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if you changed the thermostat and res. I'd say your heater-core is clogged or the radiator, or your fans are not turning. Could also be your coolant is to diluted with water as in 70 percent water 30 percent collant.
If the "noise" is a fluttering sound (like fan blades are engaging housing or other internal structure), you need to trace this and clean or adjust it internally so it doesn't hit stuff. Cleaning it periodically (monthly) should be a given.
If the fan motor itself is grinding/losing a bearing, you will need to replace the motor. Note that there are different models/configurations for various models, you need the right one. I used to buy mine direct from EcoQuest, but they've changed owners in the last year, don't know if they still sell them as parts.
I think you can find motors on the Web, but you'll pay a premium price for single units, better to buy a used purifier off eBay/craigslist or find one at a garage sale, and cannibalize it.
I think I have one fan motor left in-stock (new); I can check to see if it's the right version if you want. I'd want $30 for it, plus shipping - you can likely do better than that if you're willing to hunt.
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Sounds like the same problem I had with mine. I had to call and get an RMA number and they replaced the key pad, lcd display, and main board. This repair was covered under warranty. (Under 3 years old) They had it repaired and returned in about a week.
The control component or the control circuit for the fan can be causing the speed variation, or the bearings on the thing can be wearing (or contaminated) with the same result. If you can make a test bench, look (feel with a test pad, really) for drive transistors that get hotter than they should or an inconstant power resistor or shunt.
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