Malibu 2001-2005

Electric Engine Fan

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Removal & Installation



3.1L Engine

CAUTION
To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

  1. Remove the bolt which retains the A/C line to the fan shroud.
  2.  
  3. Remove air deflector shield.
  4.  
  5. Remove electrical harness from cooling fan retainers.
  6.  
  7. Disconnect the cooling fan electrical connector.
  8.  
  9. Remove the four upper fan bolts.
  10.  
  11. Raise the vehicle.
  12.  
  13. Remove lower closeout panel.
  14.  
  15. Remove the four lower fan bolts.
  16.  
  17. Remove the fan from the shroud.
  18.  
  19. Remove fan shroud from radiator.

    Click image to see an enlarged view

    Fig. The removal and installation of the fan

  20.  

To install:

  1. Install fan shroud to radiator.
  2.  
  3. Install the fan to the shroud.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4.  
  5. Install the four lower fan bolts, and tighten bolts to 89 lb inches (10 Nm).
  6.  
  7. Install lower closeout panel.
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the four upper fan bolts, and tighten bolts to 89 lb inches (10 Nm).
  12.  
  13. Connect the cooling fan electrical connector.
  14.  
  15. Install wiring harness to retainers on cooling fans.
  16.  
  17. Install air deflector.
  18.  
  19. Install bolt to retain A/C line to fan shroud, and tighten bolt to 89 lb inches (10 Nm).
  20.  

3.5L Engine
  1. Drain the coolant.
  2.  
  3. Remove the left headlamp.
  4.  
  5. Remove the right headlamp.
  6.  
  7. Remove the upper transmission oil cooler pipe from the radiator.
  8.  
  9. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
  10.  
  11. Remove the upper radiator support bracket bolts.
  12.  
  13. Remove the upper radiator support brackets.
  14.  
  15. Pry upward on the fan shroud tabs at the radiator clips.
  16.  
  17. Raise the vehicle.
  18.  
  19. Remove the lower radiator air deflector retainers.
  20.  
  21. Remove the lower radiator air deflector.
  22.  
  23. Remove the right front fender liner.
  24.  
  25. Remove the right radiator air deflector retainers.
  26.  
  27. Remove the right radiator air deflector.
  28.  
  29. Remove the left radiator air deflector retainers.
  30.  
  31. Remove the left radiator air deflector.
  32.  
  33. Reposition the radiator outlet hose clamp at the radiator using the special tool J38185.
  34.  
  35. Remove the radiator outlet hose from the radiator.
  36.  
  37. Remove the fan wire harness connectors.
  38.  
  39. Remove the lower radiator support bracket bolts.
  40.  
  41. Remove the lower radiator support brackets.
  42.  
  43. Place a drain pan under the transmission oil cooler pipes.
  44.  
  45. Remove the transmission oil cooler pipes attachment nut from the transmission.
  46.  
  47. Remove both transmission oil cooler pipes from the transmission.
  48.  
  49. Remove the transmission oil cooler pipe clip from the fan shroud.
  50.  
  51. Remove the lower transmission oil cooler pipe from the radiator.
  52.  
  53. Remove the transmission oil cooler pipes.
  54.  
  55. Remove the fan wire harness connectors.
  56.  
  57. Remove the fan shroud assembly.
  58.  

To install:

  1. Install the fan shroud assembly.
  2.  
  3. Install the transmission oil cooler pipes.
  4.  
  5. Install the lower transmission oil cooler pipe to the radiator.
  6.  
  7. Install the transmission oil cooler pipe clip to the fan shroud.
  8.  
  9. Install both transmission oil cooler pipes to the transmission.
  10.  
  11. Install the transmission oil cooler pipe attachment nut to the transmission, and tighten the nut to 62 lb inches (7 Nm).
  12.  
  13. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  14.  
  15. The radiator air side seals must be in the proper position for proper air flow.
  16.  
  17. Install the lower radiator support brackets.
  18.  
  19. Install the lower radiator support bracket bolts, and tighten the bolts to 44 ft. lbs. (60 Nm).
  20.  
  21. Install the fan wire harness connectors.
  22.  
  23. Install the radiator outlet hose to the radiator.
  24.  
  25. Reposition the radiator outlet hose clamp at the radiator using the special tool J38185.
    NOTE
    Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  26.  
  27. Install the left radiator air deflector.
  28.  
  29. Install the left radiator air deflector retainers.
  30.  
  31. Install the right radiator air deflector.
  32.  
  33. Install the right radiator air deflector retainers.
  34.  
  35. Install the right front fender liner.
  36.  
  37. Install the lower radiator air deflector.
  38.  
  39. Install the lower radiator air deflector retainers.
  40.  
  41. Lower the vehicle.
  42.  
  43. Snap fan shroud tabs into the radiator clips.
  44.  
  45. Remove the rope attached to the condenser and upper tie bar.
  46.  
  47. Install the upper radiator support brackets.
    NOTE
    Do not allow the upper bracket to twist when tightening the screw or vibration may result.

  48.  
  49. Install the upper radiator support bracket bolts, and tighten the bolts to 89 lb inches (10 Nm).
  50.  
  51. Install the upper transmission oil cooler pipe to the radiator.
  52.  
  53. Install the right headlamp.
  54.  
  55. Install the left headlamp.
  56.  
  57. Fill the coolant.
  58.  
  59. Inspect the transmission fluid level.
  60.  

 
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