'03 Ion HVAC fan problem

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.

 

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.

 

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).

 

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.

 

Bulletin says VINs up to those ending in 3Z161066.