Originally Posted By: mechtech2
Originally Posted By: eljefino
Sounds like your blower motor and or its resistor is on its way out.
I'd check these out first.
X2.
Start with the simplest/cheapest suspect. The blower motor/fan assembly that pushes air through the vents is in the engine compartment, so it could be causing the noise. It's easy enough to test...with the key in the on position and the engine off, turn the fan on with just the vent setting (no AC, no defrost). If the fan blows air through the vents without making any strange noises, and it works on all speeds, it's not your problem. If it does make a lot of noise, or doesn't work on all speeds, it could be your problem. The fan/motor would need to be removed and checked for debris and damage. If there is no debris/apparent damage, check the resistor mounted on the motor to see if it's corroded.
If the blower does not seem to be the problem, move on to the A/C compressor. Turn the van on, then turn the A/C on and see what happens. If you get a repeat of the engine stalling, or the noise only comes back with A/C or defrost turned on, that's your problem. If the van runs fine with the A/C/defrost turned off, you can just leave it that way. You may want to bypass the dead compressor though by using a shorter belt, though that may require removal of the compressor to make room. Dorman makes or used to make a pulley that would go in place of a dead compressor, but I only ever saw them for GM trucks and that was years ago.
This is a tough one with the info we have because the burning plastic smell in the vents points more towards the blower motor/fan, while the stalling when turning the defrost on points to the A/C compressor.