2019 Polo Cabin Fan resistor pack.

John.G

Cabin fan only runs on speed 4, suspect the resistor pack, this happened again in January, resistor pack replaced under warranty, so this means two have packed up since new car, January 2019. Is this indicative of fan motor problem or is it a known fault in these models?.

It should be criminal to use resistor pack on new cars. There is no energy saving if you run the fan lower speed. It takes about the same power as max fan max speed, just part of the energy is transformed to heat trough the resistors. That heat can kill the resistors. The low fan speed generate the most of heat and there is not enough air flow. Try to not use the slowest fan speed if possible. Check the pollen filter. If it is dirty, replace it because it reduce the air flow. Not properly installed pollen filter can allow dust inside the cabin and dust can cover the resistor pack heatsink. Is it really so hard for manufacturers to use bit silicon and make a fan motor controllers?

John.G

Probably used the "resistor" word to describe the unit, it probably/possibly uses some electronic means but a well known model (not VW) with a well known fan speed controller heat problem (for years) allegedly burned out a shopping archade in Douglas, Cork.

Whatever the inefficiencies of the older "resistors" they certainly lasted for years, I had two cars, 21 years & 19 years, respectively, with fan speeds always run on speed 1 or 2 with no problems and currently a 15 year old Polo, ditto so there must be some fundamental flaw in this car IMO. Pollen filter I suppose is a possibility but unlikely in a 3 year old car with 13,300 kms up?.

Watch this space for updates.

Pollen filter is designed to replace by every year if it is not active carbon one. Better cars have 2 pollen filters, 1 for pr-efilter and 2nd active carbon.

The factory schematic is useless but it tells there is only 1 part number for resistor 6Q0 959 263.

The pollen filters part numbers

32Q0819669 odour and allergen filter,

2Q0819653 filter insert with odour and harmful substance filtering

2Q0819644 dust and pollen filter.

If there is no dust or air flow problem, then you have a just bad luck. I do not think it is the motor problem because the resistor is series by motor. Just resistor can not dissipate enough heat and burns down.

John.G

Thanks, I have a feeling that I will be installing one of these resistors every year or two until I pass away, can you tell me how to access this please.

Typically it is somewhere near to the fan (the passenger side). The factory schematics is useless, number 4 on the picture. It does not look even similar like a real product and no dotted line where it goes.

Screenshot from 2021-10-10 22-21-25.png

John.G

Got it replaced today, service manager said they had replaced a few on Skoda Fabias and few Golfs but not Polos. Its accessed from the passenger side footwell and is attached to the fan motor casing more or less like shown in the screenshot above.

John.G

Apparently quite common according to a UK website. Turn photo 90 deg anti clockwise, its the white item, here is a link, apparently same resistor.

SEAT Ibiza 2018-2021 Heater Blower Motor Resistor Ibiza 2018-2021 Heater Blower Motor Resistor - 2Q0959263 (seatdirectparts.co.uk)

that way

John.G

Is there a air flow over the resistor in that location?.

https://www.boards.ie/discussion/comment/118742869#Comment_118742869

Yes, until end of warranty. After that, may not. Nobody does not care about cabin filter. Reduce the air flow and smoky resistors. I "love" how engineers f us all by cad programs...

John.G

IMO, there is a fundamental design fault with that resistor that has nothing to do with the air flow or filter, I have a 17 year old Polo in which I replace the pollen filter approx every 4/5 years and it has the original resistor. I had a Bora for 19 years, filter replaced probably 4 times, again no problems, a Formel E Golf for 21 years, ditto. a Beetle for 20 years, no fan, no filter, no trouble!!.

John.G

Took a few current readings off the blower and got 17,11,6 & 4 amps for speeds 4 (max) to speed 1 (min) and a rough calculation shows that the resistors might generate 0,48,48 & 38 watts for speeds 4 (max) to speed 1 (min), if anyway near the mark shows a fair bit of cooling required to keep the resistor pack at a reasonable temperature, when I next replace one I will measure the resistances before installation.

