Cooling fan wiring

[white944]

White944 is an 85.5 with a single cooling fan and conventional sized relay rather than the double one. The fan doesn't work, and I've traced the fault to an open circuit between the fan switch and pin TS (the small pin) on the relay. If I run an extra wire to bypass the existing circuit it all works fine. So.... I appear to have a problem at the fuse board. Before I pull it apart, do they suffer from internal faults? Anything common I should look for?

Thanks.[]

 

[Waylander]

manky connection ?

broken wire, mouse?

 

[bmnelsc]

Pull the fuse block and check for corrosion underneath ... I had to replace a fuse block once as it was all green and fuzzy underneath...

 

[Waylander]

Bet that was a job you would not like to do twice!

 

[white944]

Found it! After a lot of probing and head scratching.

Internal break in the brown and yellow wire just after it comes through the bulkhead under the fuse board. You can just see the cut end sticking up out of the engine harness here.... the brown wire at the bottom is the one I fed through the harness to repair it.

Made an incision in the harness just inside the engine bay and pulled a few inches of wire out. You can see the green end where it had somehow corroded inside .......

Managed to attach a new section to a piece of welding wire and feed it through the original harness back through the bulkhead.

Then soldered the new wire in and heat shrunk before tucking back into the harness.

Fan now working properly. Of course, the b*stard thing wouldn't start afterwards. some of the multi plugs in the underside of the fuse board don't appear to lock in properly, so when you lift it, they try to come out. Must have been damaged in a previous life, I suppose. Ended up refitting the board and them giving them a good push in from under the dash to make sure they were all properly seated. Hopefully they will stay put now.