Radiator Fan keeps blowing fuse =(

[keganater]

So the wife's 92 keeps blowing the radiator fan fuse (which is super convenient because it's super hot outside). It runs for a few minutes and then pops the fuse. I replaced the relay and the relay harness to get rid of any corrosion that might have been drawing extra amps but still does the same thing.

I have triple checked the wiring for any grounding out and have not found anything (not to mention it runs for a little bit before blowing the fuse).

Could a fan switch cause this issue? Or is it just time for a new fan???

Money is tight and I don't want to just throw parts at it. Tempted to just run a bigger fuse but I don't want to catch my car on fire either.

(PS - Previous owner just had solid wire in place of the fuse. Guess he didn't want to figure out what the problem was and liked the risk of an electrical fire ).

Thanks for any tips!

[shortwave360]

I'd check the grounds through out the car and clean & coat them. The best one to start with is the one that ground that circuit. Look for it in your Bentley or Cabby Info.

I think you have a bad ground somewhere making the circuit will draw too much resistance. Look for excessive heat scars on any related wires and maybe test with a meter on different points in the harness to see what it's running at.

Keep a fire extinguisher in the car.

GL!

[keganater]

So I finally figured out when the fuse pops!!! See if you can follow me through this...

When you turn on the A/C, the radiator fan also turns on, (built that way on purpose by volkswagen).
Also, when the engine reaches a hot enough temperature, the fan switch in the radiator turns the fan on.

Both of these functions work for me.... However, if both functions occur, the radiator fan fuse blows. So the fan works for either operation but not at the same time, (ex. trying to run the A/C when the car is hot).

Additionally, the fan makes a nice squeaking noise when it is working.

I'm thinking the fan is just on its last leg and needs to be replaced. Anyone else want to contribute their thoughts???

[briano1234]

So I finally figured out when the fuse pops!!! See if you can follow me through this...

When you turn on the A/C, the radiator fan also turns on, (built that way on purpose by volkswagen).
Also, when the engine reaches a hot enough temperature, the fan switch in the radiator turns the fan on.

Both of these functions work for me.... However, if both functions occur, the radiator fan fuse blows. So the fan works for either operation but not at the same time, (ex. trying to run the A/C when the car is hot).

Additionally, the fan makes a nice squeaking noise when it is working.

I'm thinking the fan is just on its last leg and needs to be replaced. Anyone else want to contribute their thoughts???

Fan has 2 speeds, Hi and low, hence the usual 3 pin connector.

One side will blow the fuse so you have 1/2 the fan ca-ca, or 1/2 the circuit that is shorting to ground.

[keganater]

I have checked all wiring and found no shorting out. Could the fan be drawing too much current when trying to run on the higher speed?

Also, can anyone send me a picture of their wiring running to the relay? Just want to double check everything is running to the right terminals on the relay. TIA

[tolusina]

....... the fan makes a nice squeaking noise when it is working......

Right there is a pretty solid clue that fan fan needs replacement.

If you really want to KNOW what is going on regarding electrical current, connect an ammeter across the fuse in question and measure.

[keganater]

Don't have an amp meter handy right now... Will have to get my hands on one and see what current it is drawing.

[native-texan_in_tn]

Have to agree with Ron... If the fan's squeaking/squalling, it sounds like there is a bearing in pain... If it's trying to remachine itself, it could ultimately just say, "enough is enough" and lock up. I replaced mine a few years ago after it became noisy, then discovered at some point afterward while pulling fuses for something else that my fuse had become warm (distorted but, for whatever reason, not quite enough to blow it). Since I've never had the a/c operational in my '89, I never ran into the fuse blowing with combined operation.

I have a feeling you'll stop blowing fuses once you replace the fan, for there's no telling how much physical resistance that bad bearing is creating.

[ExpoAccel]

I would go ahead and replace the fan motor. They do go out, I changed one in a '92 many years ago that had an internal short. It did not go off when the fan switch was open. If you want to measure the current you need to have the meter in series with the circuit. The advice to measure across the fuse will only work if the fuse is blown. I also do not see how a bad ground would cause an increase in power draw. The extra resistance should allow less current.

[briano1234]

secondly if your meter doesn't measure 40amps don't bother as you will just fry yours. Harbor Freight sells a clamp on amp meter, but to be honest, I have never needed one on a car.

Years ago I got a spare heater motor, and a couple of fans out of the Junk yard, for id I ever need them. I have used one of the fans.... When taking the fan out of the Junk yard, just be sure that you get the connector with it, as they changed the 3 pin connection on newer cars like the Golf or Jetta. If you have a single speed fan, then you can use a 2 speed if you have the connector.

[keganater]

Installed a new fan this last weekend and haven't had a problem since . The old fan had all sorts of play, bearings must have been pretty shot.

[native-texan_in_tn]

Had a sneaking suspicion that would probably do the trick and glad to hear it seems to have resolved the issues. Kinda nice to be able to walk off and hear only a "whirring" instead of all sorts of squeaking and squalling, eh? {chuckle}

[keganater]

Ya the new fan is great. It blows sooooo much better than the old one. I was stoked when we turned off the car and all I heard was a nice strong fan blowing instead of a squeaky whirling noise.