Yeah, it's a new dealership and they are doing exactly what you said. 1 replace part, 2 replace part, hoping we're all not going to figure out the corporate pattern they are forced to follow, following their "chart" of what to replace next instead of doing actual analysis of the real problem. They have a great customer service staff though and a great waiting area, shuttle service and I have a loaner vehicle after all this, which has helped tremendously instead of the monthly incovenience of not being able to drive my overheating van due to their lack of "sight" in to the problem. Not complaining about any of their handling of me personally, but when it comes to figuring out a "real problem" there is no "figuring involved" here no matter how pretty the dealership looks. It looks as though they are holding to their Honda company procedures manual and "hoping they get it right" along the way.
I think what would be a good idea is to tell them to keep and drive the van a few days and check the resistance drop on the new relay after each drive till they witness the pastic around it starting to melt again. If the resistance starts to climb during the relay's "closed gate/door mode" (electrical talk) then they will see that they haven't fixed the problem yet again because that relay is gonna melt all over again with 30 to 40 days time "like clockwork".
Yes, I could fix this myself. I'm very good at DIY for cars and otherwise, but I don't have the time right now. I know another shop that could fix it in a day, because they actually do "ANALYSIS" and not a book procedure without thought involved..... but honestly I'm hoping that the lead service manager's analysis of a "loose connection at the relay/fuse box" will prove true if anything else to prove he was right, because his master tech hasn't been right once (on this issue).
Parts paid for so far after 5 visits are:
1. 1 New OEM Honda cooling (or condenser) fan - and I can't remember which one I paid for because they ended up replacing BOTH AGAIN on their DIME along with the radiator they punctured.
2. 2 or 4 sets of relays
3. Labor to replace all that 1 time
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4. All other visits labor including replacing the fans a second time has been covered by them.
5. What they want me to pay for (Monday likely) is a new engine compartment fuse/relay box.
6. I'm not sure there will be a #6. I know they don't want me to come back when it fails again the exact same way, but on principle it should go back for a #6 and them fix it as was intended many months back on the 1st visit for the cooling fan they had me replace that was actually FINE to begin with, but they won't admit that now (too much muddy water).
Take 2 wire with alagator clips and hoo then direct to the fan in question with the loose end to your battery. Fan will run if good or it won't.
Thanks for that procedure as well sir, but we're at the point far past just 1 cooling fan motor being the culprit. As nitely2 said, it's in the wiring somewhere and likely as easy as a ground point or bad cable or bad battery cell or alternator on the border of death - ALL OF WHICH THEY HAVEN'T BOTHERED TO MENTION IF THEY'VE CHECKED AT ALL YET despite me giving them these helpful suggestions.
The world is full of "speed" and these days when people can't fix or do something fast it's looked at as not worth it or worse yet "too much trouble to deal with" - and this is the attitude I am encountering at the dealership whenever I challenge anything they tell me..... as if I'm supposed to still be calm and cool and HAPPY as I was the 1st day many months and many visits ago when I dropped it off. I've got no reason to be professional or HAPPY or even calm about any of this and what is more frustrating is that I sense they think I'm "messing with them" on this whole thing because they can't believe they haven't fixed it yet when they are not giving the problem true ANALYSIS to resolve it. YOU HAVE TO STEP OUT OF THE BOOK TO SOLVE THESE KINDS OF PROBLEMS...... BUT I SHOULDN'T HAVE TO TELL THEM THAT. THEY SHOULD'VE JUST REPAIRED IT THE 1ST GO AROUND. But here I am on my quest of principle because "It's what's right, no matter the trouble."
Thank ya'll and I shall post back the results of this debacle.