NHTSA ID Number: 10231095
Manufacturer Communication Number: IS-19901E
TSB/Document Date: 2023-02-04
Summary
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH BOSCH
ALTERNATOR. REVISION: E Note added regarding power cable connection
D: tie mount #509490 (1x) + rivet #504610 (1x) +
nylon tie #509491 (1x)
E: « handcuff » nylon tie #N37749 (1x)
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
FIGURE 122
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97. When stretched, the end of the ground cable and
the fan drive power cable connector should be at
approximately 1½″ to 2¼″ (38 mm to 57 mm)
from the lower flat surface.
98. Once properly adjusted, tighten the nylon ties
previously installed.
FIGURE 123
99. Apply Loctite Color Guard Rubber Coating on
the ground stud connection.
FIGURE 124: GROUND STUD WITH RUBBER COATING
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100. INSTALLATION OF THE ALTERNATOR
CONTROL CABLE #069511
a) Connect the harness #069511 to the
alternator.
b) Secure the harness with nylon ties as
shown on the pictures.
FIGURE 125: C: NYLON TIES #504016 (2x)
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101. Partially route the “alternator control cable”
#069511 along the “alternator power cable” as
shown on the images. Secure the “alternator
control cable” on the “alternator power cable”
using nylon ties.
A: nylon tie #504016 (9x)
B: « handcuff » type nylon tie #N37749
required
as
NOTE: The “alternator control cable” #069511
will be connected to the “fan to RJB interface”
harness #23488790. For this reason, do not route
the “alternator control cable” further than what
is shown on the images.
FIGURE 126
FIGURE 127
FIGURE 128
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FIGURE 129
FIGURE 130
102. Route the “fan drive power cable” and the
“alternator power cable” up to the electrical
compartment.
DO NOT PASS THE CABLES through the upper
cable boot AT THIS MOMENT. Refer to the
pictures at right as a guide for the installation.
Secure both cables with the four (4) tie mounts
previously installed. Secure the cables on the tie
mounts as previously done with nylon ties.
A: nylon tie #509491 (8x)
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
FIGURE 131
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103. Route the “fan to RJB interface harness”
#23488790 up to the electrical compartment,
passing through the upper cable boot. But first,
place connector A34-J1 next to the red
connector of the fan drive power cable (see
image at right).
A: fan to RJB interface harness #23488790
FIGURE 132
104. Secure harness #23488790 along the fan
drive power cable, placing a nylon tie #504016
every 6 inches (150 mm).
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
FIGURE 133
105. Secure connector C-ALT3 as shown on the
image with one (1) nylon tie #504016 and then
connect to the alternator control cable #069511
previously installed.
FIGURE 134
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106. Apply Color Guard rubber coating at the
alternator ground
connections.
(
)
and
positive
(+)
FIGURE 135: GROUND CONNECTION ON THE
ALTERNATOR
FIGURE 136: POSITIVE (+) CONNECTION ON THE
ALTERNATOR
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107. Pre-install the new CAC inlet pipe #050328.
Use one new #030096 CAC flexible hose.
Secure the hose using two (2) spring-loaded
clamps #21490630.
•
•
#030096 hose (1x)
#21490630 spring loaded clamp (2X), final
torque: 5 lbf-ft
NOTE: On vehicles prior serial G-5932 (2016),
remove the 90° elbow diffuser pipe and replace
with straight turbo diffuser pipe #053662. Use the
following parts:
A: straight turbo diffuser pipe #053662 (1x)
B: gasket #21096684 (1x)
C: V-band clamp #20592787 (1x)
FIGURE 137: CONNECTION AT THE TURBO OUTLET
ELBOW
108. Preinstall all the flexible hoses at the cooling
pack connections. Use the following parts:
A: flexible hose #531469 (1x)
B: flexible hose #531471 (1x)
C: silicone hose #053617 (2x)
D: clamp #21490616 (8x)
E: caillau clamp #992089 (8x)
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 14
FIGURE 138
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109. 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 #050351
C: 2x screw #5001738 , 2x nut #502837
D: 2x screw #5001738 , 2x washer #500942
E: 2x screw #5001745 , 2x washer #500942
FIGURE 139:
FIGURE 140
110. Install the upper attachment on the cooling
pack.
FIGURE 141
111. Reinstall the cooling pack in its compartment.
FIGURE 142
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112. Secure the cooling pack base with the
following parts:
A: 4x screw #502804
B: 8x washer #5001751
C: 4x nut #502859
FIGURE 143
113. Bolt the anti-vibration mount onto the vehicle
chassis
FIGURE 144
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114. Complete the connection
with the cooling pack.
For proper clamp torque,
refer to
HOSE CLAMP
TORQUE on page 14
FIGURE 145
115. Connect the radiator vent hose on top of the
radiator.
116. Reinstall the cooling pack protector tube with
the following hardware:
A: Screw #502804 (3x)
B: split lock washer #5001737 (3x)
C: flat washer #5001751 (2)
FIGURE 146
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117. Remove all the old spring nuts on the cooling
pack and replace with new spring nuts.
•
spring nut #5001965 (18x)
FIGURE 147
118. Install the sealing element #050355. Secure
with the following hardware:
4x bolt #5001697
4x lock washer #502570
Use foam tape #506040 to fill the gap between the
sealing element and the charge air cooler if
necessary.
FIGURE 148
FIGURE 149
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119. Install the sealing element #050362. Screw it
on the existing threaded holes on the bottom
of the radiator. Secure with the following
hardware:
4x bolt #5001697
4x lock washer #502570
Use foam tape #506040 to fill the gap
between the sealing element and the charge
air cooler if necessary.
FIGURE 150
120. Install the sealing element #050360. Screw
them onto the upper and lower sealing
elements installed at the previous steps.
Secure with the following hardware:
9x bolt #5001697
9x lock washer #502570
A: #050360
FIGURE 151
121. Install the sealing element #050380. Secure
with the following hardware:
5x bolt #5001697
5x lock washer #502570
B: #050380
FIGURE 152
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122. Install the sealing element #050359. Secure
with the following hardware:
6x bolt #5001697
6x lock washer #502570
C: #050359
FIGURE 153
123. Cut two pieces of 39 3/8 inches (1000 mm)
long of rubber extrusion #506025.
124. 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 #050343.
FIGURE 154
FIGURE 155
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125. Install panel #050343. Secure with the
following hardware:
22 x bolt #5001697
22 x lock washer #502570
FIGURE 156
126. Install the circuit breaker box #564612.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 157
127. Install the upper sealing element #050366.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 158
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128. Install the pull-rod box #050369.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 159
129. Install the lower sealing element #050365.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 160
130. Install the R.H. side sealing element #050367.
Secure with the following hardware:
bolts #5001697 (5x)
lock washers #502570 (5x)
FIGURE 161
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131. Install the fans and fan hand guards on the
panel. Snap the fan blue connector in the
holes punched on the panel for that matter.
FAN HAND GUARD
Install with the following hardware:
32x bolts #502686
32x lock washers #5001833
Prescribed torque:40 lbf-in
FIGURE 162
132. Get the fan drive harnesses kit #068820. Take
note that each harness is specifically
identified with a number corresponding to
an appropriate fan location.
FIGURