Help no heat-Plymouth Voyager

[pampereddarlene]

I am in need of help. I bought a 1996 Plymouth Voyager in 5-2000. When I bought it the fan blower only worked in a few of the settings. I explained it to the dealer and they looked at the car. They couldn't fix it because they had to order the part. The invoice said "fan motor in INOP on 1st and 4th speeds. Fan switch faulty, ordered Fan Switch" I was supposed to bring it in when the part came in and I never did. Boy do I regret that now. Two years later the fan blower was only working in the highest setting. Again I thought I could bring it to the dealer and they could quickly fix it with the part they had on hand. (ha ha ha) In December I shut off the van and noticed that the blower was still running with the car off. I thought that was wierd and within a week the blower stopped working totally. By the way winter is COLD in Maine. I called the dealer and they basically laughed in my face. They said the best they could do is to give us a used part for $200(two years later the brand new part is almost $400 versus the $238 in 2000) Well I didn't have the money so I waited and drove around cold. We decided to call a junk yard and they gave us a part(heater/Ac Control Switch) for $120. We put it in and still no heat. I called a mechanic friend that works at the dealership and he suggested to try the blower resistor. He said usually with a blower resistor your heat would only work on the highest postion for a little bit before not working at all. We said that was the case so we called a motor supply store and found out that the resistor is a dealer only part. So we called the junk yard again and asked for the resistor. When they checked to make sure our parts were compatible the man noticed that my wires in the plug had fried. He explained to me how to splice the wires and hook up the new"used" one. I had a electrician friend do it but it still didn't work. We even tried the new resistor with the new AC Control Switch still nothing. Checked by eye the fuses that have anything to do with heat. Appears fine. I am at my wits end with keeping the kids home because of a freezing car. My husband will try anything. Need to keep it inexpensive if possible. I hope someone can help. Thanks:help:

[Norm Petersen]

Wow !! Ya got me kinda confused on what was replaced and the problem.

So, I'll give it my best shot in the dark and that is, you don't have an overheating problem and your heat selector switch screwed up a few times. You have heat inside but nothing to blow it around like it's suppose to, right?? Blower motor was changed also??

Best I could suggest and cheap is that there is a wire plug connection on the heater blower motor up in behind the dash. Tough to get at maybe but you're looking for a heavy black wire and a heavy green wire(unless they changed the wire code). This is only if your blower motor is working correctly and the selective switch is toast!! Once finding the two wires leading to the motor unplug the wire connection and then splice onto those going to the blower motor with a toggle switch/or some other multi-switch. With one good direct positive + lead and a good ground - lead hooked up then you should be able to control the blower motor to turn on and off when you want.

I'm only saying this because it sounds like you are having troubles getting your heat selector switch to run the blower motor fan.

If not correct me!! Gooooood Luuuckkk!!!

[pampereddarlene]

I know I can be confusing at times. I am a woman what do you expect. I feel like I have to tell the WHOLE story for anyone to understand. My husband hates that. Anyway thank you for responding. I finally have heat but it was rigged up by my mechanic friend. He grounded a wire under the glove compartment and bypassed the resistor and plugged it into my radio fuse. Now I only have heat when the car is running and only on high. He did mention that I could place a toggle switch to be able to turn it on and off but it would still only work on high. Yes you are correct, the blower motor does work. (Is that exactly what you were suggesting?)
A day after the mechanic looked at it he asked me to check the blower relay? Well unfortunately I never got the juction box cover with my van so I have no idea what relay is what. I purchased a Haynes repair manual yesterday and guess what it doesn't say it either. Now I am very frustrated! I have to call him today and maybe he can help now that I have the book. Who knows. Thank you again for responding and if you have any other suggestions let me know. Thanks

[Norm Petersen]

Hi, Again

I reread everthing and now if I can explain it so you will understand.

Basic Wiring:

(I just spent a couple of hours tearing apart an older wrecked van I have in the backyard, and did some tests on the heater switch/condensor/heater blower motor/and heater blower motor resistor, Because I was curious).

There is a hot/live wire going to the fan selector unit and from there depending on the year are a few more leading out, but three main wires for sure. With one being a ground wire and a live wire again and one that goes to " the heater blower motor resistor " (under the hood passenger side by the hood hindge the unit is bolted on with two small bolts and however many wires connected to it depending on the year again). What I found out was that if I disconnected the Condensor there was no change (everthing worked as normal) with my jump wires in place. I then hooked the Condensor back up. (I do believe that is just so you don't get static noises in the radio from the blower motor while it's running) .

Next, I pulled the plug off of the " heater blower motor resistor " (the unit under the hood) and all I ended up with was the fan on high and off "ONLY" !! No, Low or Medium etc. I hope your still with me!!

That might have been the problem in the first place.

When the weather is better you might what to redo this job back to the original state. I hope you have kept all the new/used/or old parts because you might have to resort back to them.

You also said you eye-balled the fuse and it looked good, just a word of caution is always use a 12v tester etc. to know for sure that it is good, o.k.

In your Haynes book at the back there should also be a wiring diagram for the heater.

I wish ya Luck and let me know how ya make out, o.k. :smoker2:

[pampereddarlene]

Wow, thank you so much for putting so much time in my question. I really appreciate it.
Now Im not sure exactly which parts are what.
What part is the fan selector unit and where is it?
I do know what the resistor is as I had to help install it!
I haven't heard about the condensor yet, what is that and where and how does that relate to the heat? (okay stupid ?s I know)
Let me see if I understood you right. You are suggesting that the blower resistor was the problem in the first place right? I do believe that was the case two years ago. But after running it like that for a couple of years it burnt all the wires at the resistor. We had that replaced. The mechanic friend said the problem is somewhere between the two fuse boxes. He suggested that a wire could be the problem but then thought about changing the relay. Does the relay stuff make sense? I am going to check my Haynes manual right now for the heating diagram but I swear I have looked at that umpteen times and only understand a 10th of it.
My mechanic friend did check the fuse with a meter. It was a different friend that eyeballed it before. If I tried to eyeball the fuses I wouldn't know what the heck I was looking at. Thanks for the advise though. I would like to get one of those meters as it looked pretty handy to me. Again, thanks for all your help. I am willing to try anything. :flash:

[pampereddarlene]

Hi me again, I called my mechanic friend and asked about the relay situation. He said to take out the AC compressor relay and switch it with the Blower relay and if it works then I need a new blower relay. He said that both relays are located in the Power Distribution center under the hood (fuse box). Well guess what I only have the AC Compressor relay located there. I read the fuse box cover and it does not say anywhere that there is a blower relay. I then went to my Hanyes Manual. I did find the wiring diagram you mentioned. I studied it for quite sometime and did find that I should have a blower relay in the Power Distribution center. WHY DONT I?
I assume that it is in the Juction box under the steering column but I don't have the cover for that to know which relay is what. I couldn't find it in the book but I will still look! I am calling my wonderful dealership tomorrow to ask for a manual and a junction box cover I hope I am making sense because I am beginning to question it myself. thanks again:smoker2:

[Norm Petersen]

Hi, I'm Still with you and I guess things are making alittle more sense now that I'm realizing that this is a newer year/model than what I usually work on. Principles are basically the same but with the newer models they like to hide all the little extra goodies they have installed on ya!! :bandit:

A few questions are:

What size engine is it ?
Do you also have the rear heater in this Van ??

I think your Mechanic friend is on to something ,because I was thinking the same about the A/C fan relay being part of the heating circuit.

Now, The Power Distribution center under the hood when you pull the plastic cover off isn't it written on the bottom of the lid what things are for/or on top ??
He is right about switching the two around if they are equal. Just have to locate it, Right!!

This still might end back at the melted down wiring at the resistor which might have shorted out other things, including a short in one of the wires for that circuit.

O.K. I'll leave it untill you get back at me.

I'm still hunting info for ya !! :smoker2: Norm

[Norm Petersen]

HEY !! :flash:

I found a little more info, I just gotta see if I can paste it here!!

The automotive division of Memphis-based Thomas & Betts is launching a new power distribution center system for Chrysler's Town & Country, Dodge Caravan and Plymouth Voyager minivans. The smaller, lighter devices will simplify wiring harnesses and will be installed in the minivans beginning next year. The company projects sales will reach $20 million during the life of the project.

SIMPLIFY !! Yea, Right !! :silly2:


Question: 1996 Plymouth Grand Voyager 3.3L V6 mileage: 66K. My heater fan stopped working. I put 12V across the motor and it ran. I checked the 40-amp fuse and it looks OK. I looked at the wiring diagram in the Haynes manual I have and it shows a relay, but I can't find the relay; I'd replace it if I could find it. It's not in the "power distribution center" under the hood, and it's not in the "junction box" under the dash. Do you know where to find this relay?


