Remove and replace the engine cooling fan assembly including the fan motor and shroud on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Cooling fan assembly (motor and shroud) × 1 — Use OEM specification
• Radiator mounting rubber grommets (if damaged) × 4 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 1 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery terminal and wait 3 minutes for capacitor discharge
3. Remove engine cover by pulling upward on front clips and lifting off
4. Place drain pan under radiator to catch any coolant spillage
5. Take photo of fan electrical connector orientation for reference during reassembly

Procedure

1. 1

   Disconnect fan electrical connector
   Locate the cooling fan electrical connector on the driver's side of the fan shroud. Press the release tab and pull the connector straight out from the fan motor. Move the wiring harness aside to prevent damage during removal.
2. 2

   Disconnect upper radiator hose clamp
   Locate the upper radiator hose where it connects to the radiator on the driver's side. Use needle nose pliers or flathead screwdriver to release the spring clamp and slide it back approximately 2 inches on the hose. Twist the hose gently to break the seal but do not fully remove yet.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Remove fan shroud upper mounting bolts
   Remove the two 10mm upper mounting bolts securing the fan shroud to the radiator. These are located at the top corners of the shroud. Keep these bolts in a safe place as they will be reused.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Release lower shroud tabs
   The lower portion of the fan shroud is secured by two plastic tabs that insert into the radiator lower bracket. Carefully lift the entire fan assembly upward approximately 1 inch to disengage these tabs from their slots. You may need to gently rock the assembly side to side while lifting.
5. 5

   Remove cooling fan assembly
   With the upper bolts removed and lower tabs released, carefully lift the fan assembly straight up and out of the engine bay. Tilt the top of the assembly slightly toward the engine to clear the radiator upper tank. Be careful not to damage radiator fins or pull on the upper radiator hose. Some coolant may drain from the radiator neck during removal.
6. 6

   Inspect radiator mounting points
   With the fan removed, inspect the rubber mounting grommets on the radiator where the fan shroud tabs inserted. Check for cracks, tears, or deterioration. Replace if damaged. Inspect radiator fins for damage and straighten any bent fins with a fin comb if available.
7. 7

   Install new cooling fan assembly
   Position the new fan assembly above the radiator. Tilt the top slightly toward the engine and lower the assembly into position. Align the lower shroud tabs with the slots in the radiator lower bracket and press down firmly until the tabs click into place. Ensure the shroud sits flush against the radiator on both sides.
8. 8

   Install upper mounting bolts
   Install the two 10mm upper mounting bolts through the fan shroud into the radiator upper brackets. Start both bolts by hand to ensure proper thread engagement. Tighten to specification using a torque wrench in a criss-cross pattern to ensure even pressure.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Reconnect upper radiator hose
   Push the upper radiator hose firmly onto the radiator neck if it was loosened during removal. Slide the spring clamp back into position over the radiator neck approximately 1/2 inch from the end of the hose. Ensure the clamp is seated in the hose groove.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
10. 10

    Reconnect fan electrical connector
    Connect the electrical connector to the cooling fan motor. Push firmly until you hear and feel a positive click indicating the locking tab is engaged. Gently tug on the connector to verify it is fully locked. Ensure the wiring harness is routed away from moving parts and has adequate clearance.
11. 11

    Check coolant level and refill
    Remove the radiator cap (engine must still be cold). Check coolant level and top off with Hyundai/Kia Long Life Coolant (Green) to the proper level at the radiator neck. Replace the radiator cap and also check the overflow reservoir, filling to the FULL COLD mark if needed.

Reassembly

1. Reconnect negative battery terminal and tighten securely
2. Reinstall engine cover by aligning rear tabs first, then pressing down on front clips until they click
3. Double-check that all electrical connectors are fully seated and locked
4. Verify no tools or parts are left in engine bay

Verification

• Start engine and allow to idle. Listen for abnormal fan motor noise or vibration
• Allow engine to reach operating temperature (approximately 10 minutes). Cooling fan should activate automatically when temperature reaches threshold, typically around 200-210°F
• Verify fan runs smoothly without vibration or rubbing against shroud or radiator
• Turn on air conditioning. Fan should activate immediately and run continuously
• Check for coolant leaks around upper radiator hose connection
• Verify coolant level in overflow reservoir after engine cools down, top off if necessary
• Confirm no warning lights on instrument cluster related to cooling system or engine temperature

More procedures for this vehicle