Load of wasted power. On mass production the DC motor driver does not cost too much

9935452

https://www.boards.ie/discussion/comment/118743150#Comment_118743150

Possible that its a bad batch going around

John.G

Possible, all right, but if the resistors wattage is anywhere near what I've calculated then they certainly won't last long IMO, the problem with my calculation is that I don't know the equivalent fan motor resistance at different outputs but it may not vary hugely as the motor efficiency decreases with decreasing fan speed (load), I've assumed that it stays the same for all outputs. Once I get my hands on a replacement resistor pack to measure the actual resistances then we will know exactly what's going on as I have the actual amperages from my VCDS.

Most will remember the long running saga with the Opel Zafira which had the resistor pack mounted in the dash panel with no cooling resulting in literally dozens burning out because the thermal fuse wasn't blowing on increased current flow if fan bearing or binding problems. It also allegedly was the cause of the Douglas Shopping Centre (Cork) catching fire with thankfully no injuries or worse.

All data what you get from VCDS is processed data. Does not matter what you plug to diagnostics port, all is processed data.

John.G

I would think that the current draw off the battery with a stopped engine would be quite accurate as shown in VCDS?

All is processed data and can be inaccurate. You really think the manufacturer gives to you high speed and insane accuracy? They do not give to you raw data, you need to read it by other tools and by other methods. So, do not invest heavily to OBD2 toys. It is not bad, but i is not good too.

John.G

https://www.boards.ie/discussion/comment/118000398#Comment_118000398

I had a quick look for the filter (2019 mk10 Polo) but its not in the passenger footwell like the 2005 9N Polo, looks like its at the drivers side, is this correct LCM?, I will renew it anyway now. Thanks.

Or is it via the Glovebox?.

https://www.boards.ie/discussion/comment/118764100#Comment_118764100

Enjoy

John.G

Many thanks for that. 😊😊

John.G

Changed filter, literally 5 minute job, (easiest change out I've ever done). Just swing down glove box cover after releasing two clips, then remove Filter cover (two clips). Filter in good nick (after 3 years and two months and only 14,488 kms). Can see fan impeller with filter removed and it was spotless and spun very easily by hand so no problems there.

Post Reply 

 

 

https://www.boards.ie/discussion/comment/118767983#Comment_118767983

It is designed to replace every year. I seen never ever replaced cabin filters....nasty

John.G

I have replaced them in friends cars that complained about windscreen slow demising or not at all, by the look of them I'd say they had been installed for at least 8 years or so.

John.G

https://www.boards.ie/discussion/comment/118749111#Comment_118749111

Possibly but this car was built in Botswana in August 2018, there is no set pattern to the failures, the only constant is that the fan spends 95% of its time on speed 2 like I have run all the 4 speed fans since 2000,

The failures didn't follow any set pattern. the first (original) failed after 2.0 years and 6018 miles which based on long term MPH (converted from KPH) of 13.7 gives a "running" life of 439 hours, the second failed less than a year later (0.73 years) after a further 2164 miles or a "running" life of 158 hrs or only 36% of the first replacement. The third (second replacement) is now in place for just less than 6 months, ~ 108 "running hours", watch this space.

https://www.boards.ie/discussion/comment/118796477#Comment_118796477

I agree, this is not normal. Report the complaint to dealer/manufacturer and they may start call back if too many complaints

John.G

Took fan power readings from family 17 year old Polo (with original resistor pack), readings almost identical to present Polo, so would think "fault" elsewhere as I am now hearing of others with same problems.

Fan Power, Speeds 1,2,3&4.

9N Polo (2005), readings via M.meter. 3.7/6.3/10.2/16.2 (amps)

Mk 10 Polo (2019) , readings via VCDS. 3.9/6.2/10.8/17.0 (amps)

John.G

Can anyone please point me towards the correct replacement for my resistor which I removed to see exactly what I've got.

Mister-Auto in Germany sent me the wrong spare which is the same as what all the auto factors are coming up with when they use the part number 2QO.959.263. The one that they all show has a semi round (black) base whereas mine is (white) and rectangular, I really don't want to pay €107 in the main dealers. Its definitely the thermal fuse that's blowing for no apparent reason but don't know what its temperature rating is.

My Polo Resistance Pack..jpg

Resistor Details.jpg

XLR 8

I'd just get the part in a VW dealers. Bring it with you so they can match it, they might not be that expensive. While your there get a cabin filter and change it. Not changing the cabin filter regularly causes those regulators to fail as they depend on cool clean air for cooling.

