This thing is killing me. Its my girlfriends car...and she has no money for a dealer to poke around fixing. I'm gernerally able to resolve most issues, until they turn electrical.

She has a 2004 Cav Sport model. It has the 2.2 Ecotech, 5 speed, 60,000 miles, one owner, and the Check engine light is on. When I pull the Codes, it gives a p0480. The fuse was blown...I've replaced it, and the fan will operate when you turn the AC on. Eventually, the fuse blows again...not sure exactly what is causing it to blow, but I do know the fan functions. I've seen this problem elsewhere in this forum, but no follow up on what fixed the problem? Was it simply replacing the $25 fan motor, or a sensor? which sensor?

Any help would be greatly appreciated. I hate making her buy part after part to perform pot luck diagnosis.

I don't have an amp meter to determine what the fan is drawing when running.

i would just check the wires...i short somewhere is causing the fuse to blow

He's right, the fuse blows because more current's going through the fuse than it's rated value. You might check and see if you have the right fuse and not one that's too light. Otherwise you'll have to figure out where the shorted place is. Without a meter it's gonna be hard to tell unless you see something obvious. Might be some blockage in the heater fan making it hard to turn.

Check how well the fan is grounded. A poor ground will cause it to draw excessive current and cause a slow-blow of a fuse.

It could be a faulty fan, too, causing the same slow-blow scenario.

Thanks guys...bit the bullet...bought a new cooling fan motor...fixed the problem, cleared the code...actually solved a stalling issue she was encountering as well....I think there was a short in the fan motor. Turned out to be a simple fix.