Radiator Cooling Fan Motor: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. DISCONNECT HOSES





a. Disconnect the upper radiator hose from the radiator.
b. Disconnect the radiator reservoir hose.





c. Remove the union bolt and gasket, disconnect the pressure hose from the hydraulic motor.
d. Disconnect the return hose from the hydraulic motor.
4. REMOVE BATTERY AND TRAY





5. DISCONNECT COOLING FAN INLET PIPE FROM FAN SHROUD
Remove the 2 bolts, brackets and bushings, and disconnect the inlet pipe.
6. REMOVE COOLING FAN RESERVOIR TANK FROM FAN SHROUD





7. DISCONNECT ECT SENSOR CONNECTOR (FOR COOLING FAN)
a. Disconnect the ECT sensor connector.
b. Disconnect the wire clamp from the fan shroud.
8. REMOVE RADIATOR FAN SHROUD





a. Remove the 4 bolts, and disconnect the fan shroud from the radiator.





b. Slightly lift the fan shroud, and disconnect the 2 oil cooler hoses (for cooling fan) from the hose clamp on the fan shroud.
c. Remove the fan shroud.
9. REMOVE COOLING FAN FROM HYDRAULIC MOTOR
Loosen the pulley nut clockwise, and remove the nut, plate washer and fan.
10. REMOVE HYDRAULIC MOTOR FROM FAN SHROUD
Remove the 3 bolts and hydraulic motor.

DISASSEMBLY
1. MOUNT MOTOR HOUSING
Slightly mount the motor housing in a vise.

NOTICE: Be careful not to damage the motor housing.





2. REMOVE MOTOR COVER
a. Remove the 4 bolts and motor cover.
b. Remove the O-ring from the motor housing.





3. REMOVE REAR THRUST WASHER
4. REMOVE DRIVE SHAFT





5. REMOVE DRIVE AND DRIVEN ROTORS
6. REMOVE FRONT THRUST WASHER

INSPECTION
1. INSPECT DRIVE AND DRIVEN ROTORS





a. Install the drive and driven rotors to the motor housing with the dot mark facing upward.





b. Using a feeler gauge and precision straight edge, measure the side clearance between the rotor and precision straight edge.





Side clearance:
If the clearance is greater than maximum, replace the rotors as a set. If necessary, replace the motor assembly.








HINT: When replacing the rotors, select a new rotor set according to the imprinted mark on the motor housing.

2. INSPECT OIL CLEARANCE OF DRIVE SHAFT





a. Using a caliper gauge, measure the shaft hole inside diameter of the housing and cover.
Shaft hole inside diameter: 14.000 - 14.011 mm (0.5512 - 0.5516 inch)
b. Using a micrometer, measure the drive shaft diameter.
Shaft diameter: 13.973 - 13.984 mm (0.5501 - 0.5506 inch)
c. Subtract the drive shaft diameter measurement from the shaft hole diameter measurement.





Standard clearance:
If the clearance is greater than maximum, replace the shaft. If necessary, replace the motor assembly.

REPLACEMENT
1. REMOVE OIL SEAL





a. Using snap ring pliers, remove the snap ring and plate washer.





b. Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the housing.





2. INSTALL OIL SEAL
a. Using SST and a hammer, tap in a new oil seal to a depth of 4.5 - 5.5 mm (0.177 - 0.217 inch) from the housing edge
SST 09950-60010 (09951-00280) 09950-70010 (09951-07100)
b. Using snap ring pliers, install the plate washer and snap ring.
c. Apply fluid to the oil seal lip.

REASSEMBLY

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new fluid to all sliding and rotating surfaces.

1. MOUNT MOTOR HOUSING
Slightly mount the motor housing in a vise.

NOTICE: Be careful not to damage the motor housing.





2. INSTALL FRONT THRUST WASHER
3. INSTALL DRIVEN AND DRIVE ROTORS
Install the drive and driven rotors with the dot mark facing upward.





4. INSTALL DRIVE SHAFT
5. INSTALL REAR THRUST WASHER





6. INSTALL MOTOR COVER
a. Install a new O-ring to the motor housing groove.
b. Install the motor cover with the 4 bolts.
Torque: 28 Nm (290 kgf-cm, 21 ft. lbs.)





7. INSPECT DRIVE SHAFT PRELOAD
a. Check that the drive shaft rotates smoothly without abnormal noise.
b. Temporarily install the pulley nut, and check the rotating torque.
Rotating torque: 0.3 Nm (3.0 kgf-cm, 2.7 inch lbs.)

INSTALLATION
1. INSTALL HYDRAULIC MOTOR TO FAN SHROUD
Install the hydraulic motor with the 3 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
2. INSTALL COOLING FAN TO HYDRAULIC MOTOR
Install the fan with the plate washer and nut. Tighten the nut by turning it counterclockwise.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)





3. INSTALL RADIATOR FAN SHROUD
a. Place the fan shroud on the radiator.
b. Slightly lift the fan shroud, and connect the 2 oil cooler hoses (for cooling fan) to the hose clamp on the fan shroud.
c. Install the fan shroud with the 4 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





4. CONNECT ECT SENSOR CONNECTOR (FOR COOLING FAN)
a. Connect the ECT sensor connector.
b. Install the wire clamp to the fan shroud.
5. INSTALL COOLING FAN RESERVOIR TANK TO FAN SHROUD
6. CONNECT COOLING FAN INLET PIPE TO FAN SHROUD
7. INSTALL BATTERY AND TRAY
8. CONNECT HOSES





a. Connect the upper radiator hose to the radiator.
b. Connect the radiator reservoir hose.





c. Connect the pressure hose to the hydraulic motor with a new gasket and union bolt.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
d. Connect the return hose to the hydraulic motor.
9. FILL WITH ENGINE COOLANT
10. FILL WITH COOLING FAN FLUID
11. START ENGINE AND CHECK FOR LEAKS
12. RECHECK ENGINE COOLANT LEVEL
13. RECHECK COOLING FAN FLUID LEVEL
14. INSTALL ENGINE UNDER COVERS