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Replacing Your Electric Fan
 
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Pelican Technical Article:

Replacing Your Electric Fan

Steve Vernon

Time:

2 hours2 hrs

Tab:

$600

Talent:

*

Tools:

10mm socket and wrench, pliers, diagonals

Applicable Models:

Mercedes-Benz W203 (2001-07)

Parts Required:

Fan and shroud

Hot Tip:

Be careful working around the radiator

Performance Gain:

Proper engine temperature

Complementary Modification:

New radiator

The auxiliary fan and shroud assembly for the Mercedes-Benz W203 is only sold as a set and is not cheap. Make sure you have checked all your electrical issues (fuses and connections) before you order a new fan assembly. The removal and installation itself is not difficult, just be careful working around the radiator as you do not want to damage it.

Begin by disconnecting the ground from the battery and making sure it can not accidentally make contact again while you are working.

You will need to remove the two air inlet ducts as well as the front engine cover.

Remove each duct by compressing them towards the engine and slipping them off the air inlet.

With the ducts off remove the front engine cover. It pulls up and away from the engine. The cover is held on by five clips and will easily come off with hand pressure.

In front of the radiator you will find the horns. Remove the four electrical contacts for the two horns and using a 10mm socket remove the horns from the center bracket.

Cut the zip tie that holds the horn wiring harness to the center bracket on the cross member.

Remove the 10mm bolt that holds the power steering line to the center bracket.

There are two 10mm bolts holding the center bracket to the front of the car from the back of the bracket. Use a small wrench and working from behind the bracket remove these two bolts.

Unscrew the two hood stops (one on each side), they simply unscrew and then pull out. This will allow you to compress the plastic clip from the radiator shroud when removing the cross member.

Use a 10mm wrench and remove the two bolts holding down the hood releases on both sides of the cross member.

Pull the hood releases up through the cross member and detach the release cables from the release mechanism.

Remove the upper two 10mm bolts on each side of the cross member.

Compress the two plastic clips holding the wiring harness to the cross member and push them down through the holes in the cross member.

Lift the cross member out and flip it over. Next you need to remove the hood release cable on the right side. It just slips out of its plastic retaining clip.

Remove the two air inlet ducts. They have a small clip on the top, push it down and slide the duct off.

Undo the electrical connection from the wiring harness to the fan assembly.

Carefully remove the fan assembly from the car. Take care that you do not damage the four clips (two on each side) that help secure the assembly to the radiator.

Installation is the reverse of removal.

Begin by disconnecting the ground from the battery and making sure it can not accidentally make contact again while you are working.
Figure 1

Begin by disconnecting the ground from the battery and making sure it can not accidentally make contact again while you are working.

You will need to remove the two air inlet ducts (red arrows) as well as the front engine cover (yellow arrow) to get access to the air filter housing on top of the engine.
Figure 2

You will need to remove the two air inlet ducts (red arrows) as well as the front engine cover (yellow arrow) to get access to the air filter housing on top of the engine.

Remove each duct by compressing them towards the engine (red arrow) and slipping them off the air inlet.
Figure 3

Remove each duct by compressing them towards the engine (red arrow) and slipping them off the air inlet.

With the ducts off remove the front engine cover.
Figure 4

With the ducts off remove the front engine cover. It pulls up and away from the engine (yellow arrow).

The cover is held on by five clips (red arrows) and will easily come off with hand pressure.
Figure 5

The cover is held on by five clips (red arrows) and will easily come off with hand pressure.

In front of the radiator you will find the horns.
Figure 6

In front of the radiator you will find the horns. Remove the four electrical contacts (yellow arrows) for the two horns and using a 10mm socket remove the horns from the center bracket (red arrow).

Cut the zip tie (red arrow) that holds the horn wiring harness to the center bracket on the cross member.
Figure 7

Cut the zip tie (red arrow) that holds the horn wiring harness to the center bracket on the cross member.

