Service Procedure
1. Open the hood.2. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.
3. Disconnect the left (driver's side) radiator fan motor electrical connector at the fan motor (Figure 1).
4. Inspect the radiator cooling fan motor connector:
> If the radiator cooling fan motor connector is melted or the motor terminal is discolored from overheating, replace the left radiator fan motor.
Continue with Step 5 of this procedure.
> If the radiator cooling fan motor connector is NOT melted and the motor terminal is NOT discolored from overheating, but engine coolant is found in the motor side of the connector, clean out the coolant using Mopar Electrical Contact Cleaner (P/N 05018045AA) or equivalent. Continue with Step 6 of this procedure.
> If the radiator cooling fan connector is NOT melted, the motor terminal is NOT discolored from overheating and there is no engine coolant found in the motor side of the connector, continue with Step 6 of this procedure.
5. Use the following procedure to replace the left radiator fan motor:
a. Remove the air filter housing air inlet snorkel.
b. Remove the grill from the front fascia.
NOTE:
There are four clips that hold the bottom of the grill to the fascia. Carefully pull upward on the grill to disengage the clips.
c. Remove the upper hose filler neck support bracket bolts (Figure 2).
d. Unfasten the large white wiring connector from the fan shroud (Figure 8).
e. Disconnect the wiring to the right radiator cooling fan motor.
f. Unclip the fan motor wiring harness from the fan shroud.
g. Remove the six (6) mounting screws that hold the wiring harness to the upper radiator support (Figure 3).
h. Temporarily relocate the wiring harness and upper hose filler neck support bracket using a bungee cord or equivalent (Figure 4).
i. Remove the right and left upper radiator mounting screws (Figure 5).
j. Lean the cooling module rearward and remove the five (5) plastic push pins from the upper radiator air seal (Figure 6).
k. Remove the upper radiator air seal from the radiator.
l. Unclip the radiator fan module from the radiator assembly.
m. Carefully remove the radiator fan and shroud assembly from the vehicle.
n. Remove and discard the radiator fan retaining nut from the left radiator cooling fan.
CAUTION:
The radiator cooling fan retaining nut has left-handed threads.
o. Remove the radiator cooling fan from the fan motor.
p. Remove and discard the three (3) radiator fan motor retaining screws (Figure 7).
q. Remove and discard the old fan motor from the radiator fan shroud.
r. Install the new fan motor into position in the fan shroud.
s. Install the three (3) new radiator fan motor retaining screws. Tighten the screws to 45 in. lbs. (5 N.m).
t. Install the fan onto the new fan motor.
u. Install the new fan retaining nut and tighten to 53 in. lbs. (6 N.m).
CAUTION:
The radiator cooling fan retaining nut has left-handed threads.
v. Carefully place the radiator fan and shroud assembly into the vehicle and clip the radiator fan and shroud assembly to the radiator.
CAUTION:
Be sure that all four radiator fan shroud clips are engaged.
w. Install the upper radiator air seal using the five (5) push pins removed earlier in this procedure (Figure 6).
x. Place the radiator assembly in position and install the right and left upper radiator mounting screws (Figure 5).
y. Remove the bungee cord, place the core support wiring harness in position and install the six (6) wiring harness retaining screws (Figure 3). Tighten the screws to 18 in. lbs. (2 N.m).
z. Install the large white connector to the radiator fan shroud (Figure 8).
aa. Connect the right fan motor electrical connector to the right fan motor receptacle.
ab. Secure the radiator fan wiring harness to the fan shroud using the existing harness clips.
ac. Place the upper hose filler neck support bracket into position and install the retaining bolts. Tighten the bolts to 45 in. lbs. (5 N�m).
ad. Install the front fascia grill.
ae. Continue with Step 7 of this procedure.
6. Remove the air filter housing air inlet snorkel.
7. Disconnect the four-way gray electrical connector located on the radiator shroud, in front of the air filter housing (Figure 8).
8. Remove the white electrical connector lock from the inside of the gray four-way male connector (Figure 9).
9. Using a small screwdriver or pick, pry upward on the terminal release tab located inside the connector to remove the green wire/terminal from the gray four-way connector.
10. Using diagonal cutters, cut off the green wire that was removed from the gray four-way connector flush to the main wiring harness (Figure 10).
11. Wrap the main wiring harness with electrical tape where the green wire was cut off.
12. Using diagonal cutters, cut off the left (driver's side) radiator fan connector wires flush to the main wiring harness (Figure 11).
13. Wrap the main wiring harness with electrical tape where the radiator fan connector wires were cut off.
14. Plug the overlay harness radiator fan connector into the fan motor receptacle.
15. Route the overlay harness along the existing fan main wiring harness upwards toward the radiator core support (Figure 11).
16. Insert the green wire of the overlay harness into the open cavity of the gray four-way connector (Figure 10).
17. Insert the white wire lock into the gray four-way connector (Figure 9).
18. Connect the gray four-way connector to the main harness (Figure 8).
19. Route the overlay harness black ground wire along the existing wiring harness located along the radiator core support (Figure 3).
20. Remove the coolant overflow bottle retaining screws and set the coolant bottle aside to gain access to the radiator fan ground stud (Figure 12).
NOTE:
Do not disconnect the overflow hose from the radiator.
21. Remove the ground stud wire retaining nut located on the right inner fender panel (Figure 13).
22. Remove the fan ground wire/eyelet harness from the stud and reinstall the ground stud wire retaining nut.
NOTE:
Some vehicles may have a second small black single ground wire attached to the ground stud. This ground wire must remains on the original ground stud.
23. Clean any residual engine coolant that may be on the fan ground wire eyelet.
24. Using a small round file, enlarge the ground eyelet hole until the ground bolt shank provided in the repair package can easily pass through the eyelet hole (Figure 14).
25. Reroute the existing ground wire so that it routes:
> Forward of the washer bottle fill neck (Figure 15).
> Between the power steering lines and the inner fender panel.
> Under the existing body wiring harness at the frame rail to the right frame rail weld nut.
26. Route the new fan overlay harness ground wire so that it routes:
> Along the radiator core support wiring harness (Figure 16).
> Down from the core support towards the power steering lines.
> Between the power steering lines and inner fender panel.
> Under the existing body wiring harness at the frame rail to the right frame rail weld nut.
27. Using the bolt provided in the repair package, insert the bolt through the existing ground eyelet first and then through the overlay harness eyelet (Figure 17).
CAUTION:
The ground eyelet from the overlay harness must be against the frame rail to allow the teeth on the eyelet to bite into the frame rail.
28. Screw the bolt (with the eyelets attached as described in step 27) into the weld nut located on the right frame rail (Figure 17). The eyelets must be clocked at the 10 o'clock and 2 o'clock positions before tightening. Tighten the bolt to 168 in. lbs. (19 N.m).
29. Using the tie straps provided, tie strap the overlay harness to the main harness.
CAUTION:
Be sure to secure the overlay harness away from all moving parts and sharp edges.
30. Place the coolant bottle back into its original position and install the fasteners.
Tighten the fasteners to 53 in. lbs. (6 N.m).
NOTE:
Make sure that the coolant bottle locator pin is in the locating hole.
31. Install the air filter housing air inlet snorkel.
32. Connect the negative battery cable.