Chrysler Full-Size Trucks 1989-1996 Repair Guide

Electric Engine Fan

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This fan is not serviceable. If it is found inoperative, it must be replaced with the recommended Original Equipment Manufactured (OEM) equivalent to ensure adequate strength, performance and safety.

REMOVAL & INSTALLATION



See Figure 1

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Details of the electric engine fan assembly-2.5L Dakota models only

  1. Unplug the wire connector.
  2.  
  3. Remove the fasteners and remove the fan, shroud and motor from the radiator as an assembly.
  4.  
  5. Support the fan motor and shaft on a bench. Remove the retaining clip to detach the fan blade.
  6.  


WARNING
Do not allow the fan blades to contact the bench

To install:
  1. Position the fan on the motor shaft, so that it properly engages the roll pin.
  2.  
  3. Support the fan motor and shaft on a bench WITHOUT allowing the fan to contact the bench. This will prevent the fan from being damaged by excessive force.
  4.  
  5. Install the fan retaining clip.
  6.  
  7. Install the complete assembly into the pockets in the radiator lower tank. Tighten the screws to 95 inch lbs. (11 Nm).
  8.  
  9. Plug in the electrical connector to the harness and connect the negative battery cable.
  10.  

TESTING



Fan Motor

See Figure 2

The cooling fan motor can be tested by applying 12 volts (battery voltage) to the fan motor electrical connector.



Click image to see an enlarged view

Fig. Fig. 2: When testing the fan motor, make sure to hook the correct polarity jumper wire to the harness connector-2.5L Dakota models only

  1. Unplug the fan motor connector.
  2.  
  3. Hook a 14 gauge positive jumper from the battery to the male prong of the connector (positive) and a 14 gauge negative probe to the female connector (negative)
  4.  
  5. If the fan operates normally, the motor is operating properly. Proceed to the circuit diagnosis test.
  6.  
  7. If the fan motor does not operate with voltage applied, it is faulty and should be replaced.
  8.  

Circuit Diagnosis

See Figure 3

If the fan relay does not have the circuit number embossed, you will have to acquire a schematic.

  1. With the ignition switch OFF , check for battery voltage at terminal No. 1 of the fan relay connector.
  2.  
  3. If battery voltage is not present, check the cartridge fuse in the Power Distribution Center (PDC). Inspect for an open or short to ground in circuit C26.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Test the PCM terminals-inspect to see that none are bent and not making contact

  1. If battery voltage is present, continue to the next step.
  2.  
  3. Connect a 14 gauge jumper wire between the fan relay connector terminals (B) and (D).
  4.  
  5. If the fan does not operate, check for an open in circuit C25. Check this between terminal (D) of the fan relay connector and fan motor connector.
  6.  
  7. Start the engine and allow it to reach normal operating temperature.
  8.  
  9. If the fan does operate, proceed to the next step.
  10.  
  11. Inspect the wire connectors in circuits C9, C25 and C26 for proper engagement. The circuit number appears in front of the wire gauge and color description of the wiring diagrams.
  12.  
  13. If you have available a DRB scan tool, check the on-board diagnostics for trouble codes (DTC).
  14.  
  15. If you do not have the factory scan tool, you can still check the Radiator Fan Relay Circuit on speculation, as this is the most likely DTC that would be displayed by the scan tool.
  16.  
  17. With the engine in the RUN position, test for battery voltage at the J2 circuit connection of the fan relay.
  18.  
  19. If the voltage reading is correct, proceed to Step 13a. If voltage is 0-1, proceed to Step 13b.
  20.  
  21. With the ignition OFF , disconnect the 60-way wiring harness plug from the PCM. Turn the ignition key to RUN . Test for battery voltage with a voltmeter at cavity 31.
    1. If battery voltage is present at cavity 31, and the female terminal is not damaged, replace the PCM.
    2.  
    3. If voltage is 0, repair the open or short in circuit C27.
    4.  

  22.  
  23. With the ignition OFF , unplug the 60-way connector from the PCM. Turn the ignition switch to RUN . Test for battery voltage at the J2 circuit connection of the fan relay.
    1. If battery voltage is present, replace the PCM.
    2.  
    3. If the voltage reading is 0-1, proceed to Step 15.
    4.  

  24.  
  25. With the ignition switched to the RUN position, test for battery voltage at circuit C27 connection of the fan relay.
    1. If battery voltage is present, replace the fan relay.
    2.  
    3. If the voltage is 0, repair the open or short in circuit C27.
    4.  

  26.  

 
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