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Discussion Starter #1
Hello, the fuse for the cooling fan blows when the fan tries to start and i have the error code p0481 (fan 2nd speed). If i try to start the fan with multiecuscan i hear clicking from the relay.

I noticed that the resistor is bad, i get no reading when i try to measure it with multimeter so i ordered a new one. Is this causing the fuse to blow or is it something else? I got the red injector warning light while pushing the car a few weeks ago and after that the fan wasnt working anymore. I have no other fault codes.

I tried running the fan from a motorcycle battery and it seems to work.

Does anyone know how to fix this?
 

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There are 2 relays and 2 fuses for the fan, both lurking in that fuse/relay block by the left headlight. Which one is blowing?

I'll double-check the circuit tomorrow, but I seem to recall it's pretty straightforward, fan speed 1 switches power via the resistor, fan speed 2 feeds power direct.

I think the ECU just monitors the relay coil, but as I say, let me check tomorrow as it's possible the coil gets power via the same fuse that feeds the relay load (the fan) so a code could possibly be either a faulty relay or a blown fuse.
 

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Discussion Starter #3
Its the fan speed 2 that keeps blowing. I tried switching place of the relays but the fuse gets blown anyways.

If i replace the fuse and connect multiecuscan i can delete the fault code but when i start the car i think it blows right away. Im out of fuses right now so i cant check if it blows also when the car is cold.

Can i ohm measure the fan to see if its OK? What value should i get?
 

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I'm sure you checked, but are you sure you replaced with the correct value fuse ? ;)
Also make sure the resistor doesn't have a short to ground ....
Of course speed 2 should actually bypass the resistor, so resistor shouldn't make a difference, unless there is a short somewhere
 

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Discussion Starter #5
It was a 40amp fuse in it from the start and i replaced it with another 40amp but i saw online that it should be 50amp so i ordered that instead. The fan was working before with 40amp though.

At the moment im driving the car with the resistor disconnected and it blew the fuse anyways. Can the fan motor be bad and consume more power than it should even if it spins? There is almost no resistance when turning it by hand.

I replaced the engine a few weeks ago so maybe some cables got damaged, but i dont think i touched any of the cables close to the fan. The fan was working for a few days after i replaced the engine.
 

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if the fan was drawing a lot more current, I would expect you would notice it from the higher mechanical resistance.....
basically there is no change in the fan running at first or second speed, in speed 1 it just gets a lower voltage/current due to the series resistance added in the connection lead.(which will of course also limit the max possible current in case of short)
 

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Just looking at the circuit now. In the secondary relay/fuse block by the left headlight, F8 is 50A for speed 2, F9 is 50A for speed 1. The same fused feeds power the load and relay coil, which means if the fuse is gone, the ECU will log a fault as it looks for 12V on the control lines.

Speed 1 relay feeds the resistor which then feeds the fan.

Speed 2 relay feeds the fan directly.

As @jwq says, the fan is a simple motor, no fancy electronics in there. If it runs OK on a direct feed from a test supply then it's probably OK. Most likely is a wiring fault/short rather than the fan (assuming that fan test you did was good). Try unplugging the fan power connector from the fan itself, replace both fuses then run the fan tests using MES. If the fuses blow, there's a wiring fault/short/ if they don't, the fan is to blame.
 

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Discussion Starter #8
I tried running the fan test without fan connected and the fuse didnt blow. Then i reconnected the fan and started fan test 2nd speed, the fan did spin but after a few seconds the fuse blew and the fan or the fan connector started smoking. I recorded a video, the smoke started just after i stopped recording.

https://a.uguu.se/WtAJDSFc.mp4

If youre wondering, yes i got scared when the fuse blew 😂

Do i need a new fan or can i fix the one i have?
 

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That fan sounds dreadful....and the symptoms suggest it’s the culprit. I’ve not stripped one of those, but the usual causes of excessive current drain will be shorted turns or brush/commuttor problems. Neither are easy DIY fixes unfortunately although you could maybe try and find an auto electrician/alternator specialist and see if they can help....or buy a new one ;)
 

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Discussion Starter #10
I can have a used fan for free but its for a 156 2.0ts unkown year, does that fit my car?
 

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Is it the old 166 or the facelift? My first fan speed relay was cooked and crispy, it was closer to a cornflake than a relay.
It's below the driver's side wing (in left hand drive version).
Fitted a cheap 50A relay,s til working 2 years later.

 

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Discussion Starter #15
I have the pre facelift model. My relays seems to be working though. Tomorrow i will get the fan from the 156, i will also take the whole fuse and relay holder. Is there any other spares i should take from the 156? I can take whatever i want for free :)
 

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I have the pre facelift model. My relays seems to be working though. Tomorrow i will get the fan from the 156, i will also take the whole fuse and relay holder. Is there any other spares i should take from the 156? I can take whatever i want for free :)
The resistor ?
 

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Couldn't see the video. But as they told you, if it only blows up when you plug the fan, there's not much else to blame.
Ensure the wiring is not craked at some point. But seems that the fan motor is gone.
 

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Discussion Starter #18
The 156 fan frame was a bit shorter than mine but everything else was the same so i just moved the fan motor to my old frame and it worked! No more warning lights and no more overheating :)

Thanks to everyone that helped


951982
 

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Sweet.

And thank you for reporting back. It happens far too often that a question gets posted, folk try to help, then the personas asking just vanishes - most rude!
 

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Yes, people scratching their heads and spending time to help they guy, then he disappears from earth.
That's the most f** disgusting behaviour possible.

The frame is different, but the fan itself seems the same? Were you able to put it into the 166 frame?
Anyways, who the hell needs a cooling fan in Sweden? Do you ever get over 0ºC in there? :LOL:
 
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