Cooling Fan Assembly

Remove and replace the engine cooling fan assembly, including the electric fan motor and shroud, from the radiator mounting on a 2005 Dodge Viper 8.3L V10.

Warnings

Tools required

Parts

• Cooling fan assembly (electric fan and shroud) × 1 — Use OEM specification
• Radiator drain plug washer (if damaged) × 1 — Use OEM specification

Fluids

• Zerex G-05 HOAT 50/50 — 3 qt

Preparation

1. Ensure engine is completely cool to the touch.
2. Park vehicle on level ground and apply parking brake.
3. Place drain pan under radiator drain plug location.
4. Disconnect negative battery terminal to prevent fan activation during service.
5. Remove engine cover if equipped by pulling up on quick-release fasteners.

Procedure

1. 1

   Drain Coolant (Partial)
   Locate the radiator drain point (petcock or lower radiator hose) on the 2005 Viper. If a drain petcock is present, open it and allow approximately 3 quarts of coolant to drain into the pan, enough to lower the coolant level below the upper radiator hose connection; if no petcock is present, drain via the lower radiator hose. Close/hand-tighten the drain point (petcock — do NOT over-torque). This partial drain prevents coolant spillage when disconnecting hoses.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Disconnect Upper Radiator Hose
   Locate the upper radiator hose where it connects to the radiator (confirm the exact side against the factory service manual for the 2005 Viper). Use pliers to compress and slide the spring clamp away from the radiator neck. Twist the hose gently to break the seal, then pull it off the radiator neck. Be prepared for residual coolant to drain. Position the hose away from the work area.
3. 3

   Disconnect Fan Electrical Connector
   Locate the electrical connector for the cooling fan motor on the fan shroud. Press the release tab and pull the connector apart. The connector location on the fan shroud should be confirmed visually; verify against the factory service manual for the 2005 Viper. Ensure the connector is fully separated and secure the loose end away from moving parts.
4. 4

   Remove Fan Shroud Upper Mounting Bolts
   Locate the upper mounting bolts securing the fan shroud to the radiator support. Remove the upper mounting bolts from the top of the shroud assembly (confirm exact count and size against the factory service manual for the 2005 Viper). These bolts thread into the radiator support brackets. Set bolts aside in a secure location.
5. 5

   Remove Fan Shroud Lower Mounting Hardware
   Reach down to the lower portion of the fan shroud and locate the lower mounting tabs or clips that secure the shroud to the radiator. The shroud lower attachment may use tabs that hook into slots, clips, or fasteners on the lower radiator support (confirm exact mechanism and count against the factory service manual for the 2005 Viper). Release or remove these fasteners to free the bottom of the shroud.
6. 6

   Remove Cooling Fan Assembly
   With all mounting hardware and electrical connections removed, carefully lift the cooling fan assembly straight up and out of the engine compartment. Guide the fan blades carefully to avoid contact with the radiator fins or surrounding components. The assembly includes the fan motor, fan blades, and shroud as a single unit. Inspect the radiator fins for damage and straighten any bent fins with a fin comb if necessary.
7. 7

   Install New Cooling Fan Assembly
   Position the new cooling fan assembly above the radiator, aligning it with the mounting points on the radiator support. Carefully lower the assembly into position, ensuring the lower tabs engage their slots or mounting points on the lower radiator support. Guide the fan blades to avoid contact with radiator fins. Verify the shroud seats properly against the radiator.
8. 8

   Secure Lower Mounting Hardware
   Secure the lower mounting tabs or clips to lock the bottom of the shroud to the radiator. Ensure both lower mounting points are fully engaged and secure. Verify the shroud is seated evenly against the radiator on both sides.
9. 9

   Install Upper Mounting Bolts
   Install the 2 upper mounting bolts through the fan shroud into the radiator support brackets. Hand-tighten both bolts, then torque to the factory specification (small shroud bolts are typically low torque, ~7 ft-lbs for M6 / ~17 ft-lbs for M8 — verify the exact value in the factory service manual for the 2005 Viper). Verify the shroud is secure and does not move when pulled gently.
10. 10

    Reconnect Fan Electrical Connector
    Reconnect the electrical connector to the cooling fan motor. Press firmly until the connector clicks into place and the locking tab engages. Verify the connection is secure by gently pulling on the connector.
11. 11

    Reconnect Upper Radiator Hose
    Slide the upper radiator hose back onto the radiator neck, ensuring it is fully seated against the stop on the neck. Position the spring clamp over the hose connection and slide it into the correct position on the hose. Verify the hose is secure and the clamp is properly positioned.
12. 12

    Refill Coolant and Bleed System
    Open the system fill/pressure cap (on the 2005 Viper this may be located on the coolant expansion/reservoir tank rather than the radiator — confirm the correct fill and bleed point in the factory service manual). Add Zerex G-05 HOAT 50/50 coolant to the radiator until it reaches the base of the filler neck. Also check and fill the coolant reservoir to the FULL COLD mark. Reconnect the negative battery terminal. Start the engine and allow it to reach operating temperature with the radiator cap off. Add coolant as needed as air bleeds from the system. The thermostat will open and coolant level will drop; continue adding coolant until level stabilizes. Verify the electric cooling fan cycles on when the engine reaches normal operating temperature. Once the system is fully bled and the fan has cycled, shut off the engine, allow to cool slightly, and install the radiator cap. Check coolant level in the reservoir and top off to the FULL HOT mark if needed.

Reassembly

1. Reinstall engine cover if equipped by aligning and pressing down on quick-release fasteners until they click.
2. Double-check all electrical connections are secure and all mounting hardware is tight.
3. Verify no tools or rags were left in the engine compartment.

Verification

• Start the engine and verify no coolant leaks from the upper radiator hose connection or drain plug.
• Allow engine to reach operating temperature and verify the electric cooling fan activates automatically.
• Check coolant level in the reservoir after the engine has cooled and top off if necessary.
• Verify fan operation by turning on the air conditioning; the fan should activate.
• Listen for any unusual noises from the fan assembly during operation.
• Check that fan blades spin freely and do not contact the shroud or radiator.

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