We used an air hose to blow through the blower motor and air channels. Although it helped it is still an issue. Is it possible that a buildup of dust and dirt could cause this?
First check the air intake to the climate system. ie. the cabin filter etc. for contamination.its more than likeley the blower speed control unit is faulty. may be resistance or electronic module depending on vehicle. sounds like plastic is overheating to give that problem. without knowing what vehicle it is the only clue that i can give you is that the speed control will be in the air intake before the climate unit ie. heater/aircon behind the dash. hope this helps.
The burning smell could be due to gas leakage in the engine compartment. The gas smell is being sucked into the fresh air intake of the air conditioner. It can be avoided by checking either fuel pressure regulator or fuel injector.
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