I recently purchased a 1995 Chevrolet Van G20.  It’s a Cool Custom Conversion by Turtle Top.

1995 Chevy Van G20 Turtle Top

On the way home with this new toy, the Blower Fan stopped working.  This van has front and rear A/C.  The rear fan was still working, but the main fan in the front that blows air out of the vents for both the Air and Heat stopped.  It would not run in any setting, low or high.

Here is what I did to get it blowing cold air again!

1. First I checked to see if the fan was getting power.  For this you can use a test light or multi-meter.  I turned on the ignition key and set the fan on High.  There was no voltage at the fan positive side (purple wire).
   

   1995 Chevy Van G20 Blower Fan Motor

2. Next I checked to see if I was getting voltage to the Fan Relay.  To do this I removed the wiring connector from the fan relay and tested every wire.  There was voltage to the Red wire, but no voltage to pin 85 or 86 which turn the relay on.
   

   1995 Chevy Van G20 Blower Fan Relay

3. Since there was no voltage to turn the relay on, then it either had to be a blown fuse or bad fan control switch,.  Sure enough I found a bad 20amp fuse in the fuse box.  In the first picture it’s hard to see because it is right above the silver power relay.  In the second picture you can see it’s labeled HTR A/C.  Note:  Click on a picture to enlarge it.
   

   1995 Chevy G20 Fuse Box

   

   1995 Chevy G20 Blower Fuse

4. The blower was now working but I suspected there might be something wrong with the Blower Fan Resistor that caused the fuse to blow.  The Resistor is the little guy that lowers the voltage to the fan when it’s on a setting other than high.  It’s a little hard to see because it is located right under the relay.  To get to it you have to remove the relay, then remove the two little screws holding it to the blower box.  Here is a picture of the of it under the relay.
   

   1995 Chevy G20 Blower Resistor Location

5. I removed the resistor and it looks like the picture below. I found leaves, grass, and other debris that had been sucked into the blower box.  Not only were there leaves and such stuck in the resistor coils, but the box was just packed full of stuff as well.
   

   90s Chevy Van Blower Resistor

6. I cleaned all the debris out of the resistor but I also wanted to clean everything out of the bottom of the box.  The hole from the resister is pretty small, so I could not get my hand down in there.  It was also to small to get my shop vac hose in, so I used a piece of 3/4″ PVC pipe I had laying around as a vacuum nozzle.  I just cupped my hand around the end of the vacuum and the PVC pipe to create some suction, but you could duct tape it on if you want.  It worked out pretty good.  I was able to remove all the large stuff, then I used a water hose to spray it out real good.  It’s okay to spray it out with water because there is a drain hole in the bottom for condensation.   After it was all clean, I installed the resistor, and so far so good!  🙂
7. As you can see it has a bunch of springs/coils that can easily trap anything that gets into the blower box.  These coils can get very hot when the fan is running.  I’ve heard stories of smoke coming out of the vents because of debris caught in the coils that started to smolder.  There have even been recalls on some vehicles because the blower motor resistor was a “fire hazard”  The moral of the story is; always find the cause of a blown fuse, do not just replace the fuse and continue on.
8. It would be wise to do something to prevent things like this from getting into the box in the first place.  I believe it’s entering from the vents just below the windows.  This is not the only vehicle that has this problem.  I have seen some posts about other vehicle where people have installed mesh wire (window screen wire) over/under any openings that lead to the heater box.  I plan to look into this a little more.

I hope this helps someone who has an old Chevy Van like this with the same issue.