NHTSA ID Number: 10199974
Manufacturer Communication Number: IS-19901C
TSB/Document Date: 2021-08-05
Summary
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH BOSCH
ALTERNATOR - X3 SERIES US10 UP TO GHG17 COOLING SYSTEM
IS-19901C
Page 14 / 89
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1. Raise the L.H. side rear-hinged fender.
FIGURE 1
Drain the cooling system
2. Connect the coolant extractor. Use the coolant
extractor to drain the coolant from the engine.
An alternate method is to drain the coolant into
a suitable container using the drain hose.
FIGURE 2
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QF7720959 rev 5>
IS-19901C
Page 16 / 89
3. Unfasten two (2) cap screws and remove
access panel located behind the tag axle L.H.
side wheel.
FIGURE 3
4. Open radiator door to access radiator assembly.
Unfasten upper arm assembly.
FIGURE 4
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5. Remove radiator sealing frame.
FIGURE 5
6. Remove the rear bumper (undo three nuts each
side).
FIGURE 6
7. Remove the fan drive casting.
FIGURE 7
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8. Remove clamps and then break hoses of the
coolant and charge air pipes shown.
FIGURE 8
9. Remove the coolant and charge air hose
clamps shown then break hoses loose.
FIGURE 9
10. Remove the upper radiator assembly support
bracket.
FIGURE 10
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11. Remove the radiator assembly protector tube.
FIGURE 11
12. Disconnect the radiator vent hose on top of the
radiator.
13. Disconnect electrical connector from the fan
clutch. The remaining connector on the chassis
cable will be capped and left in place.
14. Remove fan drive shaft fasteners at the fan
clutch.
FIGURE 12
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15. Open the secondary lock of connector
#561610. Insert a cavity plug #561783 in each
of the four (4) cavities with the smallest end
protruding as shown on the example at right.
Close the secondary lock.
16. Cap the chassis fan clutch cable with this
connector. Secure the connector on the
existing harness:
FIGURE 13
nylon tie #504016 (1x)
•
FIGURE 14
FIGURE 15
17. Unscrew all lower radiator assembly mounting
fasteners (2 bolts on R.H. side, 2 bolts on L.H.
side).
FIGURE 16
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18. Position a forklift under the radiator assembly
that is capable of safely lifting the radiator. With
assistance, slide radiator assembly out and onto
the forklift. Transfer radiator assembly to a
secure location.
FIGURE 17
19. Remove the tripod from the radiator/CAC
assembly.
FIGURE 18
FIGURE 19
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20. Remove the fan shroud.
FIGURE 20
21. The new cooling pack arrangement requires
being located four inches closer to the engine
to give the needed clearance for the electric
fans. For this reason, rotate both the
radiator/CAC assembly mounting support
180° and reinstall.
BEFORE
FIGURE 21: MOUNTING SUPPORT IN INITIAL POSITION
AFTER
FIGURE 22: MOUNTING SUPPORT AFTER 180° ROTATION
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Page 23 / 89
22. Remove the exhaust pipe section located
between the DPF and the flexible section.
FIGURE 23: REMOVE THIS EXHAUST PIPE SECTION
23. On the engine hot side, remove the following
pipes:
• radiator outlet pipe
• CAC inlet pipe
Keep the fittings found on the radiator outlet
pipe for reuse
FIGURE 24
24. Undo the two (2) V-band clamps and then
remove the engine intake elbow.
FIGURE 25: REMOVE THE INTAKE ELBOW
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25. Remove the pipe (item A) section located
downstream of the engine air filter. Prior to do
so, disconnect the air compressor fresh-air
inlet pipe (item B) connected to pipe A.
FIGURE 26
26. On the engine hot side, remove the radiator
inlet pipe.
KEEP THE BLUE HOSE, IT WILL BE USED AS
PROTECTIVE SHEATH
FIGURE 27
27. Remove and discard the CAC outlet pipe. It is
possible to remove this pipe by taking it out
from the left side (hot side)
FIGURE 28
FIGURE 29
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IS-19901C
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FIGURE 30
FIGURE 31
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Page 26 / 89
28. Replace the existing coolant surge tank
support with the coolant tank support #053040
included in the kit. Use the existing hardware.
Add one (1) new washer #500321 and one (1)
new nut #5001983.
FIGURE 32
A: REUSE EXISTING HARDWARE
FIGURE 33
A: REUSE EXISTING HARDWARE
B: NEW WASHER #500321, NEW NUT #5001983.
