Alfa Fan Failure: Common Causes and Repair Guide

Had the exact same issue with my 2005 Alfa 159 last winter. Have some experience working on basic HVAC system repairs, but this one needed professional help. The symptoms were identical, no air flow, completely dead blower motor, and unresponsive controls. After checking the basic electrical wiring and fuses myself, I took it to a workshop. Turned out the blower motor itself was totally burned out, not just the speed controller as I initially suspected. The repair included: Removing the complete HVAC unit, Replacing the blower motor, Testing the electrical connections, Resetting error codes Total cost was 365 Euro including parts and labor. Workshop time was about 3 hours. Before suggesting specific fixes, could you share: Any unusual sounds before the heater fan stopped working? Have you checked the fuses? Does the system make any noise when you switch between different settings? When was the last time the cabin air filter was changed? This info would help determine if your issue matches what I experienced or if it might be something different in your HVAC system.

Had my car serviced last month at 102506 KM. After checking the basic fuses and connections, I noticed no unusual sounds before the cabin fan stopped. The system is completely silent when switching between settings. I have not replaced the cabin air filter in a while, which could affect air circulation. Just tried checking voltage at the connector behind the glove box, getting no reading at all, suggesting it might be an electrical issue interrupting power to the heater fan rather than a mechanical failure in the HVAC system itself. Would appreciate input on whether this sounds more like a wiring problem vs a failed blower motor. Want to diagnose this correctly before replacing parts.

Thanks for those additional details. Based on your voltage readings and comparing to my Alfa 159 experience, this does point more toward an electrical issue rather than a complete blower motor failure like I had. The key difference is that my blower motor was making grinding noises before failing completely, and I still had voltage at the connector. Your situation with zero voltage suggests the problem lies in the electrical wiring or fan speed controller circuit before it even reaches the blower motor. Potential next steps to diagnose: 1. Check the fan speed controller unit behind the climate control panel 2. Test for voltage at different points in the electrical wiring harness 3. Inspect connector pins for corrosion or damage A faulty fan speed controller often causes these symptoms and would explain the complete lack of voltage. This would be a cheaper fix than the full blower motor replacement I needed, typically around 120-180 Euro for the part. Since your cabin air filter hasnt been changed recently, definitely replace that as well when fixing the electrical issue. While it wouldnt cause a complete voltage loss, a clogged filter can strain the system.

Thanks everyone for the input. After checking the voltage readings more thoroughly and tracing the electrical wiring, I found a bad connection at the fan speed controller. The connector was corroded and had a broken pin. Got the controller replaced along with a new cabin air filter. Total repair cost was 165 Euro including parts and labor. The air flow is now perfect and the heater fan responds normally to all settings. Much cheaper than a full blower motor replacement and exactly what was needed. The electrical issue definitely matched my symptoms better than mechanical failure. Good to have proper air conditioning again, the garage confirmed the old controller had completely failed, cutting power to the entire system. Really appreciate the diagnostic help in tracking down the electrical problems. Would have hated spending money on a new blower motor when it wasnt actually needed.