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Cooling Fan and Shroud Removal
 
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Pelican Technical Article:

Cooling Fan and Shroud Removal

Steve Vernon

Time:

2 hours2 hrs

Tab:

$25 to $300

Talent:

**

Tools:

8mm Allen, Mercedes Tool No. 104 589 00 01 00

Applicable Models:

300E (1985-92)
260E (1987-90)
300CE (1988-89)
300TE (1988-91)
300E2.6 (1990-92)
300TE 24 (1989-92)
300CE 24 (1990-93)
300E 24 (1990-93)
300CE (1993-94)
280E (1993-94)
300E2.8 (1993-94)
E280 (1994-96)
320TE (1993-94)
E320 (1994-96)

Parts Required:

New shroud or fan

Hot Tip:

Work on a cool car

Performance Gain:

Proper engine temperature

Complementary Modification:

New hoses

The clutch on the fan will fail over time and need to be replaced. To replace the clutch, the radiator shroud and the fan will need to be removed. The radiator shroud and the fan also need to come off the engine to allow you to perform other jobs on the motor including changing the drive belt. A word of caution here before you begin. Depending on the engine and accessories on your car there can be very, very little room to work between the fan and the radiator. You will need a short 8mm Allen to remove the viscous clutch on the fan. We ended up grinding an 8mm L-shaped Allen to fit in the space. You will also need Mercedes-Benz tool number 104 589 00 01 00 to stop the pulley the clutch is mounted to from spinning so you can remove the clutch. You can make your own tool by bending a piece of metal 6mm in diameter to fit in the locating slot in the bracket behind the pulley. Even with the Mercedes tool it can be a difficult and time consuming job. Be prepared to have and use a lot of patience.

The radiator is very expensive and delicate, and can be easily damaged while working around it. If you are going to be doing other work on the car and/or are worried about damaging your radiator, I recommend you remove it first. It is not a difficult job and can potentially save you a lot of money if you end up damaging it. Please see our article on radiator removal for further assistance. That being said, you certainly can remove and replace the fan with the radiator in, but I recommend you put a piece of cardboard over it to protect it while working.

The radiator shroud is made up of two parts: the fan guard (yellow arrow) and the shroud (red arrow).
Figure 1

The radiator shroud is made up of two parts: the fan guard (yellow arrow) and the shroud (red arrow). The green arrow indicates where someone had installed the wrong hose. A hose pinched like this will severely restrict coolant flow and lead to all kinds of problems. Our project car ended up having a blown head gasket and this was probably one of the reasons.

Squeeze in the tab that holds the radiator overflow hose and slide it back out of the clip on the shroud and fan guard (red arrow).
Figure 2

Squeeze in the tab that holds the radiator overflow hose and slide it back out of the clip on the shroud and fan guard (red arrow). Set the hose and clip aside.

Slide the fan guard to the right (yellow arrow, when facing the guard).
Figure 3

Slide the fan guard to the right (yellow arrow, when facing the guard). Rotating the guard will free it from its retainers. When reinstalling, make sure you install the guard with the "top" marking facing up (red arrow).

With the guard free from the shroud, place the guard back over the fan (red arrow).
Figure 4

With the guard free from the shroud, place the guard back over the fan (red arrow).

Remove the clip (red arrow) that holds the shroud to the radiator on the top right hand side.
Figure 5

Remove the clip (red arrow) that holds the shroud to the radiator on the top right hand side.

Remove the clip that holds the shroud to the radiator on the left side.
Figure 6

Remove the clip that holds the shroud to the radiator on the left side. The clip is located between the two hoses (red arrow).

Using care slide the shroud out between the fan and the radiator (red arrow).
Figure 7

Using care slide the shroud out between the fan and the radiator (red arrow).

Slide the guard off the fan and remove it between the fan and radiator (red arrow).
Figure 8

Slide the guard off the fan and remove it between the fan and radiator (red arrow).

