VW Passat & Audi A4 1990-2000

Engine Cooling Fan

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REMOVAL & INSTALLATION
Electric Cooling Fans
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the radiator assembly.
  4.  
  5. Remove the cooling fan shroud from the radiator assembly.
  6.  
  7. Remove the fan from the motor.
  8.  
  9. If necessary, remove the motor assembly.
  10.  
  11. Installation is in reverse order of removal.
  12.  



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Fig. Exploded view of the typical radiator and fan assembly found on 1990-97 Passat models



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Fig. Detach all wiring harnesses necessary for radiator removal



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Fig. Use caution not to snap off any plastic wiring clips



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Fig. The radiator fan assembly



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Fig. Remove the fasteners and then the fan assembly from the radiator



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Fig. The secondary fan is driven by a belt via the primary motor



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Fig. Remove the secondary fan rubber drive belt



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Fig. Detach the plastic retaining ring



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Fig. To remove the fan blades, detach the locking ring tab and then the center nut



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Fig. View of fan blade nut and locking tab



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Fig. Note the position of the fan motor wiring connectors location to the steel housing. The motor can be put in upside down



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Fig. Remove the electric fan motor mounting bolts



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Fig. Remove the radiator fan motor

Belt Driven Fan And Viscous Clutch
1.8L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front bumper, and then place the upper radiator support/hood lock carrier in the service position.
  4.  
  5. Remove the ribbed drive belt. For additional information, please refer to the following topic(s): General Information And Maintenance, Routine Maintenance And Tune-Up.
  6.  
  7. Remove the cooling fan from the viscous coupling.
  8.  
  9. To remove the viscous coupling, hold the pulley with a 5mm ( 3 / 16 ) punch and remove the mounting fastener using an 8mm hex tool.
  10.  
  11. Installation is in reverse order of removal noting the following:
  12.  
  13. Torque the viscous clutch mounting fastener to 33 ft. lbs. (45 Nm).
  14.  
  15. Tighten the fan-to-viscous clutch fasteners to 88 inch lbs. (10 Nm).
  16.  



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Fig. To remove the viscous coupling, use a 5 mm ( 3 / 16 ) punch to hold the pulley and remove using an 8 mm hex tool



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Fig. With the inner cooler-to-intake manifold hose and cruise control vacuum diaphragm removed, the 8 mm hex bolt is accessible

2.8L v6 5v engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front bumper, and then place the upper radiator support/hood lock carrier in the service position.
  4.  
  5. Remove the ribbed drive belt. For additional information, please refer to the following topic(s): General Information And Maintenance, Routine Maintenance And Tune-Up.
  6.  


NOTE
The viscous fan clutch assembly has left hand threads!

  1. To remove the fan/viscous coupling assembly, hold the pulley with a pin tool such as Tool No. 3212 or its equivalent. Remove the fan/coupling assembly by turning it CLOCKWISE using Tool No. 3312, or its equivalent, such as a suitable open-end wrench.
  2.  
  3. Installation is in reverse order of removal noting the following:
  4.  
  5. Tighten and torque the fan/viscous coupling assembly by turning it COUNTERCLOCKWISE . Torque as follows:
  6.  
  7. Using Tool No. 3312: 27 ft. lbs. (37 Nm)
  8.  
  9. Without Tool No 3312: 52 ft. lbs. (70 Nm)
  10.  



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Fig. The viscous clutch drive pulley is held stationary using Pin Tool No. 3212 or its equivalent

TESTING

The electric cooling fan operation is controlled by the engine cooling fan thermal switch and, if equipped, by the air conditioner. When the air conditioner is operating properly the electric cooling fans should be activated.

On some models, the cooling fans will operate for a short period of time when the engine is shut off if the coolant is above a given temperature. This prevents over heating, helps with hot restarts, and in extreme ambient temperatures, prevents a vapor lock condition. For additional information, please refer to the following topic(s): Engine Electrical, Engine Cooling Fan Thermal Switch.