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Old 11-29-2004, 02:11 PM   #1
BeatnikTermite
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How To: HVAC Blower fan only works on 3, 4 & 5

This has been discussed many times here before, and I thought I would bring all of the information together in a "how-to." I have personally replaced this part with one purchased at CarQuest for $20. The repair took me about one hour to complete.

Problem: HVAC Blower motor only works on fan settings 3, 4 & 5.

Reason: Blower Motor Resistor is bad, and needs to be replaced.

Affected Model Years: 1997, 1998, 1999, 2000, 2001

Permanent Fix:

You will need: 1/4" Socket set -or- a 3/8" set with a universal joint

1. Remove the plastic cover from the underside of the passenger dash held in by four bolts. Note how the two air ducts on the left and top are connected, and how the other plastic cover piece is connected to the piece you are removing. This is helpful when you go to reinstall it.
2. Slide the Control Module to the right and pull it down carefully. Push it to the right being careful not to damage the wires.
3. Remove the blower motor power cable located on the forward side of the blower near the firewall.
4. Remove the jumper cable link to the blower motor resistor located on the resistor near the forward side of the blower.
5. Remove the blower motor held in place with three 7mm (I believe) bolts. You mat not need to do this, but it helps give you some room to work. It will also let see the blower motor resistor before proceeding.
6. Remove the two 5.5 mm bolts that hold the green blower motor resistor.
7. Install the new resistor using the two retained bolts. The improved part will be longer than the original, and black not green.
8. Re-install the blower motor using the three retained bolts, if you removed it originally.
9. Re-connect the blower motor power, and the resistor jumper.
10. Test the blower fan settings prior to putting the dash back together.
11. Align and push the Control Module up into the slot and slide it back to the left.
12. Re-install the plastic cover using four retained bolts. This is where it helped to pay attention to the ducts and the other cover when removing.

Last edited by BeatnikTermite; 11-29-2004 at 03:22 PM.
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Old 12-01-2004, 09:22 PM   #2
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

lucky this hasnt happend to me yet......but i am going to copy this since it seems very detailed....Good job and nice post...
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Old 12-21-2004, 12:54 PM   #3
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Since I forgot to look at the GM number on the part before I put it in, I have been looking for the box it came in. I finally found the CarQuest box for the replacement resistor and saw a part number. CarQuest has numbered it "RU43." This will only be good at CarQuest, but it is better than nothing.
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Old 01-02-2005, 05:10 PM   #4
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

I have the same problem I think... I have a Malibu 2002 LS and the air only works on 4 and 5. I have checked and replaced all of the fuses related to the HVAC. My question is this; can I fix this problem using the same instructions for the earlier models?
Thanks in advance for any help anyone can give!

Oh yeah, when I replaced the fuse for the IPC/HVAC BATT in the driver's side instrument panel, the air conditioning worked perfect for about 4 seconds... then would only work on 4 and 5 again.
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Old 01-02-2005, 05:41 PM   #5
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

this has happened to me before and thank God that it only happened once
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Old 01-03-2005, 11:57 AM   #6
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I imagine that you need to replace the resistor as described above. The only reason this seems to stop at the 2001 model year is that Chevy started to use the new and improved resistor in 2002. You probably have an early model year 2002, and it still has the old resistor. If you want to check without doing all of the work, just do the steps up to removing the blower motor and look in the open hole. If you see a green resistor then it needs to be replaced.
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Old 01-03-2005, 12:02 PM   #7
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

Thanks so much for the reply,... I will probably get some time on Tuesday to check it out... thanks again!
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Old 01-14-2005, 02:36 AM   #8
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Thanks for the detailed instructions Beatnik!! They were to the T. And as Beatnik suggests, make sure you use a universal joint especially to get to the back screw that holds the card in place. I didn't have one and it took about 1/2 an hour to one hour just to get that one screw out. Needless to say that back screw isn't in there right now.
Also you really don't need to remove the blower motor just look past it and you'll see a blue connector plugged in. That's the resistor card.
Also instead of the 5.5 mm use a 7/32 socket it fits perfectly. I didn't have a 5.5mm socket and experimented and the 7/32 socket fits like a glove.
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Old 04-04-2005, 11:29 AM   #9
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Bump. This was asked about on the other "How To:"
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Old 04-18-2005, 02:12 PM   #10
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???????????????

is this a generic gm fix or is it malibu specific?????????????????????
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Old 03-10-2006, 08:22 AM   #11
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

Bump.

This has been brought up several times again recently.
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Old 03-13-2006, 07:25 PM   #12
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

i got that problem,
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Old 05-16-2006, 09:56 PM   #13
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

Done so many of these I can do it in less than half an hour, my gf is on her 4th one, and I have done several for friends. Every dealer and most parts stores have these in stock.
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Old 05-16-2006, 09:56 PM   #14
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

Done so many of these I can do it in less than half an hour, my gf is on her 4th one, and I have done several for friends. Every dealer and most parts stores have these in stock.
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Old 08-26-2006, 11:11 AM   #15
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Re: How To: HVAC Blower fan only works on 3, 4 & 5

Great instructions ... worked like a charm. And the Dealer would have charged $250 for this repair. Not only was the repair completed ... I found out how to be a little more 'flexible'
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