GM Astro/Safari 1985-1996 Repair Guide

Cooling Fan

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REMOVAL & INSTALLATION




CAUTION
DO NOT use or repair a damaged fan assembly. An unbalanced fan assembly could fly apart causing damage or severe personal injury. Always replace a damaged fan using a NEW assembly.

1985-95 Models

See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Exploded view of the cooling fan assembly for the 2.5L engine without a clutch



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Fig. Fig. 2: Fan removal usually boils down to a simple matter of removing the retainers (without cutting your hand) ...



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Fig. Fig. 3: ... then pulling the fan blade assembly from the water pump and pulley



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Fig. Fig. 4: Exploded view of the late-model 2.5L engine fan and clutch assembly



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Fig. Fig. 5: Exploded view of an early-model 2.5L engine fan and clutch assembly



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Fig. Fig. 6: Exploded view of a 4.3L engine fan and clutch assembly

  1. Disconnect the negative battery cable for safety.
  2.  
  3. For 1992-95 vehicles, matchmark the position of the hood latch to the radiator support, then unbolt and position the latch aside for clearance. Also, if equipped, loosen the A/C accumulator brackets.
  4.  
  5. Remove the upper fan shroud retainers, then separate the upper fan shroud from the bottom half of the shroud assembly. Remove the upper shroud from the vehicle. For many mid-to-late-model vehicles (late 80's to 1995) it will be necessary to unfasten upper radiator hose and power steering pressure switch harness from the shroud. It may also be necessary to remove the upper radiator hose from the radiator in order to provide sufficient clearance. If the hose must be removed, first partially drain the cooling system (to a level below the upper radiator hose).
  6.  
  7. Remove the fan clutch-to-water pump nuts and bolts, then remove the fan and clutch assembly from the engine.
  8.  

Some early-model 2.5L engines may not be equipped with a fan clutch assembly. For these models, the fan is bolted to directly to the water pump through a spacer. To remove the fan, simply unbolt and remove the blade with the spacer.

  1. If necessary, remove the fan blade-to-clutch retainers, and separate the blade from the clutch assembly.
  2.  

To install:
  1. If separated, install the fan blade to the clutch assembly and secure using the retainers. Tighten the fan-to-clutch retainers to 18 ft. lbs. (24 Nm) for 1985-92 4.3L engines or to 26 ft. lbs. (35 Nm) for 1993-95 4.3L engines. For 2.5L engines tighten the retainers to 89 inch lbs. (10 Nm) if they thread from the front of the fan, then back into the clutch, toward the engine or to 26 ft. lbs. (35 Nm) if they thread from the engine side, through the fan and THEN out toward the front of the vehicle and into the clutch.
  2.  
  3. Install the fan and clutch assembly (or fan and spacer on some early 2.5L engines) to the water pump pulley. Tighten the retainers to 18 ft. lbs. (24 Nm) for 2.5L engines with a clutch assembly, 20 ft. lbs. (27 Nm) for 2.5.L engines with a spacer (and no clutch) or to 22 ft. lbs. (30 Nm) for 4.3L engines.
  4.  
  5. Install the upper fan shroud.
  6.  
  7. For 1992-95 vehicles, align and install the hood latch to the radiator support using the marks made during removal. If equipped, secure the A/C accumulator brackets.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check operation.
  12.  
  13. Remember that if the upper radiator hose was removed, you should bleed and top-off the cooling system.
  14.  

1996 Models

See Figure 7



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Fig. Fig. 7: Exploded view of the fan and clutch assembly-1996 models

  1. Disconnect the negative battery cable for safety.
  2.  
  3. Place a catch pan under the radiator, open the drain cock and drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Loosen the clamp, then remove the air cleaner assembly.
  2.  
  3. Remove the upper fan shroud retaining bolts, then remove the upper shroud from the vehicle.
  4.  
  5. Remove the fan and clutch assembly retainers using J-41240, or an equivalent fan clutch wrench.
  6.  
  7. If necessary, remove the 4 bolts holding the fan blade to the clutch, then separate the fan from the clutch assembly.
  8.  

To install:
  1. If removed, install the fan to the clutch assembly, then secure using the 4 retaining bolts. Tighten the bolts to 24 ft. lbs. (33 Nm).
  2.  
  3. Install the fan blade and clutch assembly to the engine using J-41240 and tighten the retainers to 41 ft. lbs. (56 Nm).
  4.  
  5. Install the upper shroud and secure using the retaining bolts.
  6.  
  7. Install the air cleaner assembly and tighten the clamp.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check operation.
  12.  

 
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