29. Depending on the vehicle model year, drilling
of the mounting hole shown might be
necessary (see image at right).
FIGURE 34
30. Reinstall the surge tank, slightly moved to the
right in comparison with the former installation.
Note the T-bolt band clamp now located on the
other side of the filler neck on the image at tight.
FIGURE 35
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31. The area identified on the images at right will
be in interference with the radiator. For this
reason, some modifications are necessary to
eliminate the interference.
FIGURE 36
32. Cut the sheet metal along the red lines as
shown on the image at right.
FIGURE 37
FIGURE 38
33. Cut along the red line shown on the picture to
separate the sheet metal from the steel fold.
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34. The bolt seen on the picture at right secures
the last R.H.seat. This bolt is too long and must
be changed for a shorter one.
FIGURE 39
35. Unscrew the bolt identified on the picture and
change it for screw #500594.
FIGURE 40
36. Cut the steel fold shown on the picture at right.
FIGURE 41
37. Fold over the sheet metal as shown on the
picture and secure to the structure using the
following hardware:
•
rivet #504117 (5x)
38. Finally, apply sealant to assure water
tightness.
FIGURE 42
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39. Remove all the drive belts mounted on the crank
pulley.
FIGURE 43
40. Remove the crank pulley. Discard the 6 bolts.
NOTE: On vehicles prior to serial G-5986 (2016)
equipped with a trailer hitch, keep the existing
crank pulley (14 ribs) in place.
FIGURE 44
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41. Remove the rust, clean and prepare the surface
on the vibration damper as shown. Work the
surface to achieve a smooth finish.
FIGURE 45
FIGURE 46
42. Properly support the engine as one of the
engine support will be interchanged in the
upcoming steps.
FIGURE 47
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43. Remove the two (2) coolant hoses shown on the
image. Keep the two (2) banjo fittings for later
use.
BANJO FITTING
FIGURE 48
44. Remove the L.H. rear engine support (10 bolts).
Keep the hardware for reinstallation.
Take note that the water pump belt
idler/tensioner assembly will be reused as is.
Do not take apart tensioner or idler.
FIGURE 49: L.H. REAR ENGINE SUPPORT
45. Remove the water pump idler/tensioner
assembly from the former engine mount. To do
so, unscrew three (3) bolts from the back of the
engine mount.
FIGURE 50
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46. Reinstall idler/tensioner assembly as a unit on
the new L.H. engine mount #012942.
Mount the idler/tensioner assembly using
three (3) cap screws #5001643
Tighten to 14-17 lb-ft
FIGURE 51
47. Install the new engine mount #012942 using
seven (7) M14 screws saved from the former
engine support with this exception of:
•
Ground stud #012921 (1x) and nylon
insert NYRT nut #5001665 (1X)
•
•
Isolator cap screw #5001940 (2X)
Nut #5001761 (2X)
FIGURE 52
FIGURE 53: FOUR (4) SCREWS UNDER THE
REINFORCEMENT CHANNEL
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FIGURE 54: REAR VIEW – GROUND STUD
FIGURE 55
FIGURE 56
48. Install the new crank pulley using six new bolts
#5001296. Use blue Loctite on the bolt
threads.
Torque to 26 lb-ft in this numerical order: 1,
2, 3, 4, 5, 6, 1
Once done perform a final tightening to the
value of 66 lbf-ft.
FIGURE 57
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49. Reinstall the water pump drive belt.
FIGURE 58: WATER PUMP DRIVE BELT
50. Reinstall the A/C compressor drive belts.
51. Install the idler support #011213 using three (3)
screws #5001799. At the same time, install the
alternator lower bracket #060102.
screws #5001799 prescribed torque: 48 lbf-ft
FIGURE 59: BRACKET #060102
52. Make a smooth round clearance in the engine
cradle to allow required space for the alternator
lower bracket #060102 installed at the previous
step. Carefully work the edge to achieve a
smooth finish and contour.
Measurements: ↔ 2″, ↕¾″
Apply paint to protect the metal against
corrosion
FIGURE 60
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Page 35 / 89
53. Install the new idler #012349 with one (1) screw
#5001786 and one (1) washer #5002008.
Tighten to 59 lb-ft
FIGURE 61
54. Install the dust cap #453076.
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TSB/Document ID: IS-19901C
Replacement Service Bulletin Number:
MFR Communication Date: 2021-07-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
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