NHTSA ID Number: 10231094
Manufacturer Communication Number: IS-19900J
TSB/Document Date: 2023-02-04
Summary
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH BOSCH
ALTERNATOR. REVISION : J - Note added regarding power cable connection
C: nylon tie #509491
FIGURE 91
73. Route the “fan drive power cable” and the “L.H.
alternator power cable” up to the main power
compartment. Refer to the pictures at right as a
guide for the installation.
74. Secure both cables using five (5) tie mounts
#509490 fixed with five (5) rivets #504610 (hole
diameter: Ø 17/64). Secure the cables on the
tie mounts as previously done with ten (10)
nylon ties # 509491.
A: tie mount #509490
B: rivet #504610 (hole diameter: Ø 17/64)
C: nylon tie #509491
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FIGURE 92
IS-19900J
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FIGURE 93
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75. INSTALLATION OF THE “FAN TO RJB
INTERFACE” HARNESS #23488790
a) Route the “fan to RJB interface” harness
#23488790 up to the main power
compartment. Secure this harness to the
fan drive power cable using nylon ties
#504016.
b) This harness will be connected close to the
fan drive power cable, thus it also requires
26 inches of free length.
FIGURE 94
A: FAN TO RJB INTERFACE” HARNESS #23488790
B: FAN DRIVE POWER CABLE
C: NYLON TIES #504016 (23x approx.)
FIGURE 95
FIGURE 96
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FIGURE 97
76. INSTALLATION OF THE ALTERNATOR
CONTROL HARNESS #069511
a) Connect the harness #069511 to the
alternator.
b) Secure the harness with nylon ties as shown
on the pictures.
FIGURE 98: C: NYLON TIES #504016 (2x)
FIGURE 99: C: NYLON TIES #504016 (2x)
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77. Connect the new CAC outlet pipe #050406 to
the engine intake elbow. NOTE: in case of
interference between this pipe and the ping
tank, rotate the ping tank.
A: #030096 hose (1x)
B: #21490630 spring loaded clamp (2X)
FIGURE 100
Constant Torque hose clamps 4.25in - charge air
cooler (CAC)
4.5-5.5 lbf-ft
FIGURE 101: CONNECTION AT THE ENGINE INTAKE
ELBOW
FIGURE 102
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78. If your vehicle is equipped with AFSS
(Automatic Fire Suppression System), the new
CAC outlet pipe #050406 is likely to come into
interference with a AFSS extinguishing agent
hose (see image) near the end of the pipe that
connects with the Charge Air Cooler.
If this is the case, move the hose the other side
of the bracket shown, to prevent rubbing
between the hose and the CAC outlet pipe.
FIGURE 103
79. On the diagonal member, change the existing
radiator inlet pipe bracket for the new bracket
#050305. Use the existing hardware.
FIGURE 104
80. Install the new radiator inlet pipe #050414.
A: #052889 silicone hose
B: # 992089 hose clamp (4x); torque: 30 lbf-in
FIGURE 105
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81. Install the new CAC inlet pipe #050286. Use
one new #030096 CAC flexible hose. Secure
the hose using two (2) spring loaded clamps
#21490630.
A: #030096 hose
B: #21490630 spring loaded clamp (2X), torque:
5 lbf-ft
FIGURE 106: CONNECTION AT THE TURBO OUTLET
ELBOW
82. Reinstall the cooling pack.
FIGURE 107
83. Place the cooling pack supports over the new
holes that were previously made.
FIGURE 108
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84. Secure the cooling pack base with the following
parts:
A: 4x screw #502804
B: 8x washer #5001751
C: 4x nut #502859
FIGURE 109
85. In case of interference between the charge air
cooler and the DPF intake pipe, loosen the
pipe’s V-band clamps. Move the pipe in order to
increase the clearance, then hold the pipe in
place and tighten the V-band clamps.
FIGURE 110
FIGURE 111
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86. Using parts #501332, #501308, #501329,
#501027, mount the brass fitting assembly
shown on the image at right.
Apply Loctite 567 Thread Sealant on the threads
A: #501027
B: #501329
C: #501308
D: #501332
FIGURE 112: BRASS FITTING ASSEMBLY
87. Remove the vent hose fitting found on the
radiator.
FIGURE 113
88.
