'03 Ion HVAC fan problem

Discussion in 'Saturn ION' started by Biker Geek, Oct 3, 2004.

  1. Biker Geek

    Biker Geek Guest

    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.

    Biker Geek, Oct 3, 2004
  2. 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 Marcuzzi, Oct 3, 2004
  3. Biker Geek

    Kirk Kohnen Guest

    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).
    Kirk Kohnen, Oct 3, 2004
  4. 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.
    Robert Hancock, Oct 4, 2004
  5. Biker Geek

    Biker Geek Guest

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

    Biker Geek, Oct 4, 2004
  6. Bulletin says VINs up to those ending in 3Z161066.
    Robert Hancock, Oct 5, 2004
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