Electric Fan Assembly Replacement
 

Mod Note: This will mostly be the same for any 4.0 XJ.

This write up is for replacing the stock electric fan assembly on the Jeep Cherokee (XJ). I did this on my 1999 Cherokee Sport with the 4.0 liter engine.

Tools needed:

1. 8mm socket (a 1/4 inch drive and ratchet if possible, makes it easier)
2. flashlight
3. pliers


Overview:

There are 2 screws on the top of the assembly and two slots/clips on the bottom that keep it in place. The replacement is fairly easy, but allow yourself an hour in case you have trouble pulling out the old assembly and putting in the new one; or (like me) if you drop clips or screws and have to fish them out.


Step 1:

Remove the two screws on top of the assembly; they are also keeping a coolant line in place. When doing this, be sure that the little clips stay in place on the body.

Attachment 232103

Step 2:

Next, you will need to move over to the passenger side and remove the two screws holding in the coolant line and also the plastic covering for the mechanical fan. This needs to be done so that the entire coolant line can be moved out of the way of the electric fan assembly. Same thing with the clips, leave them on the body.

Attachment 232104

Step 3:

Now that all the screws are removed (4) move the coolant line out of the way so that it doesn't get in the way. Notice that it runs from the coolant tank over to the radiator cap.

Attachment 232105

Step 4:

Here is the first fun part; remove the fan assembly. Make sure that the electric connector is unplugged, then pull the fan up and out. You will need to ease it back and forth and work it around the belt pulley. Mine was already broke, so I just did some yanking. Once out, the empty bay looks like this.

Attachment 232119

Here is the old fan assembly next to the new one. The old stock one is an 8 blade and the new one is a 10 blade. I ordered mine from Quadratec.

Attachment 232121

Continued...
 

Step 5:

Now for the REALLY fun part; getting the new fan in. This is tough, and requires you to ease the fan in at an angle around the pulley. You will probably also have to move around the mechanical fan cover on the passenger side; this is okay, it can be clipped back in no problem. I had to lightly squeeze the fan blade into the assembly and go in the bay at an angle. Once it was partially in I just tapped on the left side, then the right side, until it fell down in to place. Once the assembly is in the bay, it will look like this.

Attachment 232122

Step 6:

Next comes fitting the plastic clips on the bottom of the assembly into their slots. Use your flash light to make sure the clips are in place; you may have to look from under the vehicle. Once this is done, the holes on the top of the assembly should align with the holes and clips on the body.

Attachment 232123

Step 7:

After the clips are in place and the holes aligned, make sure that the plastic fan cover on the passenger side is also back in place with its plastic tabs in their slots. Take the coolant hose and put it back into place and put all 4 screws back into position. Be careful not to strip them and rotate tightening them until they are all snug and the fan assembly does not move when you wiggle it.

Attachment 232124

Step 8:

Plug in the electric connector and you are good to go! The connector on my new fan assembly did not match the connector on the Jeep, so I had to take my old plug off my old fan and splice it into the new fan; hopefully this doesn't happen to you.