I know lots has been posted in the past regarding this issue but I don't think my question is covering old ground again. I have searched and read.

My problem is the overheated/melted/burntout resistor pack connector one.


So on to the repair -
I have ordered a new resistor pack from an ebay seller and I have a used connector and cables coming from a fiat breaker. My intention is to cut off the old connector, fit the new resistor pack, trim the wires on the 'new' connector and then join the new connector to old loom via a terminal block.

So my question is: what rating of terminal block do I need? At the moment I have a 15A one coming from another ebay seller, will this be sufficient? I think it should be fine but then I don't want to fix the car just to burn it out completely a few months later!

And can anyone see any flaws in my intended 'fix'?

Well I went ahead and fixed it. The resistor pack cost ~£17 brand new from ebay and the connector (with wires attached - about 3 inches) from a breakers cost £20. I got a 15Amp terminal block for 99p (again ebay). Total cost of repair just under £40.

The connector that I was sent was missing a wire though (4 instead of the 5 needed) so I had to remove one of the unmelted pins from the old connector and solder it onto a decent sized piece of cable I had in the garage from previously fitting a shower (in the house not the punto!).

Job done now though and the heater fan works on all speeds and every time - well pleased.

Read this post with great interest
For the life of me I cannot see how to remove the resistor pack from the bulkhead.
I read in the Haynes manual, remove a screw - in my case no screw

Can you tell me how you achieved its removal