I swapped out my cracked fan on the 2002 Sportage yesterday. I did it the hard way, and in the process found out the easy way.
The information I've read suggests removing the fan shroud, radiator hose, and so on, but that's not necessary.
Pull off the cool air intake duct from the top of the radiator, with its rubber hose to the vapor recycle cannister. That's all you need to get out of your way. Use a 10mm box end wrench, and take the nuts off of the outside of the fan clutch where it attaches to the fan pulley. You might have to loosen the alternator belt a little to be able to turn the pulley on the fan to get at all four of the nuts. I had to push down on the fan belt to hold the fan still so I could break the nuts loose.
Don't drop any nuts, or they'll end up hiding down on top of the skid plate, and you'll have to figure out a way to fish them out. Need I explain how I know this?
After the four nuts are off, the whole fan and clutch assembly lifts out pretty easily. Then you can replace the fan blade assembly, and re install. I tightened the nuts in a criss cross fashion, to assure that it's centered properly.
I did take the shroud loose, which was a major pain in the behind, because reaching the bolts at the bottom is an excercise in agility. It was a total waste of time, because you can't get the shroud off over the fan anyway.
Live and learn, I guess.
Today's project: replace the POS vacuum hubs with Warn manual hubs. CY later!
Easiest way to swap cracked cooling fan
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