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Re: AC/Heater User Fan Control - Melted Connector & Frozen Switch
That screw needs to tighten up into metal for a ground path. From looking at the wiring dia. the black wire grounds the relay case out by the blower motor. If it is not tight you will have a lot of resistance and or an open circuit. More than likely your fan switch was worn out and the extra resistance inside the switch created a voltage draw that over heated and melted the connector. I am glad to see that you were able to save the factory terminals. They are a much stronger connection then you can make by crimping a new terminal by hand. When I have to replace a terminal and hand crimp it I ALWAYS solder that new crimp.
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