ION, L-Series, S-Series 1999-2005

Electric Engine Fan

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Fan Switch



Testing
2.0L Engine
  1. Turn the ignition OFF, disconnect the series/parallel relay.
  2.  
  3. Turn the ignition ON, disconnect the ECT sensor connector. The left cooling fan should not activate. If the fan is activated, test the left fan ground circuit for a short to ground.
  4.  
  5. Turn the ignition OFF, disconnect the remaining relays.
  6.  
  7. Turn the ignition OFF, install a 30A fused jumper between the normally open switch contact terminals at the series/parallel relay connector in order to complete the fan ground circuit. Leave the jumper in place for the remainder of this procedure.
  8.  
  9. Turn the ignition OFF, one at a time, connect a 30A fused jumper between the positive terminal at the battery and the fan voltage supply circuit terminal at the cool/fan 1 and the cool/fan 2 relay connectors, and verify fan activation. If the appropriate fan does not activate, test the fan voltage supply circuit for a short to ground or open/high resistance. If the circuit tests normal, test the fan ground circuit for an open/high resistance. If the circuits test normal, replace the fan.
  10.  
  11. Turn the ignition ON, connect a 30A fused jumper between the relay switch voltage supply circuit terminal and the fan voltage supply circuit terminal at the cool/fan 1 relay and the cool/fan 2 relay connections and verify fan activation. If the fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test all connected components and replace as necessary.
  12.  
  13. If the circuits and fans test normal, replace the relay
  14.  

2.2L Engine
  1. Turn the ignition OFF, disconnect the relay.
  2.  
  3. Connect a 30A fused jumper between the positive terminal at the battery and the fan voltage supply circuit terminal X1 at the relay connection and verify fan activation. If the fan does not activate, test the fan voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal, test the fan ground circuit for an open/high resistance. If the fan did not activate and the circuits test normal, replace the fan.
  4.  
  5. Turn the ignition ON, connect a 30A fused jumper between the relay switch voltage supply circuit terminal Y3 and the fan voltage supply circuit terminal X1 at the relay connection and verify fan activation. If the fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test all connected components and replace as necessary
  6.  
  7. If the fan and all circuits test normal, replace the relay.
  8.  

2.4L Engine
  1. Turn the ignition OFF, disconnect the affected relay. Connect a 30A fused jumper wire between the positive voltage terminal at the battery and the fan voltage supply circuit terminal and verify fan activation. On fan 1 this would be relay terminal Y1. On fan 2 this would be terminal 87.
  2.  
  3. If the fan does not activate, test the fan voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal, test the fan ground circuit for an open/high resistance. If the fan did not activate and the circuits test normal, replace the fan
  4.  
  5. Turn the ignition ON, connect a 30A fused jumper wire between the relay switch voltage supply circuit terminal and the fan voltage supply circuit terminal and verify fan activation. . On fan 1 this would be relay terminal X3 and Y1. On fan 2 this would be terminal 30 and 87.
  6.  
  7. If the fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and it's fuse is open, test all connected components and replace as necessary
  8.  
  9. If the fan and all circuits test normal, replace the relay.
  10.  

Removal & Installation



2.2L Engine
  1. Disconnect the cooling fan electrical connector.
  2.  
  3. Remove the cooling fan wire from the fan shroud.
  4.  
  5. Raise and support the vehicle.

    Click image to see an enlarged view

    Fig. Remove the cooling fan assembly from the radiator

  6.  
  7. Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator.
  8.  
  9. Remove the air dam push-in retainers.

    Click image to see an enlarged view

    Fig. Remove the air dam

  10.  
  11. Remove the air dam.

    Click image to see an enlarged view

    Fig. Remove the right engine splash shield to radiator mount push-in retainer

  12.  
  13. Remove the right engine splash shield to radiator mount push-in retainer.
  14.  
  15. Remove the left engine splash shield to radiator mount push-in retainer.
  16.  
  17. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser.
  18.  
  19. Tilt the radiator and condenser forward in the vehicle. Remove the cooling fan assembly from the vehicle.
  20.  

To install:

  1. Tilt the radiator and condenser forward in the vehicle. Install the cooling fan assembly into the vehicle.
  2.  
  3. Verify that the upper radiator mounts are installed in the vehicle.
  4.  
  5. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  6.  
  7. Install the lower radiator mounts, brackets, and bolts, and tighten the bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the right engine splash shield to radiator mount push-in retainer.
  10.  
  11. Install the left engine splash shield to radiator mount push-in retainer.
  12.  
  13. Install the air dam and the push-in retainers.
  14.  
  15. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the cooling fan electrical connector.
  20.  
  21. Install the cooling fan wire to the fan shroud.
  22.  

 
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