AC troubles

[gareth29]

Hi all, been having some problems recently. So I ended up checking the electromagnet clutch on the front of the compressor - it was dead, so I ordered a new one and fitted it. It seemed to work ok but when I was driving with ac on it made the engine jerky (I now think this was the ac compressor clicking on and off repeatedly. Anyway, I stopped using it for a while until one afternoon I put it on and left it on for about 15 mins. I then started getting some funny hot smells thru the vents which I convinced myself were other cars and then finally the power steering failed.

The drive belt had come off the pulleys because the tensioner pulley had melted!! also when I stripped the compressor clutch off, all the epoxy resin holding the magnet coils had burnt away! I diagnosed this as a faulty slipping clutch which had overheated and so ordered a complete new unit and fitted it.

I all seemed to work well at first, but I noticed the air was not getting cool. Looking at the compressor it only seemed to be working very intermittently now, which would cause the lack of cooling. I then thought the air gap in the clutch must be too great, so today I removed the only washer that was in there (the original one) and tried it again. At first it seemed great and worked constantly with lovely cold air, but after about five mins it went to just working intermittently again - aaarrgghh!!!

I have had the system gassed and leak checked so no issues there. I should also say the the ac has never worked since I bought the car in 2005!

I have attached a video. Anybody out there with any suggestions?

link to video

http://i1349.photobucket.com/albums/p756/gareth291262/th_WP_20150620_15_41_12_Pro1_zpsipm9vtl7.mp4

[insanitybeard]

Have you actually replaced the compressor itself? The symptoms you are describing sound like a seized or seizing compressor, which isn't that unusual, that would cause a new clutch to burn out.

[Chrispb]

As far as I can remember the MK2's have a variable displacement compressor which doesn't cycle on and off when the aircon is on, in other words the compressor runs continuous when aircon is on.

In your video it certainly don't look good, is that bits of belt or clutch that you see flying around?

[gareth29]

I havent replaced the compressor, just the clutch and coil. I can turn the compressor easily with my fingers - surely it can be seizing?

I hadnt noticed the bits flying around - it could be from inside the clutch I suppose, dont think its from the belt as it looks light coloured

[insanitybeard]

Just bear in mind there's a big difference between turning the compressor at low speed with your fingers for a few revolutions and turning it at normal operating speed against the gas pressure, it may only be apparent when it's running under normal operating conditions. It's unusual for the original clutch to be knackered and then the replacement one to be knackered also, I'd be suspecting/ looking for another cause. 

[gareth29]

Fair points - I wondered if there was some sensor telling it to cut in and out like that, I know theres a low pressure sensor so theres probably a high pressure one as well - maybe too much gas in the system?

[SilverBeast]

I believe it's the same sensor that does high and low pressure.  It is mounted behind the bumper cover and in front of the wheel arch liner in front of the offside front wheel

[gregers]

did the original a/c clutch fall off or was just loose?
when mine went it started making awful cat like wailing the fell off,turned out the nut had come loose and the plate ended up bouncing on the spindle,luckily i bought another pump and robbed it and managed to mend mine.
so i still have the compressor sitting in my garage,so if you decide to go down the route of changing the pump,come and get mine.

[gareth29]

No the clutch overheated, presumably cos it was slipping, so it was still in one piece but the heat had burnt away the epoxy seal around the coil and the plastic tensioner pulley had melted and allowed the belt to slip off.

thanks for the offer of the compressor - i might take you up on it, I'm up in yorkshire though

[gareth29]

This is weird - it ran constantly for about 20 mins today without a problem! Going to check fuses and relays still but things are looking up.

Thanks for everyones suggestions 

[Paul.benjamin55]

Hi there I am having same sort of issue where the heater is only blowing hot air I have change the climate control unit and have had the system regased but no change anyone know what the common issues with this are so I can try and brake it down and does anyone out  there know how to bring up a fault code on the climate control unit so I can look in the right direction
Thanks
Paul .

[insanitybeard]

You'll need VCDS to read any stored fault code within the climate control module, though usually the display will flash when you switch the ignition on (when the unit powers up) if any are present. Is it actually blowing warm/ hot air when you switch the air con on or just ambient temperature air which hasn't been cooled?

[Paul.benjamin55]

 Ambient temperature  Then   Obviously get hotter when the engine gets hot 
But I don't know where to go from here as reading in to it on this site it could be lots of issues so wonder with what it is doing  is there a valve or flap that just stay on ambient air then when econ is pressed moves over to cool / air con
Please help if anyone has any advice as I want to get the bottom of this many thanks guys
Paul.

[Mirez]

Hi Paul, it really could be a number of things and having the module scanned will really help you here. However as above, is the panel flashing when you first start the car?

If yes, then the module has logged a fault code which will give you the exact fault, If not then its more mechanical (ie compressor faulty or not engaging).

[Paul.benjamin55]

Yes it is flashing for some time on start up
Would anyone be able to find me a link from eBay or somewhere for the ford 2.3 petrol as I hear that as this is a ford engine that it has to be a different unit to scan codes of car
Also do u know where the software can be downloaded from
Thanks

[insanitybeard]

Did you read the link I put in my previous post? Links to where you can download the software from, as well as the cable required are contained within it, as well as an explanation stating that although said software can't scan the engine management on the 2.0 and 2.3 Ford petrol engine fitted vehicles, it will still scan the other modules- e.g, ABS, climate control, booster heater, instrument cluster, airbag etc.