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burnt cabin heater fan fixed!
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Posted by Steven (more from Steven) on Sat, 27 Jan 2007 18:23:06 Share Post by Email
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~110K miles 2002 9-3SE (with ACC)

I first noticed my heater fan not blowing air one wet day in November. 2 days later, it started back up again. (So I couldn't really diagnose anything) Several weeks later, the fan went again, and came back the next day, along with a slight burnt plastic smell (I thought: Goodie...I can finally use my spare DI casette I have in my trunk for 2 years now! ;-). No such luck. Eventually, the smell got really bad, and one day, the fan stopped working and never came back. I followed the advice of some of the poster and narrowed down to two possibilities: heater fan is at fault, or the ACC controller is at fault. Both are relatively to get at, and both parts cost some money... I decided to look for the most likely suspect (and was correct). Because of the burnt smell, GregD suggested it could be the fan electrical connector. The black plug connected dummy resistor (white) plug was melted like someone took a soldering iron to it (from the inside). The exposed wires were all rustly and black. The connection between the dummy resistor plug to the fan wires were also heavily corroded. One of the plug actually snapped off from corrosion!

I studied the "dummy resistor" and figured (and later confirmed by reading the archives here) that in the non-ACC cars, there is a resistor pack in there. Since I have ACC, I have the "dummy no-resistor" fixture fitted, and was useless I put some clean male electrical connectors on the wires and made direct connections. I had it sealed it up with electrical tape, and the fan runs like new again... (I hope I'm not doing something too dangerous...the wires did get a little warm. I think the next time I change the cabin filter (next month), I'll take the tape off to check the condition of the connection...)

Thanks to GregD for his suggest.

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