issue, especially if you discover the spare tyre deflated due to the duration of time it spent in the boot without being checked. The worst thing ever is not being able to loosen a wheel nut that's been air torqued by the last tyre repair place you visited. 

An overheating engine can just stress you out because the first thing that comes to mind is the possible cost of repair. An overheated engine is commonly caused by a snapped fan belt or stuck thermostat which can cause the cylinder hear gasket to blow if not detected and repaired in time. When my car's engine overheated, I was some 30 Km out of Bloemfontein on the N1, enroute Cape Town; somehow the attendant at the filling station who topped up my radiator water level didn't replace its cap.  As a consequence the
water bubbled out and with insufficient water to keep the engine cool,  the  head gasket blew and I had to stay in Bloem for 13 days. It was an expensive exercise, the cost of a deco set with head gasket, the cost of the opportunistic mechanic, and the cost of hotel accommodation and obviously food.

A not so common roadside fault is locking your keys inside the vehicle or even loosing your keys. Remember the microchip inside your key can also go faulty and is the only thing that can disable your immobilizer. If this should happen it would be worthwhile having roadside assistance because they generally have a relationship with vehicle manufactureres and authorised dealers and have access to Key Assist. 

Regular services would do your driving spirit the world of good because any worm components can be detected before they actually go faulty. On of the worst roadside breakdowns is a snapped cam belt but if checked at regular services and replaced before it breaks would save you a shed load of money. It is worthwhile keeping  a set of jumper leads and a 5L can of water in you boot as well as an empy 5L can and a funnel, just in case you run out of fuel.  A spare fan belt and a mechanical toolkit would also be beneficial as boot luggage. Get into the habit of continually looking at your instrument cluster while driving to check your guages for normality, especially oil pressure, oil level and water. Check your coolant level yourself if possible before going on any long trip, and please don't allow garage attendants check it, at least not without your supervision.  Also make sure your have a spare key. 

I've never seen two VW towed in tandem like the two Toyotas above.

Two police vehicles that needs some TLC

Looking at the two images above is a least a consolation to Volkswagen owners that it's not only VW  vehicles that seems to enjoy riding on the back of rollbacks.

Feel free to upload your VW, SKODA, SEAT & AUDI scans.


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COMMON VOLKSWAGEN PROBLEMS

I've owned no less than 20 cars, the bulk of which were VW vehicles. I am thus qualified to say that the most troublesome car in the Volkswagen stable without any doubt is  the VW Jetta but it is very closely followed by the Volkswagen Polo, regardless of winning  2010 World Car of the Year. 

Whether you drive an older 6n Polo or a later 9N3 Polo classic 1.6 or 2.0L Highline, or a newer Polo Vivo 1.4 Trendline, or a VW hatch 1.4TDI Highline or a VW sedan 1.5TDI Comfortline, or a VW hatch 1.2TSI Highline, or a Polo BlueMotion or a Polo GTI, or a CrossPolo, or even a Polo 6R, either manual or auto, you are bound to encounter some or all of these problems listed below over time or even perhaps in very close proximity to one another.

Since I've had my VW Polo 2.0L Highline, I've personally experienced most of them and the only reason I know that these are common problems is because I've encountered so many people with similar problems. They go as far as to say the VW Polo is a thoroughly unreliable car, adding that it's poorly built and that they should have stuck to Japanese cars. Some complain about the high repair bills they had to foot for problems that shouldn't be haunting fairly new cars,  let alone the atrocious VW customer service they experienced. Their final words - "Stay away from Volkswagen".  "I'll never buy Volkswagen again!"

Soon after I purchased  my VW polo 2.0L highline I noticed an above normal level of cabin noise. The conclusion I came to, was that the door rubbers doesn't seal very well allowing type road noise to enter. This was even confirmed by water droplets falling onto the door panel armrest and on me when it rains. In fact when I open the back doors and look at the B-post and front door rubbers seals, I can see a air gap of about 5mm between the B-post and the rubbers door seals. I would agree that the Polo isn't  built very well. 

At another time, I noticed a humming sound emitting from its gearbox when accelerating.  Convinced that it wasn't there before, or if it was, it was hardly noticeable, I took the Polo to a VW service centre, only to be told, "There is no problem with the gearbox, that sound is perfectly normal for all Polos."  Ya right! Like its normal for a person to have 4 ears.

A friend who owns a 2011 Polo Vivo 1.4 Trendline also noticed the interior cabin noise was getting quite annoying when driving at speeds above 100 km per hour. As a result he had both front wheel bearing replaced thinking that may be the problem but it didn't make any difference. The VW service centre says it has much to do with wheel balancing and alignment.

Something else I'm quite unhappy about is that the interior fabric has  separated from the roof lining of my 2007 Polo Highline  and hanging as if filled with water. However I'm not as pissed about it as my neighbour is, who ownes a 2011 VW Polo Vivo 1.4 Trendline. He says it's totally unbelieveble that a five year old car should be falling apart whereas as his 20 year old Mercedez Benz's fabric ceiling still looks new, like the day he bought the car.

The airbag malfunction light seems to be another VW problem on an epidemic scale. Once its on, it cannot be turned off, not even by experienced auto shops. Replacement of the airbag is the only way that light is going to turn off and stay off. This was a problem that originated with the 2006 VW jetta when nearing 160,000 kilometers.  Somehow this problem found its way into other VW's especially the Polos.

Another Jetta problem that seem to have infected VW Polo, is Ignition Coil failure which tend to  appear around 120,000 kilometers. Its a good idea to keep one or two spare coils in your repair kit because they die when you least expect it.  When they do, your car shakes as if its a washing machine in spin dry mode. I've also had one or two of my radiator fan lades snap off and when it engaged shook my entire car as if I small tree in a blizzard. After the initial fright when this happens is the thought of cost immediately springs to mind.  So some reason or the other my radiator fan just disintegrated.

The Check Engine light and the EPC light turning on, are classic VW Polo problem that just waits for an opportunity to present itself. This often occurs when your decelerate, or yielding or driving slowly or when you start it first thing in the morning. Its perfectly normal or the EPC light to come on during a 3 sec self test when the ignition is turned on but should turn off when the vehicle starts. If it doesn't, your in or a very long day. 

EPC problems sometimes evokes limp mode which I found can be quite dangerous even life threatening because I've experienced limp mode with a 30 ton road-train just meters from my rear bumper, with just fractions of a second to get out of its way. I've experience EPC problems on the freeway on-ramp in peak hour traffic. I've experience EPC problems on a lonely stretch of road in the dark of the night. I've experience EPC problems to the point that I didn't want t drive my Polo anymore and even contemplated selling it.

Wiring harness problems especially on the doors and the alarm system and the DSG gearbox. The headlight connectors tend to melt from the heat of the lights and contact becomes intermittent to the point that whilst driving they go on and off.

Leaking coolant from under the water pump or from the black metal hose that runs along two side of the engine. Either the water pump needs to be replaced or the corroded pipe needs to be replaced.