Install the brass fitting assembly in place of
the former vent hose fitting and then connect
the radiator vent hose.
89. Prepare the cooling pack upper attachment
with the three (3) rectangular plates (see image)
recovered from the former installation and the
following parts:
A: anti-vibration mount #21185073
B: upper radiator support #050214
C: 2x screw #5001738 , 2x nut #502837
D: 2x screw #5001738 , 2x washer #500942
E: 2x screw #5001745 , 2x washer #500942
FIGURE 114
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One end of the upper attachment is mounted
on the radiator frame (image at right)
FIGURE 115
Bolt the anti-vibration mount onto the
vehicle chassis
FIGURE 116
90. Reinstall all the blue flexible hoses at the CAC
and radiator (at the lower connections of the
cooling pack). Install with the following parts:
A: #21490616 clamp (4x)
B: #531471 flexible hose
C: #053617 silicone hose
D: #992089 (4x)
FIGURE 117
91. Reinstall all the blue flexible hoses at the CAC
and radiator (at the upper connections of the
cooling pack). Use the following parts::
A: 1x flex hose #531469
B: 1x silicone hose #053617
C: 4x clamp #21490616
D: 4x clamp #992089
FIGURE 118
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For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12
92.
Reinstall the lower cooling pack protector
tube with the following hardware:
4x Screw #502804
4x split lock washer #5001737
FIGURE 119
93.
Install the sealing element #050200. Screw it
on the existing threaded holes on the upper
part of the radiator. Secure with the following
hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 120
FIGURE 121
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94.
Install the sealing element #050203. Screw it
on the existing threaded holes on the bottom
of the radiator. Secure with the following
hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 122
95.
Prepare the sealing elements #050201 and
#050202. On both parts, apply foam tape
#506040 on the edges as shown on the
image.
FIGURE 123
96.
Install the sealing elements #050201 and
#050202. Screw them onto the upper and
lower sealing elements installed at the
previous steps. Secure with the following
hardware:
8x bolt #5001697
8x lock washer #502570
A: #050201
B: #050202
FIGURE 124
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97.
Cut two pieces of 39 inches (990 mm) long of
rubber extrusion #506025.
98.
Using good industrial glue (Loctite 404 or
similar product), glue the two pieces of rubber
extrusion centered on the reinforcement
angles of fan support panel #050195.
FIGURE 125
FIGURE 126
99.
Install panel #050195. Secure with the
following hardware:
19x bolt #5001697
19x lock washer #502570
FIGURE 127
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100. Install the upper left #050204 and upper right
#050206 sealing elements.
Secure with the following hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 128
101. Install the lower sealing element #050213.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 129
102. Install the L.H. side sealing element #050208.
Secure with the following hardware:
4 bolts #5001697
4 lock washers #502570
FIGURE 130
103. Install the R.H. side sealing element #050255.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 131
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104. Install the fans and fan hand guards on the
panel in the same arrangement shown on the
image. Be sure to place the fan so that the
cable is at the proper location, 3 O’clock, 6
O’clock or 12 O’clock. Refer to the image at
right.
FAN HAND GUARD
FIGURE 132
Install with the following hardware:
32x bolts #502686
32x lock washers #5001833
Prescribed torque:30 lbf-in
105. Take note that each harness is labeled with a
number corresponding to an appropriate fan
location.
106. Snap the fan blue connector in the holes
punched on the panel for that matter.
FIGURE 133
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107. Route and secure the fan cables as shown on
the images.
Secure with the following parts:
A= nylon tie mount #504013 + rivet
#504379 + nylon tie #504016
B= nylon tie #504016
Do not tighten the nylon ties at this moment
FIGURE 134
FIGURE 135
108. Install the circuit breaker box #564512.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 136
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A: 2x bolt #500119 + 2x lock washer
#5001868
FIGURE 137
A: 2x bolt #500119 + 2x lock washer
#5001868
109. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 138
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110. Tighten the nylon ties previously installed
while routing the fan cables.
111. Use two (2) additional nylon ties #504016 to
secure the extra-length of cables together
close to the circuit breaker box as shown on
the image at right.
FIGURE 139
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TSB/Document ID: IS-19900J
Replacement Service Bulletin Number:
MFR Communication Date: 2023-01-17
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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