fan tests ok not coming on low or high, have new relays!

[edsidders]

Fixed IT

BAD CONNECTOR where fan plugs into wiring harness...Removed the connector and added about 6''-8'' of wire to take its place..center connector was worse than the others..Butt splices worked great on each side..Tied all back in place with ty wrap...

I did find a place that the wire was flattened inside the flex cover , it was where the wire laid across a hose around the left side of the radiator..Taped up the wires,one was almost worn thru. Wrapped repaired harness with friction tape for protection and secured out of the way..

[quicksilverdon]

Good show, Ed - now let's wish Dave luck....

[azdave]

Took out the battery to get visibility to most of wire harness. Upper portion of harness coming from PCM looked ok.
There was an area on the side where part of the harness had some corrosion was almost to the wires but not through the wire, only the tape. Wire was next so I cleaned and retaped it.
I checked the car end of the fan connector and the middle port looked somewhat brown inside. Taking wires out of connector to check them, green and yellow slipped right out. Black wire (middle) was melted into the plastic connector and connector had a brown burn mark on the outside. Melted so tight had to cut black wire and destroy connector massively to even get to where the black wire was in for inspection. Could not see obvious damage to wire, but it was GLUED in there and had burn marks all around plastic connector. Looks like I have enough wire length to splice and tape. HOPING this is my problem...... Headed up to buy more electrical tape. Could this be my problem??????

[CREWZIN]

Lets say it be be the cause of the fan problem but what caused the wires to burn/melt? That's the real problem. You may splice the wires and fix the fan and hopefully it will never happen again, but if it does, you'll know where to look first.

[azdave]

That's what I was wondering. My low speed fan motor burned up about a month ago. I was thinking maybe that would have caused it to heat up that connector? *hoping*. The low and high speed wires looked fine and slipped right out nice and clean. It was the port for the black ground wire that was melted shut around the wire. Off to buy some tape.

[edsidders]

Good chance that is the problem , I think that the plug is a little light for the amprage and when it gets hot the plastic softens and the contact gets looser,,this turns into a vicous circle ending with a burned and possibly shorted plug..With the high ambient temperatures the fan runs much more and that aggrivates the situation..These cars are getting older and the connections are likely to corrode and that doesn't help either..I spliced in some extra wire to make mine easier to hook up... Glad you found it make GOOD connections and use wire at least the same size as in the harness, unless there is further damage you should be cool tomorrow...Good Luck

I know about bad connections , I've restored several old XK series Jag's and owned a multitude of older British bikes...

[Blob]

Do either of you know which color (green or yellow) wire is for high and which is for low?

[azdave]

I'm almost positive green is low speed and yellow is high speed.....

We have a monsoon storm rolling in and I am working in my driveway. As much as I would love to know if this burned ground wire is the answer to my problem today, I'll be re-uniting the wires tomorrow am.

[CREWZIN]

Blob,

YELLOW (YL) is high, DARK GREEN (DG) is low.

[azdave]

Originally Posted by azdave

I'll be re-uniting the wires tomorrow am.

Need I say more?