okay, this is my first tutorial, so bear with me.
This is to replace or repair a radiator fan that is not working. it is easy to test this. put the key in the ignition and turn it to the on position, the car itself does not have to be running. push the A/c button and turn the blower fan on 1. now open the hood and both the fans should be spinning in unison. read more about the subject and possible causes here: http://forums.tdiclub.com/showthread...t=radiator+fan
and here is the fan repair PDF: http://pics.tdiclub.com/data/517/Fan_Repair.pdf
the car this is being performed on is a 2002 golf tdi. the process is defintitely the same for all ALH golfs and jettas, and might also apply to the PD jetta/golf and all NBs, im not sure about those.
the process is pretty much the same. the passenger side fan comes out the bottom and the drivers side can slide out the top. this tutorial demonstrates the drivers side fan being removed.
ratchet and various extensions
First, put the car up on jack stand and remove the engine cover and belly pan. dont forget to unhook the vacuum line from the engine cover before pulling it if you own a jetta or golf! now remove the battery cover. it may also be wise to remove the battery if you have big hands. my small hands plus a bit of patience and i was able to get the the torx by the battery.
belly pan off, engine cover waiting for removal
heres a picture of the things your trying to get to.
go underneath. bring your T-27 Torx you will see one of the torx bolts and the plug for the fan.
you may have to pull the fan wire out of the housing to see and get to the bottom torx.
heres what kind of plug it is. it comes off if you pull hard enough, but i suggest doing it the right way.
undo the top 2 torx and the fans ready to come out.
heres the path out. you may need to bend and push some hoses out of the way, but it will come out.
now the fan only comes into 2 pieces. undoing the 3 10mm nuts on the back of the housing allows it to come off for removal/ installation of your new fan, or just to fix the old one.
reinstallation is the same thing backwards. the 3 pronged housing IS directional in how it fits over the motor. theres a notch where the wires go through. start to finish for this was 30 minutes. it was my 3rd time.
be careful when supporting the car. if you break anything its not my fault. use common sense and dont force anything