How to Replace the Fan in a Saturn Ion

Replacing the engine fan on a Saturn Ion is rather challenging compared to other vehicles. While a novice can carefully follow these steps and successfully replace the engine fan on a Saturn Ion, make certain that you have a full ratchet set and screwdriver available, and leave yourself an entire day to work.

Instructions

1

Disconnect the negative battery cable first, and then the positive battery cable and slide the fan control module up and off the bracket. Lay the module and wiring out of the way, then remove the battery insulating cover, the battery hold down/fan control module bracket and the battery itself.

2

Unplug both the cooling fan electrical connectors. Carefully mark which is which with a marking pen or tape. Slide the sleeve back to remove the electrical connectors from the connector retainer. Remove the pusher fan electrical harness from the fan housing retainer tabs. Finally, remove the wiring harness from the clamp on the fan shroud.

3

Unbolt the fan housing from the radiator, and then remove the fan and housing from the engine compartment. Place the new fan and housing in the engine compartment and make certain the pusher fan electrical harness isn't trapped between the fan housing and the radiator; route it around the outside of the radiator end tank to the upper fan housing.

4

Plug the fan's electrical connectors back into the retainers and back into the retaining sleeve. Replace the wiring harness on the clamp on the fan shroud and place the pusher fan harness back in the routing tabs on the fan housing.

5

Make certain the battery tray is clean, then reinstall the battery and the battery hold down/fan control module bracket. Tighten the battery hold down bracket bolts to 15 ft foot pounds (20 Nm) of torque.

6

Replace the battery insulating cover. Reinstall the fan control module by sliding it down into the brackets, then reconnect first the positive, and then the negative battery cables.

7

Run your vehicle's engine and check for coolant leaks and normal engine cooling fan operation.