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1991 Dodge Caravan 3.0 auto 4sp Wires in the main wiring...

<< Back to: rec.autos.makers.chrysler FAQ, Part 1/6

Question by harv
Submitted on 4/11/2004
Related FAQ: rec.autos.makers.chrysler FAQ, Part 1/6
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1991 Dodge Caravan 3.0 auto 4sp
Wires in the main wiring harness are burning when trying to start vehicle. Suspect wire is a fused link and goes to a relay on the inner fender supposedly operating in conjunction with the rad fan and sending unit.
Any suggestions welcome!

Answer by captn_carrot@yahoo.com
Submitted on 10/30/2004
Rating: Not yet rated Rate this answer: Vote
My Mech said the reason for the relay/harness burn-out is that the rad fan is pulling too many amps.

My fan relay has burned out four times in the past year on hour-long trips when I am using all the electronics (a/c (front and rear) radio) The connector itself burns out about every other time, on the lead to the rad fans.

The relay is fairly easy to replace, (1 to 2 hour job for shade-tree type (i.e, me). I am currently looking for another new connector without spending a lot buying the whole wire-harness. (My connector burned out two days ago.) I will just cut off the old one with a few inches of wiring and crimp the newer one on.

It is said you can solder on new "leads" in the connector, but they may come out the back when pushing in the new relay.

The costs:
the relay - US $80. Just bought one at online auction for $35.

The fan - I own a 1998 dodge. two fans system: Dealer said would cost $389 plus tax. Auction has them about $90 to $150.

The connector - found on wrecked van in salvage yard, it came with the relay for $20. (Engine and other parts had been pulled- so some vans may not have the relay/connector intact). They seem harder to find than expected. Be sure to search van families (Chrysler, Plymouth) and not do like I did and just mention Dodge.


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