Service Procedure
For 1998 - 2000 Model Year Vehicles Built Before April 4, 20001. Disconnect battery ground cable.
2. Disconnect fan motor electrical connector.
3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan shroud.
4. Remove the bolt and position aside degas bottle.
NOTE
THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE A SECOND PERSON TO HOLD THE DEGAS BOTTLE OUT OF THE WAY.
5. Remove (2) bolts and remove fan and shroud assembly.
6. Install lower radiator hose support bracket onto new fan shroud.
7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m).
8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m).
9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig tail, then remove wires from the convolute.
10. Cut the existing connector from the engine compartment wiring harness make each cut an inch and a half from the previous cut so that after splicing the wires can be reinstalled into the convolute.
11. Splice the three wires in the pigtail to the engine compartment harness as follows:
a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1).
b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire.
c. Splay the strands of the cut wires (Figure 2).
d. Twist/mesh the strands of the two wires together (Figure 3).
e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4).
f. Repeat previous step.
g. Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and solder flows completely into the strands. Use rosin core mildly activated (RMA) solder. DO NOT use acid core solder.
h. Center the heat shrink tubing on the splice (Figure 6).
i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing (Figure 7).
12. Install and tape spliced wires back into convolute.
13. Connect fan motor, position back tower hose onto support bracket, and install wire harness pushpin onto new fan shroud using the lowest locating hole (Figure 8).
14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m).
15. Verify fan operation with NGS/WDS.