'03 Ion HVAC fan problem

[Biker Geek]

I have a 2003 Ion 2 with an odd problem.

The heater/AC fan doesn't work, except in position #4. In that position, it blows about as much air as one would expect from position #1.

As the car is a little over a year old and has only about 7200 miles on it, I'm expecting the dealer will cover it under warranty. But does anyone have any clue what the problem might be, and whether it's a big deal to fix? I'd like to have some idea what to expect when I take the car in on Tuesday.

Thanks.

 

[Alex Marcuzzi]

The fan speed is controlled by a blower motor resistor assembly which consists of a few heavy duty resistors connected in series with various tap points to give you the different speeds. If any one of these resistors open up (quite common with time because of the constant heating and cooling) then you loose the lower speeds but you have the high speed because at the high speed the resistors are bypassed altogether and the full 12volts are sent to the motor giving you the high speed. Once they replace the resistor assembly it should fix the problem. Since it is still under warranty let them fix it but later on if it happens again it is not a very hard thing to do yourself. Just have to follow the manual. Just ask them where the resistor pack is located in the car since because that is the hardest part to do when you have to replace it yourself.
Alex.

 

[Kirk Kohnen]

I have a 2003 Ion 2 with an odd problem.

The heater/AC fan doesn't work, except in position #4. In that position, it blows about as much air as one would expect from position #1.

At position 4, the fan should be getting the full voltage from the battery. I suspect, therefore, that it is the blower motor.

Shouldn't be a big deal to fix - about 1 hour of labor cutting out the old motor with a knife, putting the new motor in, and bolting on the metal plate that attaches the new motor to the old plastic thing (out of which the old motor was cut).

 

[Robert Hancock]

There is a TSB for the early '03 Ions stating that if the HVAC fan switch is rotated rapidly the contacts can come out of place and cause the switch to operate erratically. In this case the controls assembly has to be replaced.

 

[Biker Geek]

There is a TSB for the early '03 Ions stating that if the HVAC fan switch is rotated rapidly the contacts can come out of place and cause the switch to operate erratically. In this case the controls assembly has to be replaced.

Interesting. Do you have any info on manufacture dates or VINs to which this TSB would apply?

Thanks.

 

[Robert Hancock]

Bulletin says VINs up to those ending in 3Z161066.