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03 Beetle AV Fuse blows

1237 Views 6 Replies 3 Participants Last post by  Bobbuchanan, 
B
I have read many posts about this problem. I have replaced the melted battery fuse box. I have re wired the 30a fuse. I have re terminated the corroded main leads, I have replace both fans. When you turn on the ac, the fuse blows straight away. I have disconnected the compressor, and both fans. The fuse does NOT blow. Reconnect the compressor and the fuse stays. I have pulled relay 53 with fans connected and fuse blows. The only thing I thinking left with is the fan control module. Anyone have any other suggestions before I do that. Seems like it is a direct short, but as far as I can see all wiring is intact, no issues. But it is certainly fan related.

Thanks!
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esse10
fans

Bobbuchanan said:
I have read many posts about this problem. I have replaced the melted battery fuse box. I have re wired the 30a fuse. I have re terminated the corroded main leads, I have replace both fans. When you turn on the ac, the fuse blows straight away. I have disconnected the compressor, and both fans. The fuse does NOT blow. Reconnect the compressor and the fuse stays. I have pulled relay 53 with fans connected and fuse blows. The only thing I thinking left with is the fan control module. Anyone have any other suggestions before I do that. Seems like it is a direct short, but as far as I can see all wiring is intact, no issues. But it is certainly fan related.

Thanks!
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Could be your fan control module since everything go's through there and the power to those devices go's through it. Easy fix it's mounted under the battery tray and you can get a good quality FCM in ebay for about $50 bucks, do not buy the aftermarket quality china junk.
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B
AC Fuse Blows, Fixed!

So after replacing the fan control, the fuse would still just pop as soon as the AC was turned on. I found one forum talking about Slow Blow ATC type fuses in this application. I found that they are not a common part. So I got a marine 30A Circuit Breaker and wired it in, Problem solved. Before I did this I used a meter to be sure that the wire was not shorting to ground. Using a continuity tester, I found no short. Found the Breaker on Amazon for less than $10.00.
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esse10
A/C compressor

IMO, I believe the A/C compressor is pulling too much current and together with the fans running at the same time is blowing your fuse. They have those wire clamp on meters you can put on each wire to see how much current is being drawn while the device is on.....just don't burn your car by modifying it. :p
good luck man.
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M
ac problem

Bob: I sent you a pm
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esse10
fuse problem

Please share with us folks who are curious to find out what your problem was Mr bob this way other folks in this forum can learn about this experience.

thanks
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B
In my OP i was discussing how the AC fuse kept blowing. I had replaced almost all major components and done a re-wire of the battery top fuse box as I had found on other forums. But the fuse kept blowing. I found one thread that said to use a Atc (blade type) slow blow fuse. I had trouble finding these, so instead, I wired in a 30 amp breaker. The problem seem to have gone away after several weeks of daily driving.

I hope my experience helps someone whit a very frustrating problem.
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