the bentley electrical schematic is very hard to read for the
green resistor. BUt your symptoms definately point to it.

I bought a replacement "Ballast resistor" through BusDepot.
[$29 for models with AC] which fixed the problem on my
1990 immediately.

you can test the relays and motor by simply jumping the fan switch right?

Tom

        ----------
        From:   Steven Dodson - Epoch Product Design
        Reply To:       Steven Dodson - Epoch Product Design
        Sent:   Monday, October 20, 2003 2:23 PM
        To:     vanagon@GERRY.VANAGON.COM
        Subject:        Infamous Big Green Resistor! Help!

        My problem is: Engine runs hot when idling and driving at slower
speeds
        (especially climbing hills) because the low speed fan is not turning
on. I
        had this problem early last year and resolved the issue by replacing
the
        cooling fan switch. I find it hard to believe that the switch is bad
        already.
        Answering to an earlier plea, someone told me it was a resistor
problem.
        Can anyone tell me where Bentley refers to this Big Green Resistor
that
        resides behind the drivers-side headlight?
        I can't find a part number on mine and the VW dealer can't pin-point
one
        either.
        The best guess the dealer has is part #251 971 284 E for $146.10
(but it
        refers to a wire harness, not a resistor).
        Is this right?
        Is this resistor connected to the 2-speed cooling fan switch? I
don't see
        the resistor in the Bentley schematic.
        There is reference however, to a relay in the schematic. Do these
relays go
        bad?
        Anyone with experience in this issue?

        Any help would be greatly appreciated!

        -Steven Dodson
        Kneeland, CA
        "Inga" the 87 Syncro