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Open front hood.
Remove 4 rivets at top of air intake duct at top of radiator.
For each rivet, pry out center pin (tack lifter), then fully pry out rivet from base (tack lifter).
Lift up the air intake duct and carefully remove it from the engine bay. As you do this , take note that the air intake duct will disconnect from the air filter housing.
Remove shroud air guide rivet at shroud top.
Pry out rivet center pin (tack lifter), then fully pry out rivet from base (tack lifter).
Remove left air guide rivet at rear face of air guide.
Pry out rivet center pin (tack lifter), then fully pry out rivet from base (tack lifter).
First, remove the left air guide by pushing it to the rear to release it from the mounting bracket. Then, pull it up and carefully remove the air guide from the engine bay.
Remove right air guide rivet at right side of guide.
Pry out rivet center pin (tack lifter), then fully pry out rivet from base (tack lifter).
First, remove the right air guide from the fan shroud by pushing it to the rear to release it from the mounting bracket. Next, lift the air guide up to release the lower mounting tab. Finally, let the air guide suspend on the radiator upper hose.
Note: Radiator upper hose runs through hole in air guide and thus air guide cannot be removed without removing upper radiator hose and loosing coolant. Repair can be performed with air guide suspended on upper radiator hose.
First, disconnect the AUC (smell) sensor electrical connector located at the top left of the fan shroud. To do this, press in on the top clip of the connector, and then pull the connector out.
Start by removing the auxiliary electric fan cable connectors from the fan shroud bracket.
Next, detach the cable from the bracket side tabs, and then pull the connectors up and out of the bracket.
Finally, use a T25 Torx bit socket (1/4″ socket with a 1/4″ ratchet) to remove the fan shroud mounting bolt located at the top left of the fan shroud.
Note: Bolt is longer than other similar bolts to be removed.
First, remove the right side light bulb cable electrical connector by pressing in the connector clip and then pulling the connector out. Note that removing the connector is necessary to create access space for the next step.
Start by removing the fan shroud mounting bolt located at the top right side of the fan shroud using a T25 Torx bit socket (1/4″ socket with a 1/4″ ratchet). Next , raise the front of the car and place it securely on jack stands. Be sure to follow the appropriate procedure, including chocking both sides of both rear wheels for safety.
Start by removing the three rear mounting bolts of the engine compartment shield using an 8mm 1/4” driver.
Next, detach the two mounting bolts on the right and left sides of the shield using the same tool. Once the bolts are removed , take off the engine compartment shield.
Remove fan shroud bottom left and right mounting bolts (T25 torx bit socket 1/4″ / 1/4″ ratchet & extension).
Lower car from jack stands (follow appropriate procedure).
First, remove the fan using the belt static friction method. Begin by removing the fan and fan clutch from the water pump shaft. Next , place an open-end wrench on the fan clutch nut using a 32mm combo wrench. Position the wrench forward on the nut to avoid hitting the thermostat hose. Then , firmly strike the top side of the wrench with a heavy hammer (such as a sledgehammer) to break the nut’s seize—remember, it has a left-hand thread
Note: Nut is left hand thread, thus unscrew by hitting wrench top from left to right (car front orientation). Serpentine belt static friction on water pump pulley facilitates large enough opposing force to break nut seize. It is important to use a heavy hammer to produce a high instantaneous jerk. Several attempts will be needed before nut seize breaks. Rotate open wrench to reposition for better access.
If belt static friction method is not successful, attempt pulley holding tool method.
First, remove the fan using the pulley holding tool method. Begin by removing the fan and fan clutch from the water pump shaft. Next, position the water pump pulley to allow access for the holding tool. The water pump pulley has two adjacent pairs of mounting bolts. Position one of the bolt pairs so that the left bolt is just to the right of the top center (refer to the picture) using a 32mm combo wrench.
Once the pulley is positioned, set the air guide aside (refer to the picture). Then, install the water pump pulley holding tool onto the pulley bolts. Position the holding tool to the right, ensuring the tool’s indent curve rests against the fan clutch nut. Mount the tool’s end hole onto the bottom-left pulley bolt and the second hole onto the right pulley bolt.
Afterward, reposition the fan clutch nut for better access to the holding tool (refer to the picture). Place an open-end wrench on the fan clutch nut using a 32mm combo wrench. Counter-hold the holding tool and break the clutch nut’s seize using the same wrench; remember that it has a left-hand thread.
