Question about 2003 Saturn ION
My 2003 saturn ion blower will only blow air when its on the highest setting and even then its only a small amount,Any sugestions as to what the problem might be?
Lower settings as far as speeds for your blower motor go through a resister block to reduce the voltage your blower motor receives to make it turn slower. If it turns slow on high you would have to check the voltage at the blower motor, should be the same voltage that would be at the battery. There could also be material in the blower motor fan like things a mouse could have put there. Causes the fan to spin slower and also blocks the fins from pushing air. Any strange noises would be heard unless you have had the prob since you owned it and could not detect any changes. It could be even full of stuff and still
be in balance. but it could be a few other things.
Posted on Dec 23, 2008
I've found out exactly what is wrong with the issue of speeds 1-2-3 not working, and speed 4 acts like low speed.
I did all the usual troubleshooting of the blower otor, resistor pack, fuses, and relay, all were fine, and narrowed it down to the switch.
I fixed the problem by eventually pulling out the HVAC control panel, and implementing the following.
[B][U]Instructions on how to fix a 2003 Saturn blower control [/U][/B]
Find a safe place on a clean bench so you don't loose any parts.
1. Leave the knob attached on the front of the panel so the shaft of the switch does not fall out. It is holding springs, a plastic detent, and a steel contact BB in place, on the inside of the switch. You shouldn't have to remove the shaft. If you do, remember the steel BB goes on the spring on the outside, or larger diameter circle, and the plastic detent goes on the spring on the inner diameter circle. The steel ball is an electrical connection, and the plastic piece is for the detent positions.
2. Remove the 2 screws holding the blower switch in from the back of the panel. Orient the panel face down, and gently pry the 3 tabs open holding the back of the switch to the main control housing.
3. Pull the back of the switch apart slowly, there is a spring and a copper contact plate that will pop up when the switch back is pulled off. Note the position of the coper plate and spring.
4. If the 2 bumps on the contact plate appear clean and have dielectric grease on it, just leave it unless you have some more grease and want to clean the copper contacts.
5. On the end of the main shaft that sticks up inside the switch housing, there are 2 tabs or keys on the end. It is a 2 level double key. If these are broken or worn down so they don't grab the round copper contact plate , YOUR SCREWD :upset:, and need another HVAC Fan Control assembly or a good shaft out of another bad unit.
6. If it is still good you should be able to reinstall the spring and copper plate. With the bumps of the plate facing out towards the inside of the back of the the switch cover, and the spring on the end of the shaft, place the copper plate onto the keyed shaft while compressing the spring (there's only one way it will go on the larger first level key).
That is the first level keying, push the plate a little further till it goes past the second level of keying and turn the plate 90 degrees (I think it was counter clockwise, if not turn it 90 degrees clockwise). Start releasing the copper plate and it will fall onto the smaller set of keys, and be held in place by the larger first level keys. There is only one way the second level keying will go, because of the different sizes of the two tabs.
7. The spring will be compressed, and the copper plate should feel firmly in place, and rotate with the knob on the front of the shaft. Hopefully it should stay put.
8. Now snap the switch back into place and install the 2 screws. It should be ready to test.
Hopefully this works for you. I just did this repair and have no idea how long it will stay in place. However if the keying was in good shape, and you don't go spinning the dial wildly with great force:dizzy:, hopefully it will last awhile.
Willie The Wizard
Posted on May 04, 2012
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