Club 80-90 Forums

Desperate help needed. Off to France on Thursday and the fan blows fuses like every fifth time the fan comes on. I have noticed it running a little bit hot I think? And it seems to be blowing coolants out of the expansion tank while sucking every think up through the overflow. I have put a bigger fuse in and it has melted the fuse. Shall I try with a nail? HELP


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If you look under dash above the fusebox but over to the left, you should see a relay on a bracket which controls fan top speed (when its sucking most amps - hence need for relay). You need to unseat it and reconnect it. Usually the connectors furr up (like earth crowns) and the resistance will keep blowing the fuse. That'll sort the fuse prob (or should) but you have additional issues there I reckon. Carry a lot of water for sure. Lol - if you use a nail you'll have a dash fire. Fuse is trying to tell you something.

Chap, tomorrow, garage, go.....

I've had a fan come on once in over ten years.

You say every fifth time it blows fuse? How often is it coming on. Also say it's running hot and blowing coolant out?

Could be a fairly easy wiring fix, new cap and bleed system properly. Could also be something more sinister......

Personally if you're off to France Thursday it needs to be sorted properly ASAP.

And never ever ever use a nail etc, the wiring tends to melt/burn/set van on fire wayyyyy before your 'temporary fuse' blows.

I was only joshing with the nail. Will check the relay tomorrow. Put new cap, rad, pipes, expansion bottle, bled 100 times garage lots. Might be paranoid? Fan comes on just after the led on the temp gauge. But heats up v quick, to temp after 2 miles or 5 mins. Does nt leak lots. Did 1200 miles to the lakes couple of months ago and lots more no major worries. Just strange it's blowing a little. Most strange. Runs like a dream otherwise.


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As a rule of thumb, the need for the fan in terms of cooling, drops dramatically once you're moving and it certainly shouldn't overheat. However, in moderate traffic, without the fan, it would start to get very hot, quickly. If you're overheating under those circumstances because the fuse has blown, that would make sense. If you're overheating for other, as yet unidentified reasons, you should not attempt to drive to France.

Problem fixed for £5.25. New relay and bon voyage!!! Thank you people. Other problems not so bad to worry about. Found where coolant is seeping from too. Weeping pipe where it joins the bottle. Next one on the list please.


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Yeeha - enjoy the trip

Problem not fixed as I found out whilst driving through Bordeaux in 36* with the fan on full at highest temp to keep it cool. That's hot!!!! Ran like a dream though even with the squeaky bum thing going on.


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Do you think a bad earth could be to blame? I can't see it my self!


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I think I'd concentrate on finding the cause of the overheating rather than fixating on the fan, which after all sounds like its doing its job.

The van is running fine. Just when in traffic the temp creeps up then the fan comes on as normal but blows the fuse or doesnt turn off?


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Just a general bit of advice, as OP hasn't stated any details of their van. One cause of excess current consumption by an electric motor (which may cause a protection fuse to blow) is simply excess mechanical resistance eg. bearings on the way out. Maybe time to consider a replacement fan. Be aware there are a number of different setups on the T3, so if swapping the fan, make sure to get the correct one:

200W single-speed, 2-pin rad switch only, S1/30A fuse
200/300W dual-speed, 3-pin switch, relay in position 5, S1/30A fuse
450/500W dual-speed, 3-pin switch, separate relay, dropper resistor for low speed, S1/30A *and* 50A metal link fuse

(NB. The above relates to 'late' wiring.)

PS. It might be worth visually checking the wiring where it runs to the fan under the front of the van, to ensure it's not chafed through and is intermittently shorting to the bodywork.

True enough. An old DC motor can draw a considerable amount of amps just to get going (old blower fans a good example of that). What you should NOT do is increase the fuse rating beyond what it should be.

Checked all the wiring that I could get too and all seems ok bar the fury earth terminals but that was my only thought about the fan. It turns very easily by hand without any resistance. But it is old. That was my next step on this long road to happiness.


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