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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 12:53 pm 
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848cc
848cc

Joined: Sun Oct 02, 2016 7:19 pm
Posts: 33
I have stopped the short now, I rewired the green wire from the fusebox to the relay module/switchpack/thermostat.
I have fallen upon another issue..my compressor still has no power. It looks like the green wire that runs into the relay module isn't switching power to the black/red wire that runs to the compressor


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 1:07 pm 
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848cc
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Location: Adelaide
Condensor fan operating? I'll guess no - so probe the green with white trace at either the relay module or the AC switchpack. You should have power there.

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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 2:00 pm 
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1275cc
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Location: JIMBOOMBA QLD.
Please make sure you do not use Fused of higher rating than suggested by Car manufacturer as it makes it more expensive to repair when you melt the wiring instead of the fuse. Try checking the simplest things first. Condenser fan and Clutch coil by supplying them, direct power and make sure you use a fused lead.

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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 2:10 pm 
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848cc
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I have only tested for less than 2 seconds with fuses laying around. The fuses I use are always the correct amp.

I do have 14v to the green/white wire but no power to red/black.
What does this mean?


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 2:25 pm 
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848cc
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If you have power to the green/white wire at the relay module (C172-1 on the wiring diagram) and power to the green (C113-4) but nothing coming out to the black/red (C173-6), then check whether you have power at the pin feeding the red/white (C172-3).

Also... does the condensor fan run?

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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 2:30 pm 
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848cc
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You legend. I have just started probing all the wires and realised when the blower/temp switch pack is rolled, the black/red wire is active only for the very beginning and when I roll it to high blower it cuts out to 0v. This must mean an issue in my switchpack?


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 2:52 pm 
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848cc
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The condenser fan and compressor kick in just after I roll the blower, then power cuts as the blower is activated and blows air through


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 3:25 pm 
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848cc
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Hmmm.... does the blower work on all 4 speeds? (looks like it has an fan on/off switch and a separate 1-4 speed selector??)

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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 3:57 pm 
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848cc
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The blower works perfectly. It has a dial for temp and a dial for speed (no individual numerical settings)
As soon as you dial up the blower, it kicks on and kills the power to the compressor and fan


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 4:01 pm 
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848cc
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I don't know whether this is relay module related or from the switchpack. The switchpack I can order, it'll take a few weeks to arrive, but not the relay module


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 4:22 pm 
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848cc
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If you have a look at the wiring diagram you will see that the blower fan switch when it is on the lowest speed setting earths the relay module via pin C275-12, which also earths pin C425-1 on the resistor pack. In this position the earth from the blower fan (connected to pin C245-4 on the resistor) needs to go through all 3 resistors in the resistor pack then via pin C425-1 to the blower speed switch to earth which gives a low fan speed.
When the fan speed switch moves off the lowest setting, the earth for the relay module doesn't go via pin C425-1 from the resister module, it uses one of the other pins to get to the fan speed switch depending on which speed is selected.

Bit hard to tell without probing around and checking resistances, etc. but you may be looking for a high resistance joint/dirty connection. And there is a chance that these are not separate faults.

(edited to correct an error and describe it better!)

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Last edited by Tim I on Mon Oct 10, 2016 4:30 pm, edited 1 time in total.

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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 4:28 pm 
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848cc
848cc

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But the blower motor works on all settings? What would cause the relay module to cut power to the compressor and fan? Surely a bad earth wouldn't switch power


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 4:33 pm 
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848cc
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I can't even find the resistor pack


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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 5:13 pm 
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848cc
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Corrected an error I'd made above...

If the blower fan is working on the lowest speed, then it is earthing via the resistor pack (C425-4 is connected to C425-1) and then via C275-12 on the AC Switch pack. This indicates these wires are all connected to earth the blower motor, and as the clutch is energised it must be also connected through to pin C172-2 on the relay module.

When the blower speed is on any of the other settings, the blower fan must earth through either the resistor pack (via pins C275-2 or C275-3) for the mid speeds or via pin C275-7 on the AC Switch pack on the highest blower speed. Also, while on any of these blower speed settings, the relay module will earth via pin C275-1 on the resistor pack, through either 1, 2, or 3 resistors depending on which blower speed is selected. i.e. on the highest blower speed the relay module earth is via pin C425-4 on the resistor module, to pin C275-7 on the AC Switch pack (to the blower speed switch).

So, if the blower fan is operating in all positions including the lowest with no 'dead spot' anywhere, all the resistors must be fine and it must be a high resistance joint somewhere. Probably between C425-1 and that SJ27 connection on the diagram I'd guess.

The resistor pack is often placed on the side of an air duct with the resistors poking on the inside to cool them in the air-stream.

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 Post subject: Re: Mini air con
PostPosted: Mon Oct 10, 2016 6:00 pm 
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848cc
848cc

Joined: Sun Oct 02, 2016 7:19 pm
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You sir, are a hero! I will delve into the depths of this wiring tonight and see if I can't find a dodgy connection.
Do you think the relay module could be switching at the incorrect time?

Another option...could I just wire in a switch for the condenser fan and compressor manually?


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