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Auxiliary Cooling Fan Replacement
 
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Pelican Technical Article:

Auxiliary Cooling Fan Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$200

Talent:

*****

Tools:

Set of sockets (8, 10, 13mm), trim panel tool

Applicable Models:

BMW X5 (2000-06)

Parts Required:

Cooling fan

Hot Tip:

Work with a cool engine

Performance Gain:

Proper A/C function

Complementary Modification:

Change cabin filter

The engine-cooling fan helps to maintain a constant engine temperature. It draws air past the radiator cooling fans, which in turn cools the engine coolant. An electric fan is mounted on the front of the radiator. The fan final stage is mounted to the fan and is controlled by the DME (engine control module). An additional belt-driven cooling fan with a viscous clutch is attached to the engine coolant pump. On this fan, the fluid in the viscous clutch is affected by engine compartment temperature, which in turn controls fan speed.

When replacing the engine side-cooling fan you will want to work with the engine cold and disconnect the battery negative cable. Disconnecting the negative battery cable will prevent the electric cooling fan from starting while being serviced. The fan could start at any time and personal injury can occur. Don't skip this step.

The auxiliary or a/c condenser fan in mounted to the front of the radiator. The auxiliary fan for this vehicle is controlled by the ECM and does not use relays. The auxiliary fan request comes from the IHKA control module via the K-Bus. The fan speed request is based on the refrigerant pressure sensor input to the IHKA. Additional factors monitored by the ECM that influence fan operation are: Radiator outlet temperature sensor (exceeds the preset temperature), Vehicle speed, Battery voltage level. The auxiliary fan motor incorporates an output final stage that activates the fan motor at variable speeds. The output stage receives an output signal (pulse width modulated 10-100Hz) from the ECM, which activates the motor.

Working in the trunk, disconnect the battery negative cable and cover the battery terminal so that the cable does not accidentally come in contact with the disconnected cable. See our tech article on battery replacing for notes on disconnecting and reconnecting the battery.

The auxiliary or a/c condenser fan in mounted to the front of the radiator (red arrow).
Figure 1

The auxiliary or a/c condenser fan in mounted to the front of the radiator (red arrow). The bumper support has to be removed to access it (green arrow).

First we have to remove the intake air duct that runs from the throttle housing (yellow arrow) to the mass airflow sensor (green arrow).
Figure 2

First we have to remove the intake air duct that runs from the throttle housing (yellow arrow) to the mass airflow sensor (green arrow).

Working at the fresh air intake, remove four plastic rivets (green arrows).
Figure 3

Working at the fresh air intake, remove four plastic rivets (green arrows). Use a pair of pliers (inset) to remove the center rivet. Once all center rivets have been removed, pull the duct up to detach it from the vehicle.

Then lift the duct up on the left side while detaching it from the duct (green arrow) on the right side.
Figure 4

Then lift the duct up on the left side while detaching it from the duct (green arrow) on the right side.

Working at the right side of the cooling fan shroud on the engine compartment, pull the electrical connector out of the mount (green arrow).
Figure 5

Working at the right side of the cooling fan shroud on the engine compartment, pull the electrical connector out of the mount (green arrow). Then disconnect the auxiliary fan electrical connector (red arrow) by squeezing the tabs and pulling the connector apart.

Working on the side of the cooling fan at the shroud, remove the plastic rivets (red arrows).
Figure 6

Working on the side of the cooling fan at the shroud, remove the plastic rivets (red arrows). Pull the center pin out and remove the rivet body (inset).

Working on the left side of the bumper support below the headlight, remove the two 10mm fasteners (red arrows).
Figure 7

Working on the left side of the bumper support below the headlight, remove the two 10mm fasteners (red arrows). Repeat this step for the right side.

Working on the left side of the bumper support next to the cooling fan, remove the three 10mm fasteners (green arrows).
Figure 8

Working on the left side of the bumper support next to the cooling fan, remove the three 10mm fasteners (green arrows). Then remove the two 13mm fasteners (red arrows). Repeat this step for the right side.

Working below the front wheel at the brake-cooling duct (red arrow), remove the two 8mm brake duct fasteners (green arrows).
Figure 9

Working below the front wheel at the brake-cooling duct (red arrow), remove the two 8mm brake duct fasteners (green arrows). Swing the brake duct down and out of the way. Repeat this step for the right side.

Working on the left side of the bumper support next to the brake duct intake, remove the two 13mm fasteners (red arrows).
Figure 10

Working on the left side of the bumper support next to the brake duct intake, remove the two 13mm fasteners (red arrows). Support the bar (green arrow) when removing the final fastener. Repeat this step for the right side. Pull the bumper support away from the vehicle. Disconnect the horn connectors and parking distance sensors if equipped. Detach the wiring from the support and lay it aside.

Working on the sides of the cooling fan, remove the two 10mm fasteners (red arrows).
Figure 11

Working on the sides of the cooling fan, remove the two 10mm fasteners (red arrows).

Slide the cooling fan down out of the radiator support (red arrow) just enough to access the wiring.
Figure 12

Slide the cooling fan down out of the radiator support (red arrow) just enough to access the wiring.

Detach the wiring from the radiator and feed it through the support (red arrow).
Figure 13

Detach the wiring from the radiator and feed it through the support (red arrow). Remove the fan from the vehicle. With the cooling fan removed, clean any debris from the cooling fans and the radiator support.

To install a new fan, reverse the steps of the procedure.
Figure 14

To install a new fan, reverse the steps of the procedure. Be sure to align the upper mounting tabs (red arrow) with the slot on the vehicle (green arrow). Also route the wiring as it previously was routed.




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Comments and Suggestions:
Crondar Comments: Can you please list the sizes of the plastic rivets that are being taken out? I will not have an extra vehicle to go and get them if they break, therefore I will have to purchase them before I start.
June 23, 2016
  Followup from the Pelican Staff: http://www.pelicanparts.com/cgi-bin/ksearch/pel_search_2014.cgi?SUPERCAT_FLAG=Y&make=&Context_make=&please_wait=N&LastVisited_input=&Previous_Section=&forumid=&threadid=&command=DWsearch&description=17111712963&I1.x=0&I1.y =0

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
rupomir Comments: Hey buddy, Is it possible to access the motor and replace it without moving car's front bumper. I have to replace the motor and keep rest of the aux fan parts. Thanks!
February 19, 2016
  Followup from the Pelican Staff: No. it has to be removed. - Nick at Pelican Parts  

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Page last updated: Fri 12/9/2016 02:56:57 AM