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Old 12-04-2019, 10:02 AM
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2.4L Cooling System Help!

Hey Everyone - I just recently bought a 2006 2.4l TJ and am new to the forum. When I bought this TJ it had some front end damage prior to me buying it that the PO made a poor attempt at fixing. It was in IL and virtually rust free so I figured I could more easily deal with the mechanicals, that the body issues.

The main issue I have right now is that he essentially replaced the entire cooling system radiator, fan, shroud assembly with whatever he could find. It works, but not well. IE he had a thermostat issue that he couldn't resolve so he just set the fan up to run constantly when the motor is running. There are no origninal parts left so I can't even determine what I might be able to salvage to go back to an original set-up. My question is what would you guys do? I know I have to stay with an electric fan but would a complete aftermarket upgrade of the system make most sense? Also....could anybody send me an original 2.4L TJ cooling system diagram or pictures of your set-up if you happen to have a 2.4L? Thanks a bunch!

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Old 12-04-2019, 11:49 AM   #2
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Wiring the fan to run constant would have no effect on a thermostat issue....
I would return the system to stock and start there....

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Old 12-04-2019, 11:58 AM   #3
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The system is pretty simple... there is a wire that runs from the pcm to the fan relay in the pdc... I would imagine that that is likely still in place

If anything, they probably just snipped the stock wiring near the fan... I'd do a little digging....
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Old 12-04-2019, 02:14 PM   #4
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It is a bit more complicated than that. The original uses a 2 speed fan & 2 fan relays in the PDC. And all PCM controlled. I think it is the same or at least similar to the system used in the non-turbo PT Cruisers. Possibly even Neons.

The FSMs do not address much for the 2.4s in the cooling section but more is covered in the PT Cruiser manuals. Here is an example I found on how the fans are controlled on the PTs.

Maybe you could have success getting what you need from a wrecking yard…
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Old 12-04-2019, 03:25 PM   #5
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Still just a wire controlling a relay... in this case 2 relays...

Either way some backyard mechanic isn't gonna strip wires from the pcm to the pdc out of the harness....
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Old 12-04-2019, 03:30 PM
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Thanks for the replies guys! I hear you with regard to taking the system back to stock. That would be my preference if I can pull it of without spending an arm and leg. I'm just trying to piece together how to go about that considering that I don't have a diagram/don't know what I might be missing. Regarding the parts, it sounds like the fan assembly is either no longer made or ungodly expensive so wrecking yard probably is going to have be part of the solution there. I'll keep you posted as I progress. Thanks again!
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Old 12-04-2019, 05:38 PM   #7
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Originally Posted by Gottagofast View Post
Still just a wire controlling a relay... in this case 2 relays...

Either way some backyard mechanic isn't gonna strip wires from the pcm to the pdc out of the harness....

I agree the wiring is probably all there but I doubt a “backyard mechanic” will source & wire up a 2 speed fan & depending which relay is running the fan the desired results as far as on & off temperatures will be affected. If it is controlled like the PTs, using the high speed relay will cause it to come on later (higher temps) & shut off sooner too.





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Originally Posted by petem7290 View Post
Thanks for the replies guys! I hear you with regard to taking the system back to stock. That would be my preference if I can pull it of without spending an arm and leg. I'm just trying to piece together how to go about that considering that I don't have a diagram/don't know what I might be missing. Regarding the parts, it sounds like the fan assembly is either no longer made or ungodly expensive so wrecking yard probably is going to have be part of the solution there. I'll keep you posted as I progress. Thanks again!

You have not said what problems you are having with the current setup. It may not even be related to the e-fan. But it running all of the time is not proper.

Just wanted you to know how it is supposed to work. It is very hard to find 2.4 TJs but there should be plenty of PTs in the yards. Getting the proper 2 speed fan would be good. Not all replacement electric fans are created equal. If you find it running hot when stopped like in bad traffic even with the running constantly it could be the fan is not moving enough air.
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Old 12-04-2019, 06:04 PM
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Thanks RUBI. To answer your question, I've experienced a few issues mechanically since getting this - one being the PCM which was replaced the next being a cylinder head repair. That stuff is done so now it's on to figuring out the cooling system. I have not had it overheat but I don't think having the fan constantly running is ideal. Also the new fan did not have the set-up for the coolant or PS fluid overflows, instead the PO zip tied them . Not ideal and a more appropriate fan would obviously rectify that as well. Thanks again!
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Old 12-04-2019, 10:05 PM   #9
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I missed the fan itself having been changed...
You COULD actually wire a single speed fan to run both high and low speed by wiring a resistor in on the low speed side and then connecting low and high to the + side of the fan in parrallel...

Another option would be to pick up a taurus or volvo 2 speed fan from the junkyard.... they are often used for v8 swaps so they should handle your lil 2.4....

If all of this fails the catch all fix for anything 4 cyl related is alway an LS swap....
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Old 12-07-2019, 08:55 AM   #10
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You don,t say where you are, but I have a complete 2.4 fan and shroud you can have if you want to pick up here in So.Calif. I'm in the high desert area, near Lancaster/Palmdale. It is too big to ship, or I would find that out. I don't think the PT fan will fit, as the shroud is so different.
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Old 12-07-2019, 09:25 AM
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Thanks for the offer. I really appreciate that and would definitely take you up on that. Unfortunately, I’m in SE Wisconsin.
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Old 12-08-2019, 12:04 AM   #12
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Nothing's too big to ship....
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Currently in the stable: ... 97 tj 4.0 5 speed stock....04 tj 4.0 auto 4" and 33's... 98 tj roller for future build... 94 yj sahara 4.5" RE and 33's... 92 yj sbc 3/4 ton axles and 38's... Cj5,7,yj,xj,ex mud dragster project

TJ dash speakers that actually rock! Kicker sub and amp in center console
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Old 12-08-2019, 08:58 AM   #13
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Quote:
Originally Posted by RUBI 4 MY MRS View Post
It is a bit more complicated than that. The original uses a 2 speed fan & 2 fan relays in the PDC. And all PCM controlled. I think it is the same or at least similar to the system used in the non-turbo PT Cruisers. Possibly even Neons.

The FSMs do not address much for the 2.4s in the cooling section but more is covered in the PT Cruiser manuals. Here is an example I found on how the fans are controlled on the PTs.

Maybe you could have success getting what you need from a wrecking yard…


The 2004 turbo cruiser at least the non GT one used a 2 speed fan the 2003 one used a variable seeped fan that is really expensive to replace


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