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TURN KEY ON DON'T START THE ENGINE, IS THE ALT OR BATTERY LIGHT ON IF IT IS AND NOT CHARGING REPLACE THE ALTERNATOR, IF IT ISN'T REPLACE THE DASH BULB THAT CLOSES THE CIRCUIT TO THE ALTERNATOR, TO REPLACE ALTERNATOR, REMOVE THE BELTS, THE RADIATOR SHROUD, AND GET ROLLING.,
FIRST YOU DRAIN OUT THE COOLANT SYSTEM.DRAIN THE EXPANSION TANK REMOVE EXPANSION TANK HOSES FROM RADIATOR.REMOVE COOLING FAN MOTOR AND SHROUD.REMOVE UPPER RADIATOR HOSE, REMOVE RADIATOR LOWER COOLANT HOSE. REMOVE CONDENSOR TO RADIATOR MOUNTING BOLTS.DISCONNECT TRANSMISSION COOLER LINES FROM RADIATOR.REMOVE RADIATOR SUPPORT RELEASE CLIPS OR BOLTS MOUNTING FIXTURE. THEN REMOVE THE RADIATOR.
DISCONNECT THE ELECTRICAL CONNECTORS FROM THE FAN MOTORS, YOU HAVE TO REMOVE THE TWO FAN SHROUD BOLTS AND LIFT OUT THE FAN SHROUD AS A ASSEMBLY,THE BOTTOM OF THE FAN SHROUD HAS TWO PROJECTIONS THAT FIT INTO TABS ON THE RADIATOR.
PIA job......Of course remove the serpentine belt first. Best thing to get it off is go borrow fan clutch wrenches from an autoparts store to get it off. It has electrical connections on it for the clutch so be careful when removing it. Can be done without removing the fan shroud, but it's a tight fit. Must at the very least, loosen the shroud up to allow for play. Be very careful not to damage the fins on the radiator while trying to lift the fan clutch out. You'll end up removing quite a few things just to get to it, it's about a 3-4 hour job for the average DIY'er.
I couldn't find the plug or wire on the diagram on my online resource, either.
The fan must have a cable going to it to operate, somehow, though, I agree. Engine Cooling FanRemoval & InstallationTo Remove:
Before servicing the vehicle, refer to the precautions at the beginning of this section.
Remove or disconnect the following:
Negative battery cable
Fan blade/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front - threads on viscous fan drive are right hand.
CAUTION Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. Do not unbolt fan blade assembly from viscous fan drive at this time.
Upper fan shroud attaching hardware
Upper fan shroud and fan blade/viscous fan drive from vehicle
CAUTION Do not place viscous fan drive in horizontal position after removal because silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant.
Four bolts securing fan blade assembly to viscous fan drive.
To Install:
Install or connect the following:
Fan blade assembly to viscous fan drive.
Torque to: 17 ft. lbs. (23 Nm)
Fan blade/viscous fan drive assembly and upper shroud into vehicle
Fan shroud retaining screws
Fan blade/viscous fan drive assembly to water pump shaft
Disengage the electrical connector, then remove the integrated relay control/constant control relay module assembly located on the radiator support.
Disconnect the fan electrical connector.
Fig. 1: Disengage the fan electrical connector
If necessary, remove the air bag crash sensor.
Unbolt the fan/shroud assembly from the radiator and remove.
Fig. 2: Unbolt the fan assembly from the radiator
Fig. 3: Remove the fan from the engine
Fig. 4: Slide the fan as an assembly up and away from the radiator. Be careful not to dislodge the mounting stud on the left side.
Remove the retainer and the fan from the motor shaft and unbolt the fan motor from the shroud.
Installation is the reverse of the removal procedures. Tighten the fan shroud retaining bolt to 23–33 inch lbs. (2.6–3.7 Nm). Tighten the fan shroud retaining nut to 71–106 inch lbs. (8–12 Nm).
Fig. 5: Constant control relay module location — 3.8L engines
Loosen the fan clutch-mounting shaft from the water pump hub.
Loosen the fan shroud from its radiator mounting and remove the lower hose from the shroud.
Lift the fan and clutch assembly and the fan shroud from the vehicle.
If necessary, remove the fan-to-fan clutch retaining bolts and separate the fan from the fan clutch.
CAUTION Closely examine the fan for cracks or separation, to avoid the possibility of personal injury or vehicle damage.
To install:
Assemble the fan and fan clutch. Tighten the retaining bolts to 15–20 ft. lbs. (20–27 Nm).
Install the fan and clutch assembly and the fan shroud. Mount the fan clutch shaft to the water pump hub and tighten to 37–46 ft. lbs. (50–62 Nm).
Slip the shroud into the lower mounting clips and install the shroud retaining screws.
Fig. 6: Fan and fan clutch assembly — 4.6L engine
Loosen the fan clutch-to-water pump hub retaining bolts.
If necessary, remove the drive belt from the water pump pulley.
Remove the fan shroud upper retaining screws. Lift the shroud to disengage it from the lower retaining clips.
Remove the fan clutch-to-water pump hub bolts and remove the fan and clutch assembly and the fan shroud.
If necessary, remove the fan-to-fan clutch retaining bolts and separate the fan from the fan clutch.
CAUTION Closely examine the fan for cracks or separation, to avoid the possibility of personal injury or vehicle damage.
To install:
Assemble the fan and fan clutch. Tighten the retaining bolts evenly and alternately to 12–18 ft. lbs. (16–24 Nm).
Install the fan and clutch assembly and the fan shroud.
Install the fan clutch-to-water pump hub bolts.
Slip the shroud into the lower mounting clips and install the shroud retaining screws.
If removed, install the water pump drive pulley and adjust the belt tension; refer to Section 1.
Tighten the fan clutch-to-water pump hub bolts evenly and alternately to 15–22 ft. lbs. (20–27 Nm). Recheck the belt tension.
This is a lengthy process. Start by removing the vanity cover on the engine, the battery with its tray and the filter. Remove the large and small hose from the top of the radiator drivers side. Disconnect the fan harness and the 02 sensor harness in front of the battery tray. remove the O2 harness wires from the clips to free them completely. Remove the fan shroud mounting screws 1 on each side. Raise the car to remove the bumper next. Remove the bumper also starting by removing the lower tray from the wheel well shrouds. There is 1 10mm screw on each side of the bumper and the two next to the head lamps to remove the bumper. Drain the remaining fluid from the radiator from the lower hose drain plug, then detach the hose by lifting the spring clamp. Undo the retaining screws for the AT cooler and AC condensor to set aside. From below you will see the lower radiator support bar held by 4 13mm bolts on each side of the chassis. Remove it and the complete radiator with fan assembly will come down and out thru the bottom of the car. Installation is the reverse. Make sure to use DexCool antifreeze with distilled water or the premixed version when filling. Run until hot with heater on and remove Expansion Tank cap to purge air out of system. The car will do the remainder as time goes by. Just keep an eye on it for a week to fill to proper level as it purges.
I would attempt to take the fan blade off the water pump, then remove the fan shroud off the radiator but leave the radiator in the car.. it may take a little more finesse but save you alot of time..
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