Cooling Fan Relay

Replace the cooling fan relay in the underhood fuse/relay box to restore proper cooling fan operation.

Warnings

Tools required

Parts

• Cooling fan relay × 1 — Use OEM specification
• Dielectric grease × 1 — Optional for terminals

Preparation

1. Park vehicle on level surface and allow engine to cool completely
2. Turn ignition off and remove key from vehicle
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait 2 minutes for system discharge
5. Locate the underhood fuse/relay box on the driver side of engine compartment

Procedure

1. 1

   Remove fuse box cover
   Release the clips securing the fuse/relay box cover. On the Levante, press the release tabs on each side and lift the cover upward to remove. Set cover aside in clean location to avoid damage to seal.
2. 2

   Identify cooling fan relay
   Locate the cooling fan relay using the diagram on the underside of the fuse box cover or in the owner's manual. The cooling fan relay is typically labeled 'FAN' or 'COOLING FAN' and is a larger cube-style relay. Take a photo of relay location for reference during reinstallation.
3. 3

   Test existing relay (optional)
   If multimeter is available, test the suspect relay before removal. Check for continuity between terminals per relay diagram. This confirms diagnosis and validates the new relay later.
4. 4

   Remove failed relay
   Firmly grasp the cooling fan relay and pull straight upward with steady pressure to remove from socket. If relay is difficult to remove, use relay puller tool or needle-nose pliers at base of relay body (not terminals). Rock gently side-to-side while pulling if needed.
5. 5

   Inspect relay socket
   Examine the relay socket terminals for corrosion, melting, or discoloration. Use flashlight to inspect socket cavity. Clean terminals with electrical contact cleaner if minor corrosion is present. If socket shows heat damage or melted terminals, the fuse box may require replacement - consult qualified technician.
6. 6

   Prepare new relay
   Remove new relay from packaging and verify it matches the original relay in physical size, terminal configuration, and electrical specifications (voltage and amperage ratings). Optionally apply small amount of dielectric grease to relay terminals to prevent future corrosion.
7. 7

   Install new cooling fan relay
   Align new relay terminals with socket slots, ensuring correct orientation. Press relay firmly into socket until it seats completely and sits flush with surrounding relays. Relay should click into place and feel secure with no vertical movement.
8. 8

   Reinstall fuse box cover
   Position cover over fuse/relay box, aligning tabs with slots. Press down firmly until all clips engage with audible click. Ensure cover seal seats properly around entire perimeter to maintain weatherproof protection.
9. 9

   Reconnect battery
   Reconnect negative battery terminal and tighten securely. Do not overtighten battery clamp. Clear any fault codes that may have been stored using scan tool if available.

Reassembly

1. Ensure fuse box cover is fully seated and all clips are engaged
2. Verify no tools or parts are left in engine compartment
3. Reset vehicle clock and radio presets as needed

Verification

• Start engine and allow to reach normal operating temperature while monitoring temperature gauge
• Verify cooling fans activate when engine reaches approximately 200-210°F (93-99°C)
• Turn on air conditioning and confirm fans engage immediately
• Listen for abnormal relay clicking or buzzing from fuse box during fan operation
• Use scan tool to verify no cooling system fault codes are present
• Test drive vehicle and monitor temperature gauge remains in normal range

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