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Forums › The Car › Solved 206 Problems › Corroded Fan relay wiring, replacement and access |
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 Posted: Tue Feb 04, 2014 7:30 am |
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Joined: Feb 03, 2014
Posts: 12
Trade Rating: 0
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Following on from a previous post Re blowing fuse.
I have checked the fan relays. Neither are very clean, the lower green has lots of corrosion on the fins but, it is the fat green wire that feeds this lower box that was disconnected. It has completely corroded through at the point where it enters the box.
I have no manual or knowledge on these cars so, new questions -
1) What does this thick green wire feed?
2) Im thinking I may as well replace the relays. Where can I get them, what do I look for, are they generic or specific to this car?
3) Where can I get the 'cradle' that the relays plug into? The existing one has so much corrosion gunk on it I cant get the wires out so will need a new one, cut and refit female spades to all the wires.
4) How do I remove the front of the car so I have access to the wires? I have got the first bit of plastic off, the part with the logo badge that wraps around under the lights but Im unsure how to get the grill or more off.
Many thanks
206 1.4HDI SW 2005
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Last edited by matty_hunt on Tue Feb 04, 2014 8:00 am; edited 1 time in total
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Posted: Tue Feb 04, 2014 7:51 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Relays are just standard high current relays. Nothing special. The relay holders can be replaced with standard relay holders too. You'll just have to screw them into the housing. I can't remember how the originals are fitted.
If you look at the lower crossmember it has an earth point on the back of it - a 10mm bolt with a wire going to it. That is the earth (-ve) for the fan. Which should go direct to the fan in a roundabout way.
To each relay you'll have a thin +ve and -ve wire. That switches the relay on and off. To one relay you'll have a thick +ve wire in and out - this is for the high speed fan - thick cable = high current. The relay makes and breaks this circuit.
You'll also have a relay with the same set up but with a thinner +ve cable. This is for the low speed fan and might go via a resistor to reduce the current to the fan. Depending on how old your car is these thicker +ve wires go to the fuse box sharing the same fuse.
Ideally you need to get the front bumper off. Wheels off, arch liners removed and I bet the 10mm nuts holding your bumper to the front wings are corroded!
The 40 amp fuse here is for 2 x +ve fan wires (dependent on what age of car you have). Get a decent terminal crimper too.
All my wiring went in the bin.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Tue Feb 04, 2014 10:56 am |
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Joined: Jun 04, 2010
Posts: 1691
Trade Rating: +3
Location: northallerton
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whats this bit for??
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Posted: Tue Feb 04, 2014 11:44 am |
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Joined: May 16, 2011
Posts: 495
Trade Rating: +1
Location: huddersfield
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Thats the resistor that Edward mentioned.
Located on the fan loom near the bottom of the radiator.
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| 206 2ltr Hdi glx 53 plate | |
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Posted: Tue Feb 04, 2014 12:15 pm |
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Joined: May 16, 2011
Posts: 495
Trade Rating: +1
Location: huddersfield
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| 206 2ltr Hdi glx 53 plate | |
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Posted: Tue Feb 04, 2014 1:17 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Resistor can be seen here. Green wires going to it at the bottom of the radiator housing.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Tue Feb 04, 2014 5:45 pm |
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Joined: Feb 03, 2014
Posts: 12
Trade Rating: 0
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Many thanks guys for the help. All interesting stuff. Looks like, once the rain stops, I will have to pull the front end off and have a good inspection all 'round. I am struggling to find the parts online though. Found a relay on ebay, just waiting to hear back if its the right one, but where do I get the relay holders from? Other than possibly a scrap yard or Peugeot garage.
Cheers
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Posted: Tue Feb 04, 2014 6:59 pm |
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Joined: Feb 03, 2014
Posts: 12
Trade Rating: 0
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Are the relays simply called 'a change over relay'? Whilst the one from the car says 35Amps there are loads of changeover relays on ebay, various unknown to me brands, for a few quid 30a/40amp or 40amp, some with holders. (none came up before when searching for relays hence my previous questions) There are none marked 35Amps so will these others do? Are they the correct type of relay for the fan or should I buy a genuine part?
Cheers.
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Posted: Wed Feb 05, 2014 12:43 am |
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Joined: Apr 14, 2010
Posts: 713
Trade Rating: +2
Location: Gothenburg, Sweden
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| matty_hunt wrote: |
Are the relays simply called 'a change over relay'? Whilst the one from the car says 35Amps there are loads of changeover relays on ebay, various unknown to me brands, for a few quid 30a/40amp or 40amp, some with holders. (none came up before when searching for relays hence my previous questions) There are none marked 35Amps so will these others do? Are they the correct type of relay for the fan or should I buy a genuine part?
Cheers. |
Technical term is normally 'single pole, dual throw' for a relay that has a common terminal that while the relay is not activated is connected to one terminal and while. activated is connected to another terminal (ie change. over).
A 'single pole, single throw' only has one of the two terminals (other than the common) and can then be of either 'normally closed' or 'normally open' depending on if the terminals are connected or disconnected while the relay is inactive.
A 40A relay will do fine - a higher current rating simply means that the relay can handle more current through the switching contacts.
(run to high current and you risk [arc]welding the contact elements together).
A dual throw relay can take the place of a single throw (simply ignore one of the terminals), but not the other way around.
Also, while the layout of the terminals is generally standardized, OEM stuff can, seemingly just for the heck of it, sometimes have different layout than 'standard', so make sure to identify the terminals, their positions and don't just blindly wire it up the new sockets 'like before'...
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| Silvermetallic 2004 206 RC | |
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Posted: Wed Feb 05, 2014 1:28 am |
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Joined: Dec 03, 2012
Posts: 96
Trade Rating: 0
Location: Doncaster
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When i replaced mine i purchased the new genuine off the shelf part from Peugeot.
Relay was £5/6 each.
Resistor was £18 but that had to be ordered in for the next day.
Regards, Richard.
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| Life would be easier with universal jointed arms and fingers sometimes | |
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Posted: Wed Feb 05, 2014 9:51 am |
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Joined: Feb 03, 2014
Posts: 12
Trade Rating: 0
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Many thanks everyone. I purchased a 40Amp changeover relay with plug and wires for £4.18 from ebay. It does not have the built in resistor in the relay but does have an external diode which I understand is better at suppressing voltage spikes. Hopefully it will arrive Friday. My plan is to wire it all up and encase it in an old bicycle inner tube held on with zipties. Although probably on necessary, its taken nine years to corrode, I cant see the harm.
Cheers
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Posted: Thu Feb 06, 2014 2:08 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Just got to Auto Elec supplies or Polevolt. A bit of grease on the bottom of the terminals will seal them.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat Feb 08, 2014 6:56 am |
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Joined: Feb 03, 2014
Posts: 12
Trade Rating: 0
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Many thanks again for all the advice given guys.
Stripped off front of car yesterday, wired in new part, all working sweet. You have saved me a pretty penny by not having the garage or auto electrician look at this, so a big cheers to you. CHEERS
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