Below are several interesting photos sent to me by Elise.
They are from a 1.8 and two later (2004/2005) CDTs all are later versions of the Fan Motor assemble featuring a dirty great resistor to provide the lower speed
The motors although physically similar have had their brush connections redesigned internally the motors still use four brushes but they have now been paralleled up in pairs to increase their life
Note these motors if bought individually will not be direct swaps with earlier vehicles’ without a bit of rewiring in the relay box but a complete assembly with relay box and resistor will be a direct swap as long as somewhere can be found on the original fan shroud for the resistor which must be in the airflow or it will not last long.
You will notice only two wires going to the motors one is a permanent live from the main fuseable link the other is a switched ground.
Each Motor control box now only has two relays both switching to ground one switches the ground wire of the motor directly to ground the other via the resistor.
Pros
Extended Brush Life leading to a longer lasting motor
Cons
Now only two speed
Using a dirty great resistor is wasting electricity and therefore fuel
The resistor seem to have replaced the brushes as being a point of failure
Picture 1 2005 CDT relay wiring
(No longer available)
Picture 2 2004 CDT relay wiring
(No longer available)
Picture 3 1800 relay wiring
(No longer available)
Picture 4 Resistor wiring, please click on image for a bigger picture where it is easy to see where the cables go
(No longer available)
Pictures 5 and 6 the front and rear of the revised brush design (rear image has been flipped so left matches left of picture 5) this is from a very burnt out motor
(No longer available)