Answer: It is located on the junction box behind the left side of the dash.

Hope, this helps to locate the other one!! :sun:

[pampereddarlene]

Okay first of all I'M mad!!! I just spent 20 mins responding to your post and I accidently deleted it as I was signing my name. There is no undo button here
Oh well I will try to do again.
The answer to your first questions. 4cyl. and no rear heat.
Yes, the Powerer Distribution Center cover does have everything labeled. Just the Blower relay was not one of them. But since I don't have the junction box cover I don't know which one is the correct relay. I called my wonderful dealership today and they said they would be happy to charge me for one. I said I would be happier going to a junk yard and I have learned my lesson to not buy a car from them again. Their after service care sucks:zx11pisse

I also feel that it could still end up being a shorted wire somewhere between fuse boxes but it sounds as though it could be a lengthy diagnosis and I thought the relay switchero would be cheaper to start with.

That is so funny that you found that forum about the relay. I think I found that two months ago but at the time it didn't mean anything to me since I was looking for a different part. Sounds like he is in same situation as me. But he probably has the junction box cover:cry:

I will let you know what happens next. I can't believe the time that you put in to helping me. Thank you! I APPRECIATE IT :smoker2: -Darlene

[Norm Petersen]

Hi, Darlene !!

Yea, it happens to the best of us sometimes I'll use wordpad and write up what I want off line and then just copy and paste it. Sure beats doing it all over. But sometimes doing it twice, it gets better. :flash:

The engine must be a 4 cyl. 2.4Lt. (Right)
Some vans come with the rear heater also, so all I was thinking was, then we have more wiring to deal with. (and added problems) Good that it don't !!

DEALERS = I'm sorry they couldn't help you, but you will probably be treated and gain more knowledge from the Guys at the Junk-Yard!! :bandit:

CHEER UP !! I don't mind Helping, if I did, I won't be here.(right) :smoker2: Dang! I smoke too, much!!

I WISH, I had your Van in my Back-Yard to work on, it's so hard to figure out when the problem is not right in front of ya!! I would be just in my Glory doing the Fix !! Honest. Just ask my wife, she says my eyes Light Right up when someone pulls into the back-yard with a problem. And I DIG right in!!

Anyways, here is a web-page that might be useful for you now or later depending on whether ya keep old Betsy or not. Check it out !!

http://www.cybrrpartspro.com/chilton...oot/index.html

Yea, my money is on the short in the wiring, find that circuit harness and then follow it to locate the short, fix and take out any Mickey Mouse stuff that was installed and go back to the original setup.

Check that page out and keep me updated!! :sun: Norm

[Norm Petersen]

Darlene,

How did you make out, any Updates!! :bandit: :bandit:


Norm



-------

[pampereddarlene]

Hi Norm, No updates yet. I have been busy with other stuff recently. I did check out that website you mentioned but at the time I couldn't find any specific information that I needed. I have noticed that I am blowing the radio fuse alot. The wire that he rigged is sticking into that fuse. At first there were no problems but I have changed it a few times. (Maybe I am not putting it in right?) I have the toggle switch and fuse line to hook to the toggle switch. I just don't know what to do with it. I really need to try the relay. I hope that would fix all my problems. (only because it seems like it's the easiest way). I will let you know when I get off my rear end! -Darlene. Thanks again!

[hossierrun]

I know this post is very old and not likely to help the original person, but I have been going through much of the same. The blower relay is located way up behind the distribution box; between the firewall and the body control computer module. The resistor can be accessed in cowl. You have found that, and it is what controls all the speeds, except high. In 97 they relocated the relay into the PDC under the hood to make it easier. I wish the Haynes manual folks would get their facts correct. They obviously never tore down a 96 as was stated in the manual.

Originally Posted by pampereddarlene

Hi Norm, No updates yet. I have been busy with other stuff recently. I did check out that website you mentioned but at the time I couldn't find any specific information that I needed. I have noticed that I am blowing the radio fuse alot. The wire that he rigged is sticking into that fuse. At first there were no problems but I have changed it a few times. (Maybe I am not putting it in right?) I have the toggle switch and fuse line to hook to the toggle switch. I just don't know what to do with it. I really need to try the relay. I hope that would fix all my problems. (only because it seems like it's the easiest way). I will let you know when I get off my rear end! -Darlene. Thanks again!