AutoZone 2002 Chrysler PT Cruiser 2.4L SFI DOHC 4cyl | Repair Guides | Engine Cooling | Engine Fan | Mechanical (belt Driven) Fan | AutoZone.com

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    2002 Chrysler PT Cruiser 2.4L SFI DOHC 4cyl

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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Mechanical (Belt Driven) Fan

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    Removal & Installation




    CAUTION
    Never run the engine while the protective components are removed. Failure to follow these instructions can result in personal injury.

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner outlet pipe.
    4.  
    5. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
    6.  
    7. Remove the outlet side of the air cleaner.
    8.  
    9. Raise and support the vehicle.
    10.  
    11. If equipped, remove the skidplate.
    12.  
    13. Remove the screws and the lower section of the cooling fan shroud.
    14.  
    15. Lower the vehicle.
    16.  
    17. If equipped with the 5.4L DOHC engine, disconnect the accelerator cable, speed control cable, and the return spring. Remove the bolts and position the cable and brackets out of the way.

      Click image to see an enlarged view

      Fig. On 5.4L DOHC engines, disconnect the accelerator cable, speed control cable, and the return spring . . .



      Click image to see an enlarged view

      Fig. . . . then remove the bolts and position the cable and brackets out of the way

    18.  
    19. For vehicles equipped with 4.6L engines, remove the nut and the engine appearance cover bracket.

      Click image to see an enlarged view

      Fig. For 4.6L engines, remove the nut and the engine appearance cover bracket

    20.  
    21. Remove the mounting bolts and the upper section of the cooling fan shroud.
    22.  
    23. Remove the fan blade and the fan clutch.
    24.  
    25. Using Fan Pulley Holding Wrench Special Tool 303-239 (T84T-6312-C), or equivalent, hold the coolant pump pulley steady.
    26.  
    27. Using the Fan Clutch Nut Wrench Special tool 303-240- (T84T-6312-D), or equivalent, remove the cooling fan assembly locknut.

      Click image to see an enlarged view

      Fig. Using the special tool (1), hold the coolant pump pulley steady, then use the special tool (2) to remove the cooling fan assembly locknut

    28.  
    29. Remove the bolts and separate the fan clutch from the fan blade.
    30.  

    To install:

    1. Install the fan clutch to the fan blade and tighten the bolts to 13 ft. lbs. (17 Nm).
    2.  
    3. Using the special tools, install the cooling fan assembly. Tighten the bolt to 41 ft. lbs. (55 Nm).

      Click image to see an enlarged view

      Fig. Use the special tools to install the cooling fan assembly

    4.  
    5. Install the upper section of the fan shroud and mounting bolts. Tighten to 80 inch lbs. (9 Nm).
    6.  
    7. For vehicles equipped with 4.6L engines, install the engine appearance cover bracket and nut. Tighten to 89 inch lbs. (10 Nm).
    8.  
    9. For vehicles equipped with 5.4L DOHC engines, position the cables and bracket, and install the bolts. Tighten to 89 inch lbs. (10 Nm). Connect the accelerator cable, speed control cable and the return spring.
    10.  
    11. Raise the vehicle.
    12.  
    13. Install the screws and the lower section of the cooling fan shroud.
    14.  
    15. If equipped, install the skidplate. Tighten the retaining bolts as shown in the accompanying illustration.

      Click image to see an enlarged view

      Fig. Skidplate bolt tightening specifications

    16.  
    17. Lower the vehicle.
    18.  
    19. Install the outlet side of the air cleaner.
    20.  
    21. Connect the MAF sensor electrical connector.
    22.  
    23. Install the air cleaner outlet pipe.
    24.  

    1. Drain the cooling system.
    2.  
    3. Remove the three bolts and position the degas bottle out of the way.
    4.  
    5. Squeeze the clamp, pull the hose off and position the upper radiator hose out of the way.
      WARNING
      The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.

    6.  
    7. Using Fan Pulley Holding Wrench Special Tool 303-478 (T94T-6312-AH), or equivalent, hold the coolant pump pulley steady.
    8.  
    9. Using the Fan Clutch Nut Wrench Special tool 303-214- (T83T-6312-B), or equivalent, remove the cooling fan assembly locknut.
    10.  
    11. Remove the fan and fan clutch from the coolant pump pulley,
    12.  
    13. Carefully position the fan and the fan clutch into the shroud.
    14.  
    15. Remove the bolts, the shroud, fan and clutch.
    16.  
    17. To install, reverse the removal procedure. Observe the following tightening specifications:
      1. Upper shroud retainers: 80 inch lbs. (9 Nm)
      2.  
      3. Fan clutch nut: 84-112 ft. lbs. (113-153 Nm).
      4.  

    18.  

    6.0L Engine
    1. Remove the radiator assembly, as outlined in this section.
    2.  
    3. Disconnect the cooling fan clutch electrical connector. Unclip and position the fan wiring aside.
      NOTE
      Use a hole in the fan hub to prevent the fan from turning.

    4.  
    5. Using Fan Clutch Nut Special Tool no. 303-591, remove the cooling fan and clutch.
    6.  
    7. Remove the cooling fan and clutch assembly.
    8.  
    9. If necessary, remove the bolts and separate the cooling fan and the clutch.
    10.  
    11. To install, reverse the removal procedure. Observe the following tightening specifications:
      1. Cooling fan-to-clutch bolts: 13 ft. lbs. (17 Nm).
      2.  

    12.  
    13. Cooling fan and clutch assembly-to-engine bolt: 98 ft. lbs. (133 Nm).
    14.  

    7.3L Diesel Engine
    1. Drain the cooling system.
    2.  
    3. Remove the three bolts and position the degas bottle out of the way.
    4.  
    5. Squeeze the clamp, pull the hose off and position the upper radiator hose out of the way.
      WARNING
      The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.

    6.  
    7. Using Fan Pulley Holding Wrench Special Tool 303-478 (T94T-6312-AH), or equivalent, hold the coolant pump pulley steady.
    8.  
    9. Using the Fan Clutch Nut Wrench Special tool 303-214- (T83T-6312-B), or equivalent, remove the cooling fan assembly locknut.
    10.  
    11. Remove the fan and fan clutch from the coolant pump pulley,
    12.  
    13. Carefully position the fan and the fan clutch into the shroud.
    14.  
    15. Remove the bolts, the shroud, fan and clutch.
    16.  
    17. To install, reverse the removal procedure. Observe the following tightening specifications:
      1. Upper shroud retainers: 80 inch lbs. (9 Nm)
      2.  
      3. Fan clutch nut: 84-112 ft. lbs. (113-153 Nm).
      4.  

    18.  

     
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