Phase 1 Cooling Fan Resistors Question (1st+2nd speed controllers) - Alfa Romeo Forum
You are currently unregistered, register for more features.    
Thread Tools Search this Thread
(Post Link) post #1 of 13 Old 02-03-10 Thread Starter
Status: GTA Tiiiiiiiiiime!
AO Silver Member
JR Racing's Avatar
Join Date: May 2008
Location: United Kingdom
County: Hampshire
Posts: 1,573
Images: 5
Phase 1 Cooling Fan Resistors Question (1st+2nd speed controllers)

I think the fan resistors have gone on the g/f's car again!! Or should I say the 'thermal fuse' has broken. The first and second speeds are not cutting in when they should.

How I long for the simpler ECU controlled solution on the phase 2 cars!!

Is there a way to bypass these resistors or even better repair the old ones without the thermal fuse - without having to keep paying 25 a resistor block - which inevitably only last a year or two at a time.

We keep getting a scare when the fans don't come in as they should although the car has not overheated or gone over 100 degrees. I know something is not right. The rest of the cooling system is tip top.

Any Thoughts.


JR Racing is offline  
Sponsored Links
Status: #keepFightingMichael
AO Gold Member
EauRouge's Avatar
Join Date: Jun 2009
Location: Suriname
County: Brokopondo
Posts: 7,568
Images: 12
JR i would go to a breakers and get a 2nd hand system, i have the phase one and its never given me any bother whatsoever! I guess the fault is not in your resistors rather somewhere else in the system and therefore you are addressing the symptons rather than the cause!? Maybe the fans/fan motors themselves?

Last edited by EauRouge; 02-03-10 at 17:19.
EauRouge is offline  
Status: On a Mission.
AO Member
Join Date: Dec 2009
Location: United Kingdom
County: Buckinghamshire
Posts: 825
The resistors are for the slow speed only; they won't affect the full speed. Check the connectors; they often burn out.
Unfortunately, there are several different fan control systems on early GTV's. Does your car have the control unit under the o/s/f inner wing cover? If so, check the fuses/connections on this unit.
There is also more than one type of resistor; if you fit the wrong ones they'll work, but not for long.
FoxtrotOscar is offline  
Status: Finally got a Spider :-D
AO Silver Member
Join Date: Jan 2003
Location: Portugal
County: Setúbal
Posts: 4,074
Images: 6
I got mine fixed today... Mine had burnt connections, so a colleague of mine (automotive electrician) took them out and drilled a hole but the burnt connector to back plate of the corresponding connector and fitted a bolt and nut fixing a connector with some new wire... He said the resistor was ok and the connectors burnt because there was a loose connection... hope this helps.
My fan never stopped working, but I guess it starts a bit earlier now... around 90
montreal is offline  
Status: Constantly Nagging Lincolnshire Members !
Regional Support
For Lincolnshire - AOL
Nige005's Avatar
Join Date: Jan 2008
Location: Boston, Lincs
Posts: 16,083
Images: 22
You can buy Thermal Fuses from Maplins/CPC and the like, they are very cheap. Not sure what Temp Rating is required though, all the ones I have seen have had the colour and the printed markings burnt off. The end cap colour and/or the printed markings give the Temp Rating.

Alternatively just replace with a wire link, this is not unknown......
Nige005 is offline  
(Post Link) post #6 of 13 Old 03-03-10 Thread Starter
Status: GTA Tiiiiiiiiiime!
AO Silver Member
JR Racing's Avatar
Join Date: May 2008
Location: United Kingdom
County: Hampshire
Posts: 1,573
Images: 5
I think best step will be to take the fans out completely at the weekend, check and clean all the connectors and go from there. When the fans do cut in - they sound and perform fine. It is possibly a connector issue though rather than a part.

Do you need to take the rad out/bumper off to remove the twin fans?? Anyone know?

Unless it is not the resistors but the 2 speed relays playing about (coded L99 and L100).

