Technical Burnt wiring in heater

[Turtle]

Thanks for the speedy reply! I'm keen to fix it 'properly' - just wanted a second opinion on the state of my orange and brown wires (are they scorched?) before I purchase either a new resiator or the adapter kit you posted. Since my previous post I managed to get the resistor free using a thin flat blade screwdriver on the smaller of the 2 clips holding it in place, and note the #5 pin is a little cruddy. WD40 made no difference, I think i'll go to my local FIAT and see if I can try a new resistor before I buy

 

[cancunia]

The problem is that the single connector taking all the power to the motor is not really up to the task, replacing the connector will solve the problem but maybe only for a while. There's a design fault & that's why there are connectors on ebay. I think later models have a revised wiring loom to fix this problem. By joining the 2 wires, you double the connectors taking the load to the motor and bypass the connectors altogether when the motor is on full power.
In the end, you must decide what's best for you. It's your money & your car!

 

[Turtle]

The problem is that the single connector taking all the power to the motor is not really up to the task, replacing the connector will solve the problem but maybe only for a while. There's a design fault & that's why there are connectors on ebay. I think later models have a revised wiring loom to fix this problem. By joining the 2 wires, you double the connectors taking the load to the motor and bypass the connectors altogether when the motor is on full power.
In the end, you must decide what's best for you. It's your money & your car!

So the resistor is probably not at fault?

 

[cancunia]

So the resistor is probably not at fault?

There is no resistor or thermal fuse used for full speed on the fan afaik (see the pdf file that I attached in an earlier post) so if your fan does not work at all, chances are that the resistors in the pack are not your main problem. To be sure, you'll need to check with a multimeter.
The common problem is that the connector taking the power to the motor overheats and melts the connector and / or becomes corroded & simply stops taking the power through to the motor.

 

[Turtle]

Update with a happy ending! New resistor did the trick.

 

[cancunia]

Excellent news.

 

[theangrytramp]

Did anyone work out how to remove the heater resistor in the 2006+ models in the end?? As far as I can see there are no screws but I cant get the little s**t out :bang:

 

[ahhl]

Did anyone work out how to remove the heater resistor in the 2006+ models in the end?? As far as I can see there are no screws but I cant get the little s**t out :bang:

and do we need to remove glove compartment? where are the screws

 

[varesecrazy]

and do we need to remove glove compartment? where are the screws

Isnt this all covered in the FAQs..?

 

[theangrytramp]

No need to remove glovebox, though it's a little awkward to get at. I lowered my passenger seat as far as it would go (pushed back as far as it would go) and laid upside down on the seat with my head in the passenger foot well to get at it. As the other user said, check the FAQ for pictures etc on where precisely it is.
When it comes to removing it it seems some people have a single screw holding it in while more commonly the clip just holds itself in with a little plastic locking clip. Tried as i might, i couldn't release it just by squeezing it. In the end i got pissed off and risked breaking the mounting by whipping in a flathead screwdriver and levering it out with force. All went well for me and now my heater works fine. Good luck!

 

[ahhl]

No need to remove glovebox, though it's a little awkward to get at. I lowered my passenger seat as far as it would go (pushed back as far as it would go) and laid upside down on the seat with my head in the passenger foot well to get at it. As the other user said, check the FAQ for pictures etc on where precisely it is.
When it comes to removing it it seems some people have a single screw holding it in while more commonly the clip just holds itself in with a little plastic locking clip. Tried as i might, i couldn't release it just by squeezing it. In the end i got pissed off and risked breaking the mounting by whipping in a flathead screwdriver and levering it out with force. All went well for me and now my heater works fine. Good luck!

thanks.
i managed to pull out the heater resistor by wiggling very hard back and forth. i did a by pass individually connecting the wire to the resistor.

but when putting it back, i can't find how to lock it back using the clip. probably broken by the aircond mechanic. but how he manage to lock it place without using screw is beyond me.

it work find now. but i have to use screw to lockit in place. i do not have proper tool to screw it , :bang:

 

[theangrytramp]

thanks.
i managed to pull out the heater resistor by wiggling very hard back and forth. i did a by pass individually connecting the wire to the resistor.

but when putting it back, i can't find how to lock it back using the clip. probably broken by the aircond mechanic. but how he manage to lock it place without using screw is beyond me.

it work find now. but i have to use screw to lockit in place. i do not have proper tool to screw it , :bang:

Ahhh. Try pushing it all the way in and then sliding it hard to the left (towards the front side of the car). It should slide/clip into place.

 

[Carlcsw]

Hi there, sorry to bring this post back to life but I'm running into the same issue but on a slightly different model.

Fiat Grande Punto eleganza 2008 1.4 petrol.
It has digital climate control, which I believe is why it's different.

My heater began to blow on and off intermittently which from inspecting the two cables it's the 2-pin connector (black and brown cable) that had melted and burnt out.

I've spent a good many months trying to find a new loom for the car but all that I've found support non-digital climate control. My car has automatic dual-zone climate control.

