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2002 overheating, new rad fan not working

 
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Old 24 Mar 2019, 07:57 pm
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Question 2002 overheating, new rad fan not working

I have replaced the radiator fan, all related fuses and relays. It worked briefly: About one week. I have tried hunting for relevant wiring issues. In that process I have found a stray ground wire not connected to anything! Left front wheel well, blue, thicker, grounds to the body, about twelve inches long, hanging free.
Otherwise, I haven't been able to track down where the wiring for the fan itself directly goes. I did test the fan by connecting direct from battery to fan to ground with test leads.
Ideas most welcome before the really hot weather gets here.
Ken
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Old 24 Mar 2019, 08:42 pm
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Default Re: 2002 overheating, new rad fan not working

Do you have a copy of the Service Manual which would include the wiring diagram?
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Old 25 Mar 2019, 02:08 am
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Default Re: 2002 overheating, new rad fan not working

Warm it up and check for voltage at the harness connector.
Check the harness connector for heat damage inside the connector.

I had one the that the center pin (ground) was a bad connection which will prevent hi and low speed from working.
Checking inside the connector, you could see it melted and burnt from a loose connection.
I used a male /female push connector and it worked a few times and melted...
I eventually soldered a wire around the connector - no more problem.
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Last edited by JoeX; 25 Mar 2019 at 02:11 am.
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Old 25 Mar 2019, 12:43 pm
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Default Re: 2002 overheating, new rad fan not working

The wire in the wheel well grounds the strut to ground as wheel bearings collect static electricity an pits the races of the bearings
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Old 25 Mar 2019, 03:45 pm
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Default Re: 2002 overheating, new rad fan not working

Don't worry, I have a solution for you!!!

I had this *Exact* same issue a few months ago. Old fan died, new one worked sporadically and then not at all. I also traced all the wiring, I replaced all the fuses and relays, nothing worked!

After all that, it was the fan connector plug. It was melted a tiny bit inside, just enough to keep the fan from running. The admirable @RcktPwrd helped me diagnose it. I could have replaced the plug, but I opted to bypass it, I stripped the three wires, heat shrinked them together and it's worked flawlessly for several months. It's just tough to do, since there isn't much working room. Good luck! I can 99% guarantee this will fix your fan.
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Old 25 Mar 2019, 08:45 pm
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Default Re: 2002 overheating, new rad fan not working

I have the CHILTON manual. That's all. While I can read wiring diagrams, most show electrically defined connections, not necessarily where things actually connect. That is, a wire can go to ground from directly adjacent to the active part, or, travel to the far end of the vehicle before connecting to ground. Already I have found the wiring diagrams to not match things like the sunroof, etc.
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Old 25 Mar 2019, 08:47 pm
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Default Re: 2002 overheating, new rad fan not working

Thanks. Part way there now. No apparent meltdown, but I have already direct wired the center (ground I believe) line to ground with no results.
Thanks.
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Old 25 Mar 2019, 08:48 pm
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Default Re: 2002 overheating, new rad fan not working

Thanks! Well, now I know that I need to get that reconnected to the strut.
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Old 25 Mar 2019, 08:52 pm
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Default Re: 2002 overheating, new rad fan not working

Thanks All! I am still working it through. I have come to one conclusion:
Damn Chrysler for using marginal coverage connectors if that be the problem. WTH?
If you know something can surge to 40 amps and cook things, put a higher rated connector than the fuses and relays! Duh?!
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Old 25 Mar 2019, 09:06 pm
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Default Re: 2002 overheating, new rad fan not working

Quote:
Originally Posted by Al2eKen View Post
I have the CHILTON manual. That's all. While I can read wiring diagrams, most show electrically defined connections, not necessarily where things actually connect. That is, a wire can go to ground from directly adjacent to the active part, or, travel to the far end of the vehicle before connecting to ground. Already I have found the wiring diagrams to not match things like the sunroof, etc.
I've sent you a PM and you can download a copy of the Service Manual from my DropBox.
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