A/C - Poor Cooling Performance/Condenser Fan Fuse Blown
TECHNICALBulletin No.: 09-01-38-005A
Date: June 30, 2011
Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse and Wiring)
Models:
2006-2010 Pontiac G6
2007-2010 Saturn AURA
All Equipped with V6 Engine (RPOs LY7, LZ4, LZ9 or LZE)
Attention:
For 2008-2011 Chevrolet Malibu, refer to Corporate Bulletin Number 11-01-38-002.
Supercede:
This bulletin is being revised to remove the Chevrolet Malibu from the models involved. Please discard Corporate Bulletin Number 09-01-38-005 (Section 01 - HVAC).
Condition
Some customers may comment on poor A/C cooling performance.
Technicians may find that the cooling fan fuse is blown.
Cause
High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat.
Correction
Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse.
1. Disconnect and remove the battery. Refer to Battery Replacement in SI.
2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI.
3. Disconnect the underhood fuse block from its mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle.
4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI.
5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI.
6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape.
7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI.
8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan.
9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing.
10. Tape the end of the wire with electrical tape.
11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375.
12. Run the new wire through the fan wire connector housing as shown.
13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit.
14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire connector housing. Refer to Repairing Connector Terminals in SI.
15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape.
16. Connect the fan end electrical connector into the cooling fan.
17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance).
With RPO LY7
- Fasten the new wire and conduit to the existing harness with wire tie wraps as shown.
With RPOs LZ9, LZ4 or LZE
- Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.)
18. Trim the wire and conduit to length at the underhood fuse block area.
19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit.
20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI.
21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover.
22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI.
23. Reinstall the underhood fuse block into its mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478.
24. Reinstall the battery. Refer to Battery Replacement in SI.
25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI.
26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI.
27. Confirm the high speed cooling fan operation using the Tech 2(R).
Parts Information
* Use TXL type wire
Warranty Information
For vehicles repaired under warranty, use the table.
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