Has anyone replaced the wiring or found a decent\cheap price for a replacement plug\terminal for a 2-pin connector?
All I need is to be replace the terminal and plug but can't find them.
Has anyone had any luck with an electrician or garage?

Images attached of the plug and it's position, you can see that its burnt out.

 

[KenMavor]

For what it's worth I have similar problem.

This is the connector that goes into the fan unit itself. Not into the resistor. On mine the motor rotates slowly but if you push this connector into the housing on the motor everything works fine. Two potential faults..one the actual motor housing itself or the cable has overheated. Suggest a second hand motor and a new connector with some length of cable connected to it. There are only two wires into the fan motor I think so carefully disconnect the melted old end and use connectors to connect the new socket to the wires. Then install the new motor and I suspect, and hope, everything should be fine. Probably go to a scrappy to get the parts. I had a cable tie in there holding the connector into the socket which seemed to work and then going over a bump everything stopped working.

 

[varesecrazy]

Hi there, sorry to bring this post back to life but I'm running into the same issue but on a slightly different model.

Fiat Grande Punto eleganza 2008 1.4 petrol.
It has digital climate control, which I believe is why it's different.

My heater began to blow on and off intermittently which from inspecting the two cables it's the 2-pin connector (black and brown cable) that had melted and burnt out.

I've spent a good many months trying to find a new loom for the car but all that I've found support non-digital climate control. My car has automatic dual-zone climate control.

Has anyone replaced the wiring or found a decent\cheap price for a replacement plug\terminal for a 2-pin connector?
All I need is to be replace the terminal and plug but can't find them.
Has anyone had any luck with an electrician or garage?

Images attached of the plug and it's position, you can see that its burnt out.

Can you get an electrician to build new cable and terminals into the original plug..

 

[Carlcsw]

Thank you for your responses. The issue has now been fixed on my car, there were actually two issues at play which one most likely caused the other.

The Heater Motor Resistor in my heater motor fan had failed, simple to take it off the motor. Opening up the resister inside the board was melted with a hole in it. Managed to get a new Denso part to replace this from eBay after finding the part number, cost around £45 for a new Heater Motor Resistor With Climate Control.

As for the cable, I brought part of a wiring loom for the normal non-digital climate control and had the end with the plug I needed. eBay for around £15 but it was well worth it.

All back to normal :-D to note mine did the same when it was intermittent. I wiggled the wires round and it worked, but it did fail completely 4 months later on.

 

[Ziggy333]

Apologies for digging up an old thread but Im having the usual problems with my heater fan also that being that it doesn't work on any speed.

I checked the resister from my duff blower on another Punto and the blower worked fine on all the settings 1,2,3 & 4. So I purchased another connector for my Punto. I've connected it up and still had no joy, I've put a multimeter over the pins and I've got 12v at the brown wire which is fine, should there be a voltage across any of the other wires?

I've even taken the motor out and checked it in another car and it worked fine so I'm assuming that I've got a problem with a broken/melted wire somewhere in the loom (I've checked all the fuses etc plus Im getting 12v at the plug to the resistor.)

Has anyone bypassed the resistor? I need a temp fix to help clear my windows in the morning. My plan was to run a 12v wire to the motor off a switch and also have an inline 30a fuse on the wire.

 

[jackwhoo]

Check the continuity of the pins in New connector to wires those pins are connected too, possibly the wires badly crimped to pins.
Your idea to run new wires direct to fan is sound.

 

[Ziggy333]

Check the continuity of the pins in New connector to wires those pins are connected too, possibly the wires badly crimped to pins.
Your idea to run new wires direct to fan is sound.

Thanks for the reply.

I'll check the continuity tomorrow and see if there's any, I didn't crimp them as I had none, I just used 30a block connectors.

I even tried just connecting the brown wire to the orange wire to see if the blower would run at full speed but nothing happened which was making me think there was something amiss but even at that I would have thought it would have worked on 1,2 or 3.

I was thinking that the wire to the blower was burnt out too but its pritty unlikely that the 2 have gone at the same time.

Like others have stated my fan did work for maybe a minute or so on setting 1 when I first got the car and then I could hear it cutting out and slowing down - it done this a couple of times until it stopped completely.

 

[mminghella71]

Thank you for your responses. The issue has now been fixed on my car, there were actually two issues at play which one most likely caused the other.

The Heater Motor Resistor in my heater motor fan had failed, simple to take it off the motor. Opening up the resister inside the board was melted with a hole in it. Managed to get a new Denso part to replace this from eBay after finding the part number, cost around £45 for a new Heater Motor Resistor With Climate Control.

As for the cable, I brought part of a wiring loom for the normal non-digital climate control and had the end with the plug I needed. eBay for around £15 but it was well worth it.

All back to normal :-D to note mine did the same when it was intermittent. I wiggled the wires round and it worked, but it did fail completely 4 months later on.

I have the exact same problem as you. Do you have the part numbers you used? I checked my wires and both the black and white connectors are melted :'(