How do I change the fan relay on Jeep 2002 Jeep Grand Cherokee?

Answer 1

Answer

The fan relay is under the front bumper cover beneath the right headlight. This is a pulse width modulated relay controlled by the Powertrain Control Module. The heat sink side of this relay is bolted to the frame underneath the bumper cover. The factory service manual would have you remove the entire front bumper cover and grill. About a 2 hour operation for a dealer.

A quicker and less painful way is to remove the right headlight (remove one long bolt and pop the light assembly out). Then use a 2 inch hole saw to cut 2 overlapping holes (makes a figure 8) with the right edge of the holes down the right edge of the reinforcing groove of the composite structure under the headlight.

2009-07-26 All is correct; however, I was unsure were to cut, I used a flashlight & mirror to search for the relay behind the plastic portion of passenger side headlight cavity. The outside edge of the hole that you will need to cut starts about 3-4 inches from the outside edge of the cavity, this will make your center being about 7-8 inches from the edge. The relay is on a slope and you will need an elbow extension or will need to cut more plastic closer to the front of the vehicle - best of luck

I wish I could add a picture here. The area to cut out is the side closest to the fender. (So it would be the right side if you are sitting in the drivers seat looking forward.) Save the plastic cut outs and tape them back into place, then use silicone to fix them back into place. When the silicone dries enough, remove the tape and apply more silicone to the areas formerly covered by tape. The headlight should pop back into place fairly easily. If I had known where to cut the hole exactly the job would have taken a half an hour or so to complete. I cut a fairly large access hole (knowing it would be repaired) and had no problem at all with accessing and replacing the relay. Good luck with your repair!

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