Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Electric Cooling Fan

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner/intake duct assembly and unplug temperature sensor connector.
  4.  
  5. Unplug the wiring harness from the fan motor electrical connector.
  6.  
  7. Remove the top fan motor assembly bolt(s).
  8.  
  9. If equipped with air conditioning and an automatic transaxle, it may be necessary to loosen the top automatic transaxle cooler line and position it aside for clearance.
  10.  
  11. Lift the fan assembly off the lower mounting brackets. Move the assembly to the left and rotate counterclockwise lifting the right side up past the radiator hose, then remove the assembly from the vehicle.
  12.  
  13. If necessary, remove the fan blade and motor from the shroud:
    1. Hold the fan and remove the left-hand threaded nut, then pull the fan from the motor shaft.
    2.  
    3. Remove the motor mounting screws.
    4.  
    5. Separate the motor from the shroud.
    6.  

  14.  

To install:
  1. If removed, install the motor and fan blade. Tighten the left-hand threaded fan nut to 27-44 inch lbs. (3-5 Nm).
  2.  
  3. Install the assembly with the lower left corner 1st. Rotate the assembly clockwise to place the lower left mount under the lower radiator hose and position the assembly onto the mounting brackets.
  4.  
  5. Install and tighten the upper retaining bolt(s) to 53 inch lbs. (6 Nm).
  6.  
  7. If disconnected, install and tighten the automatic transaxle fluid cooler line. Tighten the cooler line fitting to 22 ft. lbs. (27 Nm). For 1992-98 vehicles position the transaxle cooler line 35 degrees inward from vertical and hold while tightening.
  8.  
  9. Install the wiring harness plug to the fan motor electrical connector.
  10.  
  11. If removed, install the air cleaner/intake air duct assembly and the temperature sensor connector.
  12.  
  13. Connect the negative battery cable.
  14.  



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Fig. Fig. 1: Remove the top, right side fan motor assembly mounting bolt ...



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Fig. Fig. 2: ... then remove the top, left side fan motor assembly mounting bolt



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Fig. Fig. 3: Lift the fan assembly out of the engine compartment enough ...



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Fig. Fig. 4: ... to disengage the fan motor connector and remove the assembly from the vehicle

TESTING



See Figure 5

When conducting tests on the electric cooling fan and circuit, use of a high impedance Digital Volt Ohm Meter (DVOM) is necessary.

Cooling Fan Inoperative Test
  1. Check the 30 amp cooling fan maxifuse (labeled COOL FAN) in the underhood junction block.
  2.  
  3. If the fuse is OK, disconnect the cooling fan motor connector and connect a DVOM from terminal B wire (BLK/RED on 1991-94 models or LIGHT BLUE on 1995-98 models) to ground.
  4.  
  5. Disengage the A/C compressor clutch connector in order to prevent the air conditioning system from overpressurizing and releasing refrigerant from the pressure valve.
  6.  
  7. Start the engine and turn the air conditioning ON :
    1. If there is voltage at the B wire, check for open at terminal A (BLK) wire to ground which would prevent circuit completion and keep an otherwise good motor from operating. If there is no open and voltage is present, the motor must be faulty. Repair the open wire or replace the faulty motor, as applicable.
    2.  
    3. If there is no voltage at the B wire, turn the engine OFF and with the DVOM still connected to terminal B, unplug the PCM connector. Install a jumper wire between the following PCM connector terminal and ground:

      1991-94 models-PCM terminal J2A03 (DRK GRN/WHT)
       
      1995 models-PCM terminal J2A03 (DRK GRN)
       
      1996-98 models-PCM terminal J1C01 (DRK GRN)
       

    4.  

  8.  

  1. If there is no voltage at the connector, the fan relay is faulty. If there is voltage, the PCM is bad.
  2.  
  3. The fan motor may also be checked by jumping 12 volts to the 2 wires (A = negative, B = positive). The motor should run while voltage is applied.
  4.  

Cooling Fan Constantly On Test
  1. Disconnect the negative battery cable and remove the cooling fan relay from the underhood junction block. Connect the negative battery cable and inspect the motor to see if it still operates.
  2.  
  3. If the motor operates with the relay removed, a short to power exists in the BLK/RED wire (1991-94) or LIGHT BLUE wire (1995-98) from the underhood junction block to the fan motor.
  4.  
  5. If the fan does not operate with the relay removed, substitute a new relay and watch for operation. If the fan operates with a new relay, check the DRK GRN/WHT or DRK GRN wire for a short to ground and repair, if found. If a short does not exist, yet the fan operates, the PCM is likely at fault.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Cooling fan electrical schematic

 
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