This procedure covers the removal and replacement of the engine cooling fan motor assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Engine cooling fan motor assembly × 1 — Use OEM specification
• Radiator drain plug O-ring × 1 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after operation)
2. Park vehicle on level ground and engage parking brake
3. Open hood and support securely
4. Disconnect negative battery terminal and wait 3 minutes for system discharge
5. Remove engine cover by pulling upward on retaining clips

Procedure

1. 1

   Drain partial coolant
   Place drain pan beneath radiator drain plug on driver side lower corner of radiator. Open radiator cap slowly to release any residual pressure. Remove radiator drain plug and allow approximately 2-3 quarts of coolant to drain until coolant level drops below the upper radiator hose connection. Replace drain plug O-ring and reinstall drain plug finger-tight for now.
2. 2

   Disconnect upper radiator hose
   Locate the upper radiator hose connection on the driver side of the radiator. Use flat blade screwdriver to loosen the spring-type hose clamp and slide it back approximately 2 inches away from the radiator neck. Carefully twist and pull the hose off the radiator connection. Allow any remaining coolant to drain into pan.
   Torque spec

   Hose Clamps4 Nm (3 lb-ft)
3. 3

   Remove air intake duct
   Loosen the clamp securing the air intake duct to the throttle body using a flat blade screwdriver. Disconnect the intake duct from the air box by releasing the spring clips on both sides. Remove the entire air intake duct assembly to provide access to the cooling fan.
4. 4

   Disconnect cooling fan electrical connector
   Locate the cooling fan motor electrical connector on the fan shroud assembly (passenger side). Press the locking tab and carefully pull the connector apart. Do not pull on the wires themselves. If equipped with a secondary connector for fan control module, disconnect it as well.
   Torque spec

   Electrical Connector5 Nm (4 lb-ft)
5. 5

   Remove radiator cover brackets
   Remove the upper radiator cover/support brackets if present. These are typically secured with two to four bolts along the top of the radiator support. Remove the bolts using a 10mm socket and set brackets aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
6. 6

   Remove cooling fan shroud mounting bolts
   Locate the cooling fan shroud mounting bolts around the perimeter of the fan shroud assembly. There are typically four mounting bolts: two on top and two on the bottom sides. Remove all mounting bolts using a 10mm socket with extension. Support the fan assembly with one hand while removing the final bolt.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Remove cooling fan assembly
   Carefully lift the cooling fan and shroud assembly upward and out of the engine bay. Tilt the assembly slightly toward the engine to clear the radiator, then lift straight up. Be careful not to damage the radiator fins or AC condenser during removal. Set assembly on clean work surface.
8. 8

   Remove fan motor from shroud
   Place the fan shroud assembly on a clean work surface with the motor side facing up. Remove the three or four fan motor mounting bolts using a 10mm socket. The motor is secured to the shroud with bolts arranged in a circular pattern. Carefully separate the motor from the shroud, noting the orientation of any alignment tabs or locating pins.
   Torque spec

   Fan Motor Bolts8 Nm (6 lb-ft)
9. 9

   Install new fan motor
   Position the new cooling fan motor onto the shroud assembly, ensuring proper alignment of any locating pins or tabs. Install all fan motor mounting bolts hand-tight first to ensure proper seating, then torque to specification in a cross-pattern sequence.
   Torque spec

   Fan Motor Bolts8 Nm (6 lb-ft)
10. 10

    Install cooling fan assembly
    Carefully lower the cooling fan and shroud assembly into the engine bay. Tilt slightly toward the engine to clear the radiator, then position the shroud mounting tabs into their respective slots on the radiator frame. Ensure the assembly sits flush against the radiator support before installing bolts.
11. 11

    Secure fan shroud and brackets
    Install all fan shroud mounting bolts hand-tight first to ensure proper alignment. Torque all mounting bolts to specification. Reinstall radiator cover brackets if removed and torque cover screws to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Reconnect electrical connections
    Reconnect the cooling fan motor electrical connector, ensuring it clicks securely into place. If equipped with a secondary fan control module connector, reconnect it as well. Verify connectors are fully seated and locking tabs are engaged.
    Torque spec

    Electrical Connector5 Nm (4 lb-ft)
13. 13

    Reinstall air intake duct
    Position the air intake duct back onto the air box and secure the spring clips. Connect the opposite end to the throttle body and tighten the hose clamp securely. Ensure the duct is properly seated and has no kinks or obstructions.
14. 14

    Reconnect upper radiator hose and refill coolant
    Reconnect the upper radiator hose to the radiator neck. Slide the hose clamp into position over the connection point and tighten to specification. Tighten the radiator drain plug to specification. Using a funnel, refill the cooling system with Hyundai/Kia Long Life Coolant (Green) through the radiator cap opening until the coolant reaches the full mark. Install the radiator cap securely.
    Torque spec

    Hose Clamps4 Nm (3 lb-ft)
15. 15

    Bleed cooling system and test
    Reconnect the negative battery terminal. Start the engine and allow it to reach normal operating temperature with the heater on high. Monitor coolant level and add as necessary to maintain proper level. Watch for leaks around the radiator hose connection. Once at operating temperature, verify the cooling fan activates automatically. Shut off engine, allow to cool, and recheck coolant level. Top off as needed and reinstall engine cover.

Reassembly

1. Torque all fasteners to specification in the sequence provided
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Verify radiator hose is properly clamped with no coolant leaks
4. Top off coolant to proper level after initial test run and cooling period

Verification

• Start engine and verify no coolant leaks from hose connections or drain plug
• Allow engine to reach normal operating temperature (180-195°F)
• Confirm cooling fan activates automatically when engine reaches operating temperature
• Verify fan runs smoothly without unusual noise or vibration
• Check that coolant level remains stable after test run
• Scan for diagnostic trouble codes related to cooling fan operation

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