Remove the 10mm bolt (red arrow) that holds the power steering line to the center bracket.
Figure 8

Remove the 10mm bolt (red arrow) that holds the power steering line to the center bracket.

There are two 10mm bolts holding the center bracket to the front of the car from the back of the bracket (red arrows, not shown).
Figure 9

There are two 10mm bolts holding the center bracket to the front of the car from the back of the bracket (red arrows, not shown). Use a small wrench and working from behind the bracket remove these two bolts.

Unscrew the two hood stops (one on each side), they simply unscrew and then pull out (red arrow).
Figure 10

Unscrew the two hood stops (one on each side), they simply unscrew and then pull out (red arrow). This will allow you to compress the plastic clips (yellow arrows) from the radiator shroud when removing the cross member.

Use a 10mm wrench and remove the two bolts (red arrows) holding down the hood releases on both sides of the cross member.
Figure 11

Use a 10mm wrench and remove the two bolts (red arrows) holding down the hood releases on both sides of the cross member.

Pull the hood releases up through the cross member and detach the release cables (red arrow) from the release mechanism.
Figure 12

Pull the hood releases up through the cross member and detach the release cables (red arrow) from the release mechanism.

Remove the upper two 10mm bolts (red arrows) on each side of the cross member.
Figure 13

Remove the upper two 10mm bolts (red arrows) on each side of the cross member.

Compress the two plastic clips (red arrows) holding the wiring harness to the cross member and push them down through the holes in the cross member.
Figure 14

Compress the two plastic clips (red arrows) holding the wiring harness to the cross member and push them down through the holes in the cross member.

Lift the cross member out and flip it over.
Figure 15

Lift the cross member out and flip it over. You need to remove the hood release cable on the right side. It just slips out of its plastic retaining clip (red arrow).

Remove the two air inlet ducts.
Figure 16

Remove the two air inlet ducts. They have a small clip on the top, push it down and slide the duct off (red arrow).

Undo the electrical connection from the wiring harness (red arrow) to the fan assembly.
Figure 17

Undo the electrical connection from the wiring harness (red arrow) to the fan assembly.

Carefully remove the fan assembly from the car.
Figure 18

Carefully remove the fan assembly from the car. Take care that you do not damage the four clips (red arrows, two on each side) that help secure the assembly to the radiator.

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Comments and Suggestions:
Kiena Comments: Hi, does the c180 engine fan fit on the c230 mercedes?
August 23, 2016
  Followup from the Pelican Staff: Not that I know of. 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
 
manish Comments: Thanks pelican part s
August 6, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
a_bake25 Comments: Where exactly would I plug it in if it is the control circuit for the fan relay?
June 23, 2016
  Followup from the Pelican Staff: Look on the fan housing for an empty plug. Your other option is to grab a wiring diagram for your vehicle and identify the connector using the wiring colors and terminal count. - Nick at Pelican Parts  
a_bake25 Comments: There is a small plug connected to the plug from the fan on my 2003 clk320, where does that go?
June 21, 2016
  Followup from the Pelican Staff: Looks like it may be the control circuit for the fan relay. - Nick at Pelican Parts  
andy Comments: on step 11, the driver side hood release on my car 05 c230 had a small electical plug hood open sensor. you need to unplug it before pulling out the release or you can damage the plug.
February 17, 2015
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it.
- Nick at Pelican Parts
 
John Comments: Very useful tutorial, thank you very much pelicanparts.com
October 17, 2014
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
buttah Comments: hi i have a 05 c240 4matic....do you know how to remove the fan motor from the assembly i removed screws from front and back and would like to take out the electrical connection but don't know how to take that part out...if you can email me directions or photos on how to remove it i would really appreciate it.
September 17, 2013
  Followup from the Pelican Staff: Thee is a locking tab underneath the connector. Use a pick to unlock it and slide the connector towards the fan to get if off of it's holder. - Kerry at Pelican Parts  

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