I believe (although I could be wrong) the fan relays are located under the drivers side protective cover (under the bonnet) to the rear of the D/S headlight on our car.

Ours doesn't seem to overheat but to my knowledge I think the 1st speed sounds like it's working, perhaps the 2nd speed isn't. It never seems to get to the full speed anymore, just keeps putting the slow speed on for a few seconds at a time, then off again!
JR Racing is offline  
Status: -
AO Member
tannedstamina's Avatar
Join Date: Nov 2008
Location: United Kingdom
County: Greater London
Posts: 130
Well, after months of my fan not working correctly (first speed not coming on) the second speed fan has decided it wants to run all the time. Even when the car is off. I've had to take out the relay to stop it!
tannedstamina is offline  
Status: -
AO Member
Rod Duggan's Avatar
Join Date: Jan 2008
Location: Surrey
Posts: 192
Images: 4

Member car:

Spider 2000

I had the fan unit out on mine when I replaced the radiator, and noticed the resistor assembly was prone to corrosion on the terminals. Try wire brush and grease on the electrical conections.
Rod Duggan is offline  
Status: -
AO Silver Member
.:ian:.'s Avatar
Join Date: Feb 2009
Location: United Kingdom
County: Hampshire
Posts: 1,574

Member car:

GTV twinspark

I had a look at my resistors at the weekend and both are stuffed, one has blown the element and one has melted the connector

I`m going to attempt to re-engineer the connections on both using the method mentioned above, drill through the tags and stick a bolt through, then attach pigtails with crimped eyelets.

For the one with the broken element, I reckon 18swg nichrome wire is about the same csa and resistance, so will attempt to rewire it.. you can get about 1m for 4 off ebay, enough to rewire about 3 resistors

I`m also going to rewire the fans, as all the wiring around there is hard/cracked/melted. An interesting easter project
.:ian:. is offline  
Status: -
AO Platinum Member
David C's Avatar
Join Date: Aug 2003
Location: London, England
Posts: 28,994
All the resistors do is reduce fan speed.
If you don't mind the slight increase in noise, you can bypass the resistors completely and run the fans at full speed.
They will still be controlled by the relays, but instead of off/low-speed/high-speed, they will just be off/high-speed.
David C is offline  
Status: -
AO Member
Join Date: Dec 2007
Posts: 75

Member car:

'99 GTV TS

Hi all,
After reading through a few threads on this subject I'm not 100% clear on what course of action to take. So far I've unplugged the temperature sender on the stat and started the engine which kicked in the 2nd speed of the fan immediately. I'm inferring this means that the resistor is faulty. The wiring looks fine and the connections are not burnt. Can anyone suggest what to try to restore my first fan speed? Should I try to change the thermal fuse?
Thanks in advance.
panadero is offline  
Status: -
Temp Un-Registered
Join Date: May 2014
County: -
Posts: 5

Member car:

Alfa 147


Does anybody know the value of the "thermal fuse"?
Those cost something like ~1, I just need to know which one to buy.

Anybody knows, has a new to check, or a picture where the labeling is seen?

Thermal fuse being the one marked in the attached picture.
Attached Images
File Type: jpg 51736774-341-1-800.jpg (66.2 KB, 13 views)
alfaowner12 is offline  
Status: Spider on the road again after winter hibernation
Club Member
Membro Medio
Henrik_45's Avatar
Join Date: Jan 2013
Location: Denmark
County: Aalborg
Posts: 450
I think it is 128 C thermal fuse.

Be careful when you solder it.
You can brake it if you heat it too much.
Henrik_45 is offline  

Go Back   Alfa Romeo Forum > Supported Alfa Romeo Models > Technical & Vehicle Assistance > Alfa GTV & 916 Spider

1st , 2nd , controllers , cooling , fan , phase , question , resistors , speed

Thread Tools Search this Thread
Show Printable Version Show Printable Version
Email this Page Email this Page
Search this Thread:

Advanced Search

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is Off
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

For the best viewing experience please update your browser to Google Chrome