Fan Control/Resistor - Failure
CATEGORYBody
SECTION PAGE
8 131
ISSUE CODE
10/95-0633 854
Subject: Correcting Complaint of Failed Fan Control/Fan Resistor
Application: Certain 1992-1995 9000 Models
On certain cars the fan control (ACC) or fan resistor (manual A/C) can overload and break. This is caused by a ventilation fan that is too sluggish. A sluggish fan consumes more current in maintaining the speed set by the ACC control module or fan control. This higher current draw may be enough to cause overloading of the fan control or fan resistor.
Manual A/C system: To rectify the fault, change the fan resistor and check the fan using the method described below. If the fault is due to excessive draw, the fan should also be changed.
ACC System: To cure a fault, a new fan control with automatic overloading cut-out has been developed. The overloading cut-out turns off the ventilation fan under certain driving conditions. The ventilation fan should also be checked by the method described below. If current draw is higher than the permissible limits, the fan should be changed.
Modified fans consume less current than fans of earlier types, but have the same part numbers. Stock of earlier design fan have been scrapped.
Cars Affected:
1992-1995 9000 models within VIN Serial No.
Range: N1000001 - S1005461, inclusive
Parts:
Fan control with overloading cut-out 46 32 477
Modified ventilation fan 96 28 587
Fan resistor 46 34 564
Tools:
Digital multimeter (DVOM)
Inductive ammeter
Action:
Cars with ACC:
1. Remove the rubber seal and cover panel over the bulkhead partition space.
Disconnect the washer fluid hose.
2. Remove the right-hand screening panel.
WARNING!
The fan control's heat sink is live until the connector is unplugged.
3. Unplug the fan control connector and remove the three retaining screws.
Lift out the control.
4. Fit the new fan control and three retaining screws. Plug in the connector.
5. Check the fan's current consumption as described below.
6. Refit the screening panel.
7. Reconnect the washer fluid hose to the cover panel and refit the panel and rubber seal over the bulkhead partition space.
Important
On calibration, all previous diagnostic trouble codes (DTC's) will be cleared. Obtain readouts of all stored
DTC's before starting calibration.
8. Calibrate the ACC system by pressing the "AUTO" and "VENT" buttons simultaneously, or by using SAT.
Action 1:
Cars with Manual A/C:
1. Remove the rubber seal and cover panel over the bulkhead partition space. Disconnect the washer fluid hose.
2. Remove the right-hand screening panel.
3. Unplug the fan resistor's connector.
4. Undo the clip and withdraw the fan resistor.
5. Fit a new resistor.
6. Plug in the connector.
7. Check the fan's current consumption as described on page 4.
8. Refit the screening panel.
9. Reconnect the washer fluid hose. Refit the panel and rubber seal over the bulkhead partition space.
Action 2:
Checking Ventilation Fan Current Consumption:
1. Set the controls in the following positions:
^ All dashboard vents open
^ Fan control in maximum speed position
^ Maximum air to dashboard vents
^ Temperature control set to cold
^ Recirculation flaps in fresh-air position
^ Windows and doors closed
2. Remove the cover panel from the bulkhead partition space.
3. Unplug the fan motor connector and insert a stripped cable (max. 0.5mm2) in each of the sockets of the female connector. Plug in the connector and connect the multimeter to the two cables.
4. Connect the inductive ammeter around the green cable. See Figure 4.
5. Turn the ignition switch to the ON position.
6. Note the voltage reading on the multimeter and the current draw on the inductive ammeter.
7. Check that the fan's current draw for the voltage reading obtained is correct according to the graph below.
8. If current draw is too high, the fan should be changed.
9. Remove the test cables from the connector and refit the cover panel over the bulkhead partition space.
Warranty Information:
To resolve a customer complaint for a vehicle in warranty, submit a claim using the following information:
Action 1 - cars with ACC:
Failure code: 87076-61-0-01-01.
Labor operation: 87077 for 0.3 hr.
Straight time for checking vent fan: 0.2 hr.
Action 1 - cars with manual A/C:
Failure code: 36591-61-0-01-01.
Labor operation: 36591 for 0.2 hr.
Straight time for checking vent fan: 0.2 hr.
Action 2 - Checking ventilation fan current consumption:
Failure code: 85415-61-0-01-01.
Replacement - labor operation 85425 for 1.5 hr.