1. Attachments are working again! Check out this thread for more details and to report any other bugs.

Shorted Blower Motor Wiring Harness Connector: damaged Blower Motor Controller or A/C Controller

Discussion in 'Generation 1 Prius Discussion' started by Stelu, Jun 4, 2016.

  1. Stelu

    Stelu Junior Member

    Joined:
    Jun 3, 2016
    4
    1
    0
    Location:
    Tx
    Vehicle:
    2003 Prius
    Model:
    N/A
    This is my first time on any forum of any kind. I have spent the entire day trying to fix this problem unsuccessfully and I need your help. Let me give you a brief history: I bought this 2003 Prius three months ago and the previous owner told me that it had an intermittent problem with the a/c. The fan ran only on high, and sometimes it would stop. I figured out that if I reached down and pushed on the wires connected to the blower, most of the time it would start up again. The other day, I did the same thing again and the fan stopped working for good, while I smelled burned rubber/plastic. Today, I looked into it and found a short at the blower wiring harness connector. The two wires had lost their insulation and were partially corroded and touching each other, while the connector itself was blackened at the joint (had I looked into this immediately after I purchased the car, instead of feeling around Stevie Wonder style, I wouldn't be here right now, but that's another story). Anyway, here is what I have done so far: I connected the blower motor directly to a battery and it ran; I checked all the fuses and interchanged relays; then, with the fan on high, I used a check light and found that when not plugged in, the blower connector has power on one of the wires, and on both after it's plugged in. I know from reading on this site that many resolved a dead blower by replacing the blower motor resistor when the motor was not faulty itself. From other threads, I saw that the A/C amplifier could also be a cause. I went through the sequence suggested by the service manual to detect DTS codes (IG on, Fan off, AC button pressed 3 times, Fan Auto: after the first four blinks, I got a pause and then two blinks, then again a pause and two blinks etc, but I do not have a reading tool to read any codes...). So, here is my question: what would a short in the connector be most likely to damage? When I first saw it, I almost breathed with relief thinking it surely was a fuse, and consequently, it was going to be a very easy fix. All the relief is gone! Please, help me out!
     
    #1 Stelu, Jun 4, 2016
    Last edited: Jun 4, 2016
  2. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    24,904
    16,213
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV


    Your car doesn't have a "blower motor resistor", but it does have a blower motor control that sort of looks like the blower motor resistor your grandfather's car would have had, and located in the same sort of place (mounted into the ductwork near the fan), but it's an electronic part, not just a resistor.

    It is different from the A/C amplifier, which is a circuit board behind the center dash controls, coordinating the whole thing.

    If your wiring problem damaged one of those things, my first guess would be the motor control. It's the one that's directly in that circuit. (The A/C amplifier only sends marching orders to the motor control.)

    By the way, after you discovered the wiring problem itself, what did you do to repair it?

    As to the code 22 that you pulled, I'm not near my Gen 1 service manuals right now and I don't remember what 22 is offhand, though it sounds familiar. A forum search might turn up details. It could be a separate issue from your blower issue.

    -Chap
     
  3. Stelu

    Stelu Junior Member

    Joined:
    Jun 3, 2016
    4
    1
    0
    Location:
    Tx
    Vehicle:
    2003 Prius
    Model:
    N/A
    Thank you for input, Chap. I haven't done anything about the wires yet except for making sure they don't touch each other anymore. I found the part no. 90980-10214 for the shell of that connector and ordered it. I also bought a used blower motor controller on ebay. I'll fix everything when the parts come in.