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02 Sportage
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Discussion Starter · #1 ·
Hi everyone -

2002 Sportage (4dr., 4x4, A/C, AT)

I'm trying to remove the fan clutch . having hard time removing the 4 nuts that hold the fan clutch to the pulley.
The pulley moves when trying to break the nuts loose & i dont want to round off the nuts.
IS there and easy way do to it or a way to keep the pulley from moving?
:confused:

Thanks!
 

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Greetings,

Welcome to the forum.

Warm up the motor to normal temp., let cool down to warm, and with a good pair of gloves on just grab one of the fan blades to keep the pulley from turning, use a 10mm box-end wrench.

Just spin the fan & pulley to bring up each nut to a convenient spot to remove, one by one. *Just be careful not to drop the nut, it'll end up in the twilight zone / in the front shield guard.. :D

HTH & Regards,
GottaCruise
 

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Then I would over-tighten the belt @ the Alternator bracket, and use a wood/plastic/rubber wedge @ the alternator pulley to "lock" the fan clutch pulley..

* If somebody over-torqued the nuts and they are impossible to remove with a box wrench (or box wrench & rubber mallet), you may end up having to go through the process of removing the radiator, to gain enough room to get a socket in there..
 

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2-2000 1-2006ALL SPORTAGES also 96 dodge van to transport dogs and 84 gmc snow plow.
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Use a strap wrench ,wrap it around the snout of the pulley ,loosen the nut and proceed to the next one.If not available try using two wrenches / sockets hold one while loosing the other. On the last one insert a screw drive between the stud and pulley snout while loosing the last nut. Try not to damage the groves in the pulley. Hope this helps.
chief
 

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Discussion Starter · #6 ·
ugghhh two of the nut are rounded out ..now what? can they be cut off?
am trying to do without having to remove radiator.
 

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2-2000 1-2006ALL SPORTAGES also 96 dodge van to transport dogs and 84 gmc snow plow.
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You can try applying heat directly to the nut from a hand held propane torch , get the nut as hot as possible without melting everything. Using caution not to ignite leaked oil rubber hoses ect. Use a good fitting vice grip pliers and and holding the pulley with one of methods described above. Try working the nut back & forth until loose. This may need to repeated a couple times. A small hand held grinder with a cut off wheel may also be used, cut the nut only avoid cutting the stud. A pair of work gloves may be a good ideal do to heat.
 

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2000 Sportage 4x4 , 1998 Saturn SC2
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Its too late for Kroil , but next time use it the day before on those nuts and bolts that have not been remove in years.

Vice grips may be your next option after spraying Kroil on it.
 

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Discussion Starter · #10 ·
Thanks for all the useful info.

just found out there's a fan blade recall on these 2002 Sportages.
They'll have to remove the fan clutch assembly to replace the blade, right?
so am hoping they put on new nuts. then I can put on this new fan clutch after they fix the blade.
(cuz I am not going to pay Kia oem price for fan clutch & labor)
 

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Next time take a long screwdriver, on the left of the fan put it down between one of the nuts and the shaft of the fan. Put your 10 mm six sided box wrench on a nut on the other (right) side. Push down on both. The screwdriver will keep the fan from turning, and it is pretty difficult to round off a nut using the proper wrench (dont use a twelve point unless you have to they tend to round nuts). When you go to reinstall swap sides (wrench and screwdriver) Im in the middle of an engine swap and the donor engine is a 97 that doesnt look like its ever beeen apart. The nuts came right off, they shouldnt be torqued very tight to begin with.
 

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Next time take a long screwdriver, on the left of the fan put it down between one of the nuts and the shaft of the fan. Put your 10 mm six sided box wrench on a nut on the other (right) side. Push down on both. The screwdriver will keep the fan from turning, and it is pretty difficult to round off a nut using the proper wrench (dont use a twelve point unless you have to they tend to round nuts). When you go to reinstall swap sides (wrench and screwdriver) Im in the middle of an engine swap and the donor engine is a 97 that doesnt look like its ever beeen apart. The nuts came right off, they shouldnt be torqued very tight to begin with.
you state to push down on both the wrench and screwdriver. Wouldn't this tighten the bolt? Am I thinking backwards or are the screws reverse threaded?
 

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Threads are standard, counter-clockwise to loosen, clockwise to tighten..
--
+1 on spraying the nuts and threads w/ penetrating lubricant and letting sit, if difficult to remove, and +1 on using a 6-point box wrench to remove, to avoid rounding-off..
 
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