This photo illustrates how the plastic pegs on the guard (yellow arrows) sit in the corresponding receptacles (red arrows).
Figure 9

This photo illustrates how the plastic pegs on the guard (yellow arrows) sit in the corresponding receptacles (red arrows).

To remove the fan and clutch you will need Mercedes-Benz tool # 104 589 00 01 00 or you can make one out of 6mm rod.
Figure 10

To remove the fan and clutch you will need Mercedes-Benz tool # 104 589 00 01 00 or you can make one out of 6mm rod. The lower part of the tool will sit in a retaining groove while the end of the tool sits in a hole in the pulley to hold everything while tightening or loosening the bolt (red arrow).

This picture shows what you will be doing with the tool.
Figure 11

This picture shows what you will be doing with the tool. The fan, clutch and pulley have all been removed for illustration purpose; you will be doing this by feel.

Insert the end of the tool (yellow arrow) into the retaining groove behind the pulley.
Figure 12

Insert the end of the tool (yellow arrow) into the retaining groove behind the pulley. You will need to rotate the pulley until the tool finds its seat in the pulley (red arrow); this can take a fair amount of trial and error. It is much easier to spin the pulley if you remove the drive belt. Please see our article on drive belt removal for additional assistance.

Here is an 8mm Allen that I cut off to fit the space between the nut and radiator.
Figure 13

Here is an 8mm Allen that I cut off to fit the space between the nut and radiator.

I recommend placing a piece of cardboard (red arrow) over the radiator then installing the 8mm Allen; this will help prevent damage to the radiator while you are working.
Figure 14

I recommend placing a piece of cardboard (red arrow) over the radiator then installing the 8mm Allen; this will help prevent damage to the radiator while you are working.

The bolt that holds the clutch and fan on is quite long.
Figure 15

The bolt that holds the clutch and fan on is quite long. Be prepared to turn it for a while (red arrow).

Wiggle the fan and clutch off the front of the pulley and remove it from the vehicle (red arrow).
Figure 16

Wiggle the fan and clutch off the front of the pulley and remove it from the vehicle (red arrow).

If you are replacing the clutch, use a 5mm Allen and separate the three Allen bolts (red arrows) holding the clutch to the fan.
Figure 17

If you are replacing the clutch, use a 5mm Allen and separate the three Allen bolts (red arrows) holding the clutch to the fan. Installation is the reverse of removal.

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Comments and Suggestions:
Scott Comments: I had to replace the cooling fan bracket as it came apart on my drive home one day, I thought i put everything back together correctly, but my cooling fan/clutch seems to be rubbing against the outside of the fan pulley. I'm just wondering if there is a spacing washer of some sort between these parts I overlooked when I put these parts back together. Thanks for you help!
October 25, 2016
  Followup from the Pelican Staff: No. you may have the wrong part installed or something is still broken. - Nick at Pelican Parts  
S T Choo Comments: How do we know when to replace the fan clutch? Is it when we hear knocking sound from the engine compartment? My 280E1994 has knocking sound whenever I step on the accelerator. The sound will disappear when I lift my leg off the accelerator.
September 21, 2016
  Followup from the Pelican Staff: usually when they have excessive play or noise. I would try to isolate the area of the knocking. - Nick at Pelican Parts  
Bashir Chughtai Comments: Great write up but may add the following:
1. In Figure 1, you mentioned a existing kink in hose but faile to show picture with no kink or what is fix to get rid off kink. What end of hose did you cut to fix it. It will be nice I'd you can add a picture after the fix.
2. Sharoud/guard is held against radiator in several hole; it will be nice to include a picture showing those notches to insure proper installation of Sharoud against radiator..
Thx for the write up. You may consider making video of this and upload on YouTube.
May 24, 2016
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 
sid Comments: Is there a washer required between the long bolt and fan clutch?
April 24, 2016
  Followup from the Pelican Staff: I don't believe there is one. - Nick at Pelican Parts  

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Page last updated: Fri 12/9/2016 02:57:55 AM