Note: Nut is left hand thread, thus unscrew by turning wrench from left to right (car front orientation).
If fun clutch nut seize difficult to break, apply lubricant to nut/threads contact surfaces (spray lubricant).
Once nut seize is broken, remove tools and spin fan blades to unscrew nut; left hand thread.
When nut is close to shaft end, turn fan slowly while continuously holding fan blades. This will keep fan from falling and damaging radiator fins when fully disconnected.
Remove fan/clutch from fan shroud.
Place right air guide to right and front.
Lift fan shroud up while maneuvering fan/clutch out of fan shroud and engine bay.
Note: Rotate fan to facilitate better positioning.
- First, remove the fan shroud from the engine bay.
- Then, move the right air guide to the left and rear.
- After that, push the fan shroud to the left and pull up the right side of the fan shroud.
- Next, push the fan shroud to the right and pull up the left side of the fan shroud.
- Finally, remove the fan shroud completely from the engine bay.
Fan & shroud installation (E46 M3 Fan & Shroud)
Place right air guide to left and rear.
Install fan shroud in engine bay.
Push shroud to right and tilt down left side.
Push shroud to left and lower down right side.
Maneuver shroud to center and against radiator.
Mount shroud by pulling up, forward, and dropping into position.
Place right air guide to right and front (picture).
Insert fan/clutch in fan shroud. Lift shroud up and forward while maneuvering fan/clutch into shroud.
Note: Fan is oriented with clutch nut to car rear.
Mount fan/clutch onto water pump shaft.
Lift fan and mate (hang) fan clutch nut onto water pump shaft. Rotate fan to find best nut thread to shaft thread mate. At optimal fit, fan will hang on shaft without threading (picture).
With fan hanging independently on shaft, slowly turn fan blades to thread nut onto shaft; left hand thread. Fully thread nut onto shaft.
Fully mount shroud by pulling up, forward, and dropping down into left side frame slot.
Place open wrench on fan clutch nut (32mm combo wrench) and lightly hit wrench top with heavy hammer, one time; left hand thread (sledge hammer).
Note: Serpentine belt static friction on water pump pulley facilitates large enough opposing force to tighten clutch nut. Fan opposing spin also tightens fan clutch nut.
Install fan shroud mounting bolt at top right side of fan shroud (T25 torx bit socket 1/4″ / 1/4″ ratchet).
Note: Shroud right mounting bolt is short.
Install right side light bulb cable electrical connector.
Press in connector until clip snaps into place.
Install fan shroud mounting bolt at top left of fan shroud (T25 torx bit socket 1/4″ / 1/4″ ratchet).
Note: Shroud left mounting bolt is long.
Install auxiliary electric fan cable connectors in fan shroud bracket.
Pull connectors up and insert into bracket.
Install cable in bracket side tabs.
Install AUC (smell) sensor electrical cable connector at top left of fan shroud.
Press in connector until clip snaps into place.
Raise front of car and place on jack stands (follow appropriate procedure; chock both sides of both rear wheels).
Install fan shroud bottom left and right mounting bolts (T25 torx bit socket 1/4″ / 1/4″ ratchet & extension).
Insert engine compartment shield into front bumper and align into install position.
Install engine compartment shield 3 rear mounting bolts (8mm 1/4″ / 1/4″ driver).
Install engine compartment shield 2 mounting bolts at right and left side of shield (8mm 1/4″ / 1/4″ driver).
Lower car from jack stands (follow appropriate procedure).
Insert right air guide lower hook into shroud slot.
Press right air guide forward and insert guide square hole onto shroud bracket.
Install rivet at right air guide bracket.
Pry rivet center pin out, fully insert rivet base into air guide and shroud, then press in rivet center pin.
Insert shroud left air guide into place.
Insert guide right lower hook into shroud slot.
Press guide forward and insert guide square hole onto shroud bracket.
Install rivet at rear face of left air guide.
Pry rivet center pin out, fully insert rivet base into air guide and shroud, then press in rivet center pin.
Align left and right shroud air guides at shroud top center.
Install rivet at shroud top center. Pry rivet center pin out, fully insert rivet base into right and left guides and shroud, then press in rivet center pin.
Install air intake duct on top of radiator.
Insert duct into air filter housing.
Install 4 rivets at top air intake duct. For each rivet, pry rivet center pin out, fully insert rivet base into air intake duct, then press in rivet center pin.
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