Heater smelled like plastic was burning. Shut off the heater. Now light won't come on. Plastic on quick connectos to small switch (dime sized in diameter with two terminals) at the bottom of heater were burned. How can i test this switch to see if it's good.
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Are you loosing radiator fluid. sometimes the heater core will rupture and you will smell burn odor. also check for strange rubbing sounds or screeching coming from the blower fan motor. or engine exhaust manifolds are hot when car is on, make sure nothing is leaning on them which will cause a burn odor. Any odor coming from outside will find it's way inside through the fresh air vents.
This is a bad sign. The heating element has either come loose or the thermostat has failed to shut the heater down. Dont use it anymore. You can disassemble it and see what the damage is but the smell leads me to believe that it is damaged to the point that is should be replaced. Check the warranty to see if it is covered.
I have an older Chrysler Town and Country but I had the same problem, I found mine to be a leaking radiator, check all of your hose connections and if you have the flimsy plastic radiator in your van, get the more expensive aluminum version. The plastic radiator melts at the bottom because the are required to be grounded and sometimes this is not done properly, therefore sending an electric current through the radiator melting out the bottom, went through three of these before anyone let me know that they had to be grounded. If there are no leaks under your radiator or hoses, the next thing I would check is your cylinder head the burning smell could be dripping from your head to your exhaust. I would say you have a nice sized leak some where because with these vans if you do not have enough coolant in them they will not produce hot air fill your radiator up with more coolant and then test your heater, it should work but until you find the leak I would make sure to keep extra water/coolant inside the van.
It could be your heater blower motor or the blower speed regulating reisitor.
Try different blower speeds, see if the smell goes away. Also if one or more speed setting don't work, it is more than likely it is the resistor, if no to the tests, it is more likely to be the blower motor.
Also check to see if the blower intake is blocked.
it sounds like you have a main air movement system motor that is burning out. it will probably quit on you in the next few days. likely cost to repair from company 375-700 somtimes more if you have a variable speed furnace, in which case you should consider replacing the whole furnace for what it would cost for the motor on one of those.
the problem could be in the blower wheel or motor, is there a vibration with the blower on and grinding. i rec removing blower motor and inspecting that further. debris could be cought inside it or blower may need replacing. it may not be that bad of a repair $$.