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Q: What's that fan noise? on 2003 Saturn Ion

When I turn on the fan in the cabin (for heating or cooling), I get this strange noise, like there is a leaf or something stuck in the fan. It is worse on the lower settings with less air flow, and seems to minimize when on high.
Any thoughts for what this is? The dealership people say they have to take the entire dashboard apart just to diagnose it, but that seems quite excessive!
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Leaves or debris in HVAC fans are common. Sometimes they will clear out over time but the best way is to remove the fan motor and clean all the debris from the HVAC system. Some vehicles are more difficult than others getting to the fan motor.
or HVCA fan needs to be lubed up! (wd40) in the gapping hole where the filter sits!
Fan control module actually recently went out, and I'm in the process of searching junk yards for a used one, since Saturn parts are hard to come by these days. Problem will probably be solved when this work is done. Thanks!
My 2005 ion experienced the same irritating noise. I brought it in to the dealer and they had the nerve to say that it is a common noise and all car heater fans make similar noises. I told them that I have been in cars since 1971 and never heard that sound. After contacting Saturn's corporate headquarters - when they were around - they authorized a replacement heater. The technician who installed it admitted the fans have problems in how they are secured. The technician said he used a rubber gasket like piece where it was secured and made sure it was tight. Never heard the noise again. You are correct about the noise being worse in the lower fan settings. Get the fan secured better and you should stop hearing the noise.
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