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Old 08-09-2011, 06:35 PM   #31
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Re: 2003 chevy astro blower motor

Check amperage draw of the blower motor using the terminals on the motor itself, (bypass the vehicle harness). Post your result.
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Old 08-20-2012, 11:51 PM   #32
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Re: 2003 chevy astro blower motor

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Common problem to burn at the connector to the relay/resistor. While you're at the boneyard, might as well get the resistor AND the harness connector. Do yourself a favor and solder the connector on, don't use crimp connectors.

Another option is to bypass the relay and install an external 40amp relay They're about $5 and a couple feet of wire, a few terminals, 20 minutes time and you're done. If you need directions on how to do it, just ask.
Hi Old_Master, I too have the same issue and going to take your Great advise and By Pass with Relay. I was wondering if the vehicle is safe to drive with this electrical issue going on, just wondering if this can effect the other components in anyway?
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Old 08-21-2012, 12:04 AM   #33
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Re: 2003 chevy astro blower motor

I lose A/C when i'm driving up a bridge, like it loses power, still working but nothing coming out of vents until i get over the top of bridge. What could cause this? It's a 2000 Chevy Astro Van, Thanks in Advance..
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Old 08-21-2012, 09:00 PM   #34
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Re: 2003 chevy astro blower motor

Best to repair it. If the connector is melted, heat caused it.... where there's smoke, there's fire

The issue with air flow is caused by a leak in the HVAC vacuum system. Common problem is the source line where it crosses the engine in front. Dry rots or burns.... needs new vacuum line
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Old 08-22-2012, 01:52 AM   #35
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Re: 2003 chevy astro blower motor

Here is a Pic of mine, just finished, works great but now it only is blowing through the defrost.
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Old 08-22-2012, 04:38 PM   #36
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Re: 2003 chevy astro blower motor

Relay looks good! Follow the vacuum line, next to the relay, back to the intake manifold on the driver side, (next to the throttle body). I think you'll find a rotten vacuum line or it came loose.
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Old 08-23-2012, 12:11 AM   #37
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Re: 2003 chevy astro blower motor

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Relay looks good! Follow the vacuum line, next to the relay, back to the intake manifold on the driver side, (next to the throttle body). I think you'll find a rotten vacuum line or it came loose.
Thanks, what happened i was just checking it with the key in the forward position and not with the van running, it was only blowing in de-frost mode. When i started it up to move it out of garage, it was working fine.. I'm guessing the engine needs to be running for vacuum?
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Old 08-23-2012, 04:44 PM   #38
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Re: 2003 chevy astro blower motor

The HVAC system uses vacuum to operate the water valve, blend & mode doors, however, there is a check valve near the AC accumulator that is supposed to keep HVAC vacuum in the HVAC system. If there are no leaks in the HVAC system, and the mode switch is not moved, vacuum should hold the doors in the same position, even when the engine is off.
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Old 09-03-2012, 01:04 PM   #39
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Re: 2003 chevy astro blower motor

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Here is a Pic of mine, just finished, works great but now it only is blowing through the defrost.
Ronnie,

Your wiring looks really great and professional. If you have pictures of where the wires are spliced into the wires to the connector and to the wire from the blower motor, can you post those, too? I'm better with pictures. Thanks
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Old 09-05-2012, 08:22 PM   #40
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Re: 2003 chevy astro blower motor

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The HVAC system uses vacuum to operate the water valve, blend & mode doors, however, there is a check valve near the AC accumulator that is supposed to keep HVAC vacuum in the HVAC system. If there are no leaks in the HVAC system, and the mode switch is not moved, vacuum should hold the doors in the same position, even when the engine is off.
Thanks.. I found the check valve but it is a 3 way, can't seem to find it anywhere, O'Reilly's, Rock Auto ?? Would you happen to know the P/N or where to find it ?
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Old 09-05-2012, 08:25 PM   #41
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Re: 2003 chevy astro blower motor

http://shop.advanceautoparts.com/web...um+check+valve

The cone shaped single fitting goes toward the engine.
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Old 09-05-2012, 08:40 PM   #42
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Re: 2003 chevy astro blower motor

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http://shop.advanceautoparts.com/web...um+check+valve

The cone shaped single fitting goes toward the engine.
Thank You SO Much, you are such Great help : ) Really appreciate you
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Old 06-07-2013, 09:59 PM   #43
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Re: 2003 chevy astro blower motor

HI Old Master, sorry to pester you but maybe you could help.

I found this thread along time ago and just now found this again after a lot of searching and finally found it again!!!!!!!!!!!!! Woooo hooo!

So if your still around and have time I'd sure appreciate your advice, so here goes.

I have a 96 Chevy Astro and I only have one orange wire.
No Purple wire at all like the other feller from a couple posts up...

Color of wires are from left to right on resistor are as follows...

Red fat wire... Little Orange wire...Black Fat wire...Little Light-Brown wire...Little Yellow wire...and a Little blue wire.

From the bottom of the resistor are two wires that go to the blower motor. They are Red and Black.

I'd sure like to fix this thing soon if I could but I really aint about cutting wires with out knowing which to cut.

Either way....thanks for figuring out this by-pass and I hope you got time to respond.

Thanks!

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Old 06-08-2013, 04:39 PM   #44
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Re: 2003 chevy astro blower motor

The wiring on your 1996 Astro is different from the 2003 explained above. Here is how to bypass the high blower relay on your 1996:

On the add-on relay:
Terminal #86 goes to ground.
Cut the orange wire at the blower resistor and connect it to terminal #85.
Cut the red wire at the blower resistor and connect it to terminal #30. You need to use 10 gauge wire to extend it.
Splice a 10 gauge wire on to the red wire that goes to the blower motor, (do not cut the red wire) and connect the other end to terminal #87.
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Old 06-08-2013, 04:57 PM   #45
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Re: 2003 chevy astro blower motor

Hey Old Master ,

Thank you for the reply. I figured that was how it was with the orange and red wire. I checked voltage and it seems to be the red wire is HIGH and the orange wire is Med-High.

Only thing is... I just now this very minute... just hooked it all up and I used the 14 gauge wire. OH NOOOOOOOOOOOoooooooooooooooooo......... too impatient I reckon.

It all seems to be working except the HIGH though still. Maybe the bigger gauge wire is what needs to be changed and might fix it....either way I've got to redo all this now to the 10 gauge.

If it dont work after that I suspect it might be the switch on the dash cause I've changed everything else. Checked voltage, ground , replaced blower motor, voltage resistor, voltage resistor harness etc....

Again thank you for your help! Your the man!


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