Technical ducato 2017 blower resistor

[jabmesen]

Hi- I hope someone can help me!
I have a Fiat Ducato 2017 130 Multijet 2.3 D 250_
However somebody has cut off the blower resistor and plastic connector and taped up the wires.
The blower does work at full speed but there is no 1,2,or 3 speed. The part I am told is a 77364061 ....like this:

HEATER BLOWER RESISTOR + WIRING LOOM REPAIR PLUG FITS BERLINGO PUNTO CORSA | eBay

Find many great new & used options and get the best deals for HEATER BLOWER RESISTOR + WIRING LOOM REPAIR PLUG FITS BERLINGO PUNTO CORSA at the best online prices at eBay! Free delivery for many products.

www.ebay.co.uk

However, unless I have the wrong cables- which I would be very surprised at- there are only 4 cables (black, grey with red stripe, grey with black stripe and white with black stripe). so they don't tally with the loom repair that I could buy, so I won't know which ones to connect and unless 2 of the cables need to be connected together (quite possible), I don't have enough connections. I found this wiring diagram- though I'm not 100% that its the one I need

E6010 HEATER WIRING DIAGRAM - Fiat - DUCATO - eLearn - 4CarData

I'm a bit stuck. can anyone help please ? any help would be gratefully received

 

[Communicator]

A similar problem has been previously discussed on this forum. May I suggest using the forum search facility to search for "heater blower resistor", or perhaps "Ducato heater blower resistor".

The drawing that you have found online is incorrect, and will not work, due to a drawing error in Fiat eLearn, also it is for the earlier x244 (2002-2006) model.

If you have aircon, the wiring may be different. I am attaching my corrected version of the drawing that you posted, a colour code translation chart, and a previosly posted photo copy of the diagram relating to your vehicle.

I have just discovered that I have a copy of the eLearn Packet Print for x250 aircon, which also shows the heater fan. Added.

.

 

[Anthony489]

Hi

The blower fan resistor pack you have linked to does not seem to specifically list the Ducato. There are many versions of resistor pack for different vehicles which are all slightly different.

I would strongly urge you to fit a proper replacement, even if this means sourcing it from a Fiat dealer. If the loom and plug is undamaged, it is an easy plug-in replacement with no need to faff about joining wires or work out which colour goes where.

If the plug and socket has developed a poor contact, the high current flow may have generated enough heat in the past to damage the loom plug. Look for damaged/melted plastic and/or discoloured metal contacts. In that instance you will have to splice in a new plug.

It seems very odd that someone has not already repaired this properly and safely. It's possible that the airflow is restricted in some way (e.g. blocked pollen filter), which will have overheated the resistor pack and blown its built-in thermal fuse. Any replacement pack may have quickly suffered the same fate, so I suggest you check this out.

WARNING: These resistors generate a lot (tens of watts) of heat, and would glow red hot were it not for being placed in the cooling airstream inside the ducting. If anything goes seriously wrong with this process there is a risk of a fire breaking out in the plastic duct. Just google "Vauxhall Zafira Fire" to see what I mean. It is therefore essential that a proper repair is done.

To add to communicators diagrams, I attach a marked up elearn one for the 2006 to 2014 X250 models. If you have aircon it will be slightly different.

 

[jabmesen]

Thanks communicator and Anthony489-I really do appreciate your response and concern.... I will hopefully be able to piece together the info I need from the other threads- but as yet- I'm still a little in the dark.

The ebay resistor and loom doesn't mention Ducato in the headline, Anthony, but when I put my reg no. in- it says it is suitable, so...

There is no air con in my Ducato (unfortunately) so the diagrams could help a lot-what are the codes on the wiring diagram (N,BN,HN,HR)- colour codes or something else? I'm getting the impression from another thread (that one of the cables is redundant from the replacement loom...If I can't work out the colours pehaps I can do continuity test between the neutral and the other cables with the blower in different positions? I wonder if I need to have ignition on for this?

