I swear about every 6 months or so, I need to redo the wiring before the relays to one or both of the fans. I don't get it. I also can't even remember how many times I have replace the fan motors. Are these cars notorious for this or did I just get a lemon? What could possibly be making this happen?

 

Are your fans staying on all the time?

What wires are frying?
Wires to relay coils, or wires to the fan motors?

Does your ECM control both motors, or just one?

 

No, the fans do not stay on all the time. They are factory so they should only come on as programmed. One is ECM controlled while the other is strictly temp sensor controlled I believe. The wires before the relays.

 

They are obviously getting heat from somewhere. If from the wires than you are drawing to much current and the wires are getting to warm. Could be from an outside source like the exhaust.

 

possibly incorrect gauge of wire maybe?

 

Gremlins! They do it every time!!

Need to know exactly where the wires are burning out. Is it at the connectors? In the middle of the wires? Before the relay? After the relay?

 

Seems to always be at the connectors prior to the relay. The last fix I did was basically like a heart bypass surgery where I tapped on a wire from before and after the connector since the connector was extremely fried. I beginning to think that the connectors in these cars were totally under engineered as I have other connectors fried in this car. Or maybe it is those pesky little gremlins that seem to love these cars!

 

It could be a number of things, poor wiring, bad grounds, ect.... I have seen cases where fans have started to go bad and started taking out other parts of the electrical system due to a much higher current draw.

 

That's what I'm wondering. Do you think these particular model fans are just a bad design? Seems like the fans start getting rusted after awhile and start making more and more noise as they spin.

 

Are they GM, or aftermarket fans? By any chance do you have a radiator or hose leak, that might be spraying on the fan motors however small(reason for rust)?

 

You may have something there. I do occasionally smell radiator fluid and I do have to fill it up now and then but it must be small because I can never find the darn leak. I replaced the water pump about 2 years or so ago but it was after market from AutoZone with a lifetime warranty.

 

check your grounds, just because they look good it means nothing, remove them and clean them, check they amp draw of the fans, i believe they should be under 20 amps for both. make sure you have the right relays also. just because they plug in does not make them correct

 

Is there any free or low cost way of determining the amp draw of the fans? Last time I was going to do this I realized I had to buy an expensive amp meter that I would probably never use again.

 

This would have been twice!
There are inexpensive gauges out there,or try a auto repair shop they would probably check them for free, if they think they would be getting some work.

 

hit up a mechanic friend, or go to radio shack and buy one. once you learn to use one and get used to waveforms you would be amazed what you can check ie:fuel pumps