At 11:36 AM 10/21/2010  -0400, Jonathan Berg wrote:
>My first Westy (an 89) melted the switch on the #3 setting.

I've said it before and no doubt I'll say it again: that switch is
overloaded at the full-speed position.  I recommend using that
position to control a relay that does the actual switching.  Saves
having the body melt and the contact sink down so you can't switch
the blower off.

On the 1.9l the circuit is also overloaded, which is why the fuse
cover is melted over that position.   For these vans I also recommend
adding a separate fused circuit to actually power the high speed,
which draws about twelve amps.

To add a relay, use a standard 4-terminal automotive relay.  Hook the
30 (B+) terminal into the wire feeding the switch (or on a 1.9l add a
fused circuit for the 30 terminal).  Ground the 85* terminal.  Cut
the high-speed wire from switch to fan; hook the wire from the switch
to the 86* terminal and the wire going to the fan to the 87 (load) terminal.

* The 85 and 86 terminals are the control terminals.  It doesn't
really matter which one you ground.

And if you get a switch from a junkyard, make sure it's from the rear
blower and not the front.  The rear blower doesn't overstress the switch.

Yours,
David