It is noteable that the cables all seem the same gauge on the replacement looms that Ive seen and the cut cables are, I think 2 thicker and 2 thinner gauge - so I will bear this in mind as you tell me there is a lot of current involved....

Also just for your interest- I bought this van at an auction ; it was a highway maintenance van in it's previous life and I suspect that they ripped the resistor and loom out for another vehicle in the same way as they ripped a few other things out(eg. surely they wouldn't have just lost all of the headlight dust covers!!!) auction buyers beware

 

[jabmesen]

oh - just seen the colour code sheet- thanks communicator!

 

[Anthony489]

Hi again

Just to guide you through the operation, and referring to the circuit I attached:

Power goes first to the fan motor, then flows through the resistor unit, then through the speed switch and finally to ground. With the wiper of the switch fully anticlockwise and connected to Pin 2, you get the lowest speed using all three resistors (rectangles) in series. Move the switch to Pin 3 and only 2 of the resistors are in circuit. Pin 4 is Speed 3 with only one resistor, and finally Pin 5 is Max speed with the resistors bypassed. At Max speed the current is typically 20 to 25 Amps, at lower speeds it is reduced by the action of the resistors.

The colours are noted on this diagram in yellow.

If you use a multimeter to check resistance or continuity, it's always done with the circuit "dead" (no power). The multimeter produces its own small test current, and if the circuit was live that would swamp it and you would read nonsense.

The resistors are only about 1 ohm each, so not easy to read accurately but it can be done with care.

 

[jabmesen]

Thanks Anthony489- you are a gent! yes- that makes perfect sense and according to the diagram- it is pin 4 that is not used.....I will post my resolution (probably in the new year!) when/if I get one......so impressed with the help- thanks.

 

[jabmesen]

New Year's Resolution!....right - I have just soldered the loom and put the resistor in- and it works on 4 speeds, so thank you very much Communicator and Anthony489 for your great help!!!
There are two noteable caveats!
1. I could not buy a loom from the dealer for less than a few hundred pounds! so I bought a resistor with the loom- however all the cables are a standard cross sectional area on the bought loom, while 2 cables in the existing system are bigger (you'd think that would be because they carry more current- but I'm not sure that is the case!? but I will be keeping careful note as to whether there is any burning smells, at least for a while...)
2. I had to swap the BN and HR cables round from that shown on the diagram as the blower speeds were in the wrong order to start with...
Again- many thanks for the support- fab!

 

[Communicator]

New Year's Resolution!....right - I have just soldered the loom and put the resistor in- and it works on 4 speeds, so thank you very much Communicator and Anthony489 for your great help!!!
There are two noteable caveats!
1. I could not buy a loom from the dealer for less than a few hundred pounds! so I bought a resistor with the loom- however all the cables are a standard cross sectional area on the bought loom, while 2 cables in the existing system are bigger (you'd think that would be because they carry more current- but I'm not sure that is the case!? but I will be keeping careful note as to whether there is any burning smells, at least for a while...)
2. I had to swap the BN and HR cables round from that shown on the diagram as the blower speeds were in the wrong order to start with...
Again- many thanks for the support- fab!

Sorry about that. It may be that I didn't dig deep enough when correcting the error in the original eLearn diagram, which was nonesensical.

Pleased that you have succeeded and reported back.

 

[MilkShakeDnB]

New Year's Resolution!....right - I have just soldered the loom and put the resistor in- and it works on 4 speeds, so thank you very much Communicator and Anthony489 for your great help!!!
There are two noteable caveats!
1. I could not buy a loom from the dealer for less than a few hundred pounds! so I bought a resistor with the loom- however all the cables are a standard cross sectional area on the bought loom, while 2 cables in the existing system are bigger (you'd think that would be because they carry more current- but I'm not sure that is the case!? but I will be keeping careful note as to whether there is any burning smells, at least for a while...)
2. I had to swap the BN and HR cables round from that shown on the diagram as the blower speeds were in the wrong order to start with...
Again- many thanks for the support- fab!

Hello, is it possible for you to send a photo of how you connected the cables to the plug?