Chrysler Caravan/Voyager/Town and Country 1996-1999

Electric Cooling Fan

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Cooling fan assembly mounting points



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Fig. Fig. 2: Unplug the connectors that supply power to the cooling fan



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Fig. Fig. 3: Removing the cooling fan assembly

The electric cooling fan assembly cannot be disassembled. If the fan is warped, cracked or otherwise damaged, it must be replaced as an assembly.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the radiator outlet hose from the radiator hose retaining clip and remove the retaining clip from the shroud.
  6.  
  7. If equipped, remove the lower auxiliary transaxle cooler lines from the retaining clips on the cooling fan module shroud.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the entire air cleaner assembly and the air intake resonator.
  12.  
  13. Disconnect the fan motor electrical connector(s).
  14.  
  15. Remove the Coolant Recovery System (CRS) mounting screw from the upper radiator crossmember.
  16.  
  17. Disconnect the mounts to the upper radiator from the radiator crossmember.
  18.  
  19. Remove the upper radiator crossmember.
  20.  
  21. Remove the cooling fan module mounting screws.
  22.  
  23. If equipped, remove the upper auxiliary transaxle cooler lines from the retaining clips on the cooling fan module shroud.
  24.  
  25. Disconnect and plug the transaxle oil cooler line from the radiator fitting on the lower left side.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Remove the filter/drier, cooling fan module and radiator mounting bolts located on the lower right of the cooling fan module.
  30.  
  31. Lower the vehicle. Remove the upper cooling fan module-to-radiator retaining clips.
  32.  
  33. Remove the cooling fan module from the vehicle.
  34.  

To install:
  1. Install the cooling fan module assembly into the retaining clips of the radiator.
  2.  
  3. Install the upper cooling fan module-to-radiator retaining clips.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the filter/drier, cooling fan module and radiator mounting bolts located on the lower right of the cooling fan module.
  8.  
  9. Lower the vehicle. Reconnect the transaxle cooler line to the radiator fitting on the lower left side.
  10.  
  11. If equipped, install the upper auxiliary transaxle cooler lines to the retaining clips on the cooling fan module shroud.
  12.  
  13. Install the cooling fan module retaining screws and torque to 105 inch lbs. (12 Nm).
  14.  
  15. Install the entire air cleaner assembly.
  16.  
  17. Install the upper radiator crossmember and connect the upper radiator mounts to the crossmember. Torque the mounting fasteners to 105 inch lbs. (12 Nm).
  18.  
  19. Install the Coolant Recovery System (CRS) mounting screw to the upper radiator crossmember. Torque the mounting screw to 18 inch lbs. (2 Nm).
  20.  
  21. Reconnect the fan motor electrical connector.
  22.  
  23. Install the air intake resonator to the air cleaner assembly.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. If equipped, install the lower auxiliary transaxle cooler lines to the retaining clips on the cooling fan module shroud.
  28.  
  29. Install the radiator outlet hose retainer clip to the fan module shroud.
  30.  
  31. Install the radiator outlet hose to the retaining clip. Lower the vehicle.
  32.  
  33. Reconnect the negative battery cable. Run the engine and check for proper cooling fan operation when the engine reaches operating temperature.
  34.  

TESTING



When diagnosing an inoperative cooling fan it may be necessary to use a diagnostic scan tool to monitor engine coolant temperature and the engine control computer.

  1. Perform a visual inspection of the cooling fan. If the fan does not turn with ease, the fan motor is seized and needs to be replaced.
  2.  
  3. Check all the fuses and fusible links related to the cooling fan circuit.
  4.  
  5. Check the integrity of the electrical connections related to the cooling fan circuit.
  6.  
  7. Check the cooling fan motor.
  8.  
  9. Check the relays associated with the cooling fan circuit.
  10.  
  11. Using a scan tool, determine if the engine control computer is calling for the fan to activate.
  12.  

Cooling Fan Motor
  1. Disconnect the negative battery cable.
  2.  
  3. Disengage the cooling fan motor connector.
  4.  
  5. Identify and label the ground and the power terminals of the cooling fan connector using the wiring diagrams provided.
  6.  
  7. Using jumper leads with a fuse in series, apply battery voltage to the appropriate terminals of the cooling fan.
  8.  


CAUTION
Keep away from the fan blades when performing this procedure.

  1. The cooling fan should operate. If not, replace the cooling fan.
  2.  

If the cooling fan functions properly during this test, proceed to the cooling fan relay test.

Cooling Fan Relay

See Figure 4

  1. Turn the ignition OFF .
  2.  
  3. Remove the relay.
  4.  
  5. Locate the two terminals on the relay, which are connected to the coil windings. Check the relay coil for continuity. Connect the common meter lead to terminal 85 and positive meter lead to terminal 86. There should be continuity. If not, replace the relay.
  6.  



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Fig. Fig. 4: Use an ohmmeter to check for circuit continuity of the coil in the relay

  1. Check the operation of the internal relay contacts.
    1. Connect the meter leads to terminals 30 and 87. Meter polarity does not matter for this step.
    2.  
    3. Apply positive battery voltage to terminal 86 and ground to terminal 85. The relay should click as the contacts are drawn toward the coil and the meter should indicate continuity. Replace the relay if your results are different.
    4.  

  2.  

If the relay functions properly during this test, inspect the coolant temperature sensor and the cooling fan system wiring for defects.

 
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