John.G

Main dealers only want €107 for a new one. I don't think anyone could seriously say its normal to say that the first replacement lasted 6 months (with a new cabin filter) and approx 2500kms driving?. The original last 2 years and around 10k kms. I will wait until this one fails to see what part is actually failing, this ( second replacement) has been in place for ~ 6 months.

whizbang

I'd just get the part in a VW dealers.

When the main dealer part is proven rubbish, you still pay top money to ensure they continue robbing everybody else, with more proven rubbish..?

Time for a rewire job John,

About €1 each.

whizbang

Slightly Kwackers

https://www.boards.ie/discussion/comment/118938955#Comment_118938955

Hi,

I just came across this thread and I have a Seat Ibiza. It's not old, in fact not NCT'd yet.

The fan works on "4" only.

The main dealer quoted 82 euro for an OEM replacement.

Now OEM in a new car suggests that an independent is the way to go.

Resistors for various models are from £7-00 in the UK [ebay].

Now 7 quid for a fuse and tapped wirewound resistor seems fine, but any more is a bit much I think. The other models are larger also.

I'm hoping mine is the thermal fuse, but before I pay the 82 euro, I will buy some nichrome wire and replace the blown element. Has anyone done this or found a replacement for a 2021 mkV Ibiza?

The resistor from independents is very high, but if I go down that route, they are all out of stock.

Methinks there is maybe a design fault if the smaller size dissipates the same power?

User1998

https://www.boards.ie/discussion/comment/121152809#Comment_121152809

Just get one from your local motor factors. Only takes 10 minutes to change it.

Slightly Kwackers

https://www.boards.ie/discussion/comment/121153176#Comment_121153176

The lack of replies is overwhelming. All out of stock on the internet and Peevers Tralee was the only one that got back suggesting I go to the main dealer.

So I am left with the choice of 82 euro for a thing that should not cost ten, and I suspect from the pictures that the unit might have a design issue.

Physically the device seems 33% smaller than previous models and if it's doing the same job, it explains why it went in such a short time period.

If the weather improves I will try to get the thing out and see if there is room for an Ebay alternative.

I bought OEM roof bars for my car, thinking that the premium would result in a no nonsense straight fit and forget safe installation.

The bars were a joke. The things were cheap as the locks let in water and are corroding and the things couldn't be installed. I waited a month for the first set only to have the wrong keys supplied. I had another wait for replacement bars and then a mix & match to find keys that worked. Those supplied with the new bars given as a replacement were wrong too.

So I do have little faith in the quality of Seat's OEM parts.

One Focus was at nearly 200k miles before it blew its resistor pack, it looked like the earlier seat models too.

That was the only car I was aware of the pack being faulty on and I got through three Ford Focus's in my last UK job.

Thanks for the suggestion and advice.

I wasn't looking forward to delving in, the internet suggests that the thing is a tad difficult to locate which is why I'm waiting for a break in the weather.

Large clumsy fingers :-(

John.G

My one (Jan 2019 Polo) has now been installed for 2 years!!., I change the cabin filter now every year to see will it help prolong its life, I never had a resistor failure, (Family) Golf for +20 years, Bora +19 years (and original clutch after ~ 300k miles) and presently a +18 year old Polo.

Slightly Kwackers

https://www.boards.ie/discussion/comment/121156185#Comment_121156185

I had a look and it's the thermal fuse.

I had a 240C fuse in the parts box and fitted that. It was for a mains powered plastic bodied heater, so should be o/k.

82 euro is well OTT

An email to Seat gave the expected answer of it being the "approved" component, nothing else.

The airflow is good, the car gets little use so I am of the opinion that the resistor is physically too small to dissipate its own I^2 R's.

I base this on the fact that it is around 33% smaller than other models doing the same job.

It proved easier than expected to remove and there is space for a decent switching regulator if I have further problems. There must be a reason why no independent carries stock of the part. Oddly enough the part is three times the cost of the larger units they sell for other vehicles. An odd situation when you consider that the Seat device I wanted to replace uses less materials due to the smaller size. The mechanical tolerance isn't tight either, so machining can't be more expensive.