fan not working

I have a 200 tdi disco 1. The previous owner put a new electric engine fan in. There is a rocker switch in the cab which (to my knowledge) allows a manual over ride (off / setting 1 / setting 2).

The fan has never come on! I found a fuse holder today and the fuse was blow, so i replaced that, but still, the fan doesnt come on.

I am wondering if the thermostat could be broken? Am i right in assuming it would be the item with the 4 red crimp connectors on? If so, whats the best way to test?

Thanks

From the added timing case breather Id say your PO was a wading fanatic, coupled with a blown fuse, suggests the fan is FUBAR.

Discokids said:

From the added timing case breather Id say your PO was a wading fanatic, coupled with a blown fuse, suggests the fan is FUBAR.

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surly a blown fuse doesnt mean the whole thing is nakered? I have been reading the the fans don't often come on as the engines are very cold running, so ideally i guess i just want to trick the sensor so that i can test it...

Not necessarily but with the info I have (doesn't work, blown fuse, likes driving in water) it's a fair assumption. You're right about them hardly ever needing the fan, but Start with the easy stuff, put 12v to the fan and see if it works. If it does, test the sender. If it doesn't, it doesn't. Imagine the scenario, you're on s pay and play site, hi revs, low gear, you've been there all day, engines lovely and warm, fan going like the clappers, plough into a muddy puddle and boom, fan conks out and blows the fuse.

A blown fuse could mean an elecrical fault on the system somewhere, fuses very rarely blow for no good reason.
The first thing is to check that the fan actually works without all the sensing stuff, so I would disconnect it completely from the vehicle electrics and use two wires direct from the battery to power the thing. If it works as expected then proceed to checking into the temperature sensing stuff and its wiring. If it doesn't work then you've found the first fault.
The temperature sensor should switch at a given temperature, but to test the whole system, with the fan reconnected switch the ingition on to the normal running position, but without actually running the engine 'cos your fingers are going to be in there somewhere and that could smart a bit if you got caught in running engine!
Once you've got to that point, arrange to connect the two terminals of the temperature sensor together and the fan should run. If not then the fault is in the wiring, if it does run then the fault is in the sensor.
Just one other thing, I'd be checking that the pullies for that drive belt are properly in line, that bend as it comes off the bottom of the water pump pully doesn't look quite right.

[QUOTE="brian47, post:
Just one other thing, I'd be checking that the pullies for that drive belt are properly in line, that bend as it comes off the bottom of the water pump pully doesn't look quite right.[/QUOTE]

That caught my eye, I think it's actually his drag link.

Discokids said:

[QUOTE="brian47, post:
Just one other thing, I'd be checking that the pullies for that drive belt are properly in line, that bend as it comes off the bottom of the water pump pully doesn't look quite right.

Click to expand...

That caught my eye, I think it's actually his drag link.[/QUOTE]
Oh, yeah. Had to take a closer look at it before I could see that it was the drag link. Forget that I ever mentioned the drive belt!

Ok, I see where you are coming from now, Discokids.

Thanks for the advice ppl, I will have a look and see what I can work out! I am anxious I will not be able to identify what connectors are for the power though as I cant actually see where they go into the fan. I think the sensor has 4 connectors on it! I'll do some digging....

Right, so i took the feed cable off the relay and hooked it up to the battery - success, the fan works.

On the temp sensor (in the photo i attached) there are three cables, one is an earth. I then put the ignition on and joint the two - the fuse blew. Did i do something wrong, or is there a fault?

The wiring is all wrapped up in heat shrink so i cannot really see where the wiring is going to map it all out. If i can prove the system works without taking the heat shrink off, that would be great as its in a really awkward place!

Any help appreciated!

ok, looking for a bit of help / detective work for this one. I cannot trace what wires are connected to what as some are within heat shrink. I have traced out the wiring and switch connectors and hopefully somebody can fill in the blanks and avoid me cutting off the heat shrink! Any help with understanding how the rocker switch works would also be appreciated!

I disconnected the relay 30 and 87, bridged them and the fan came on.

One of the blue wires that comes out the switch is joint to several other blue wires from other switches (for the winch) and vanishes into the dash. I cannot trace it!