Removing Radiator Cooling Fan on C4S

[spender]

Firstly, apologies for the cross-post. I put this topic up at Rennlist this morning, but got no replies...

I need to change a ballast resistor on my C4S, and on this car, it's not as easy as for the slim-body 996s. I'd rather not remove the rads because it seems to me that would add a lot of work. Once I get the fan out, it'll be easy for me to change the ballast resistor (I'm an electronics guy).

Based on instructions that I've seen in the Bentley workshop manual (pages 19-22 and 19-23), it looks like the whole fan housing assembly just slides off the back of the radiators (with the wheel liner removed) without too much fuss - apparently without the need for removing the radiator.

Basically, I believe the order (adapted from Bentley) is to:

1. Remove rad mounting "circlips".

2. Remove bracket mounting bolts and bracket.

3. Remove radiator support bracket.

4. Disconnect fan electrical connection and detach remaining clips from fan housing.

5. Slide fan housing out of bracket.

Is it really this simple? Am I correct then that you don't need to remove the full radiator to get the fan off?

I've studied a picture of the 996 Turbo/C4S radiator, and it looks like if I undo the two screws noted (near the edge of the car) and then pull out, the fan housing should slide right out - it is only slide clips that hold the fan housing to the back of the rad.

This correct?

Also, how do you remove the "circlip" that the outer edge of the radiator is fastened to?

[xmac]

Go to the 996 DIY Tutorials and look under the Common Fixes section.

[DaveCarrera4S]

Here is the resistor tutorial, http://www.renntech.org/forums/tutorials/article/40-removing-and-installing-ballast-resistor-for-the-radiator-fan-motor/

[spender]

Thanks Mac and Dave - appreciate the replies. However, the "resistor structure" on the 996 C4S fan is pretty different from the C2 996 resistor - part looks completely different and is stuck to the back of the fan assembly, rather than hanging down like a cigar. Anyway, I'm pretty sure it is still doable without removing the rads, might try next weekend.

[Loren]

I do not see why you can not go through the wheel well.

If you remove the wheel and the wheel well liner you should have plenty of access to the back of the radiator mounting.

[xmac]

Thanks Mac and Dave - appreciate the replies. However, the "resistor structure" on the 996 C4S fan is pretty different from the C2 996 resistor - part looks completely different and is stuck to the back of the fan assembly, rather than hanging down like a cigar. Anyway, I'm pretty sure it is still doable without removing the rads, might try next weekend.

Sorry, too quick on the keyboard. Looks like it is an integrated part of the fan assembly. If it was me, I would remove the front bumper to get full access and then clean the radiators while removed.

[spender]

Greetings - I went ahead and did this on the weekend. Was not really a bad job, just lots to pay attention to! Took about 4 hours to get everything done (replaced one whole fan unit, and replaced the ballast resistor on one side) -- and this included cleaning out the rads.

As it turns out, to be able to pull the radiator fans out on a C4S / 996 Turbo, you do need to remove the bumper as one of the bolts is hidden far beneath the bumper (the other 3 are easily accessible just by removing the wheel well cover). Once these are off, easy to pull out the fan mounts and either replace the whole fan unit (as I did on one side), and a little more work to replace the ballast resistors. What makes the ballast resistor a little more work to replace is that there is literally zero-tolerance on the amount of wire available (i.e you get one cut, that's it) and on one of the solder points, you need to splice two wires together and yet still join them to a fairly small mounting point.

Anyway, I will post some pictures shortly.

[Saadi996tt]

Hi Spender,

I read your post about replacing the ballast resistor on your C4s and I wanted to ask you how you went about replacing it. I have an 02 996tt and the driver side fan only comes on high speed when I put the AC on and the passenger side doesn't work at all. I just purchased the new fan motor with the ballast resistor but don't know where to buy just the resistor or how to go about replacing it. Any advise would be greatly appreciated...

Thanks,

Saadi

[Loren]

Hi Spender,

I read your post about replacing the ballast resistor on your C4s and I wanted to ask you how you went about replacing it. I have an 02 996tt and the driver side fan only comes on high speed when I put the AC on and the passenger side doesn't work at all. I just purchased the new fan motor with the ballast resistor but don't know where to buy just the resistor or how to go about replacing it. Any advise would be greatly appreciated...

Thanks,

Saadi

 

http://www.renntech.org/forums/tutorials/article/40-removing-and-installing-ballast-resistor-for-the-radiator-fan-motor/

[Saadi996tt]

Hi Loren,

The link took me to a post talking about 3 center dash strip removal. Don't know if the link is correct or I'm doing something wrong?

[JFP in PA]

Hi Loren,

The link took me to a post talking about 3 center dash strip removal. Don't know if the link is correct or I'm doing something wrong?

 

I just tried it and it took me to the DIY for replacing ballast resistors................