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Electrical Problem with the Air Conditioning in a Volkswagen Sharan

Model: Volkswagen Sharan 7M, MK 1 - Years: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Part: Air conditioner

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Video tutorial

In this video, see the solution to a dangerous electrical problem where a connector in a Volkswagen Sharan overheats and catches fire when the air conditioning is turned on. The electrical connector overheats and burns when the air conditioning is at maximum power.

The problem is a malfunctioning electrical contact within the connector, oxidised or damaged.

The current does not pass correctly through the contact point, generating heat until it melts the plastic and causes smoke. The fuse does not blow, as the overheating occurs downstream of the fuse itself, on the load side.

The solution is to remove the connector to view the damage (blackened and melted contacts); cut the damaged terminals and thoroughly clean the wires. To eliminate the faulty connector, the wires are soldered to create a new secure contact.

The video emphasises the importance of checking electrical connectors when experiencing overheating issues, especially with systems that draw a lot of current, such as the air conditioning system.


Posted on 30 April 2026 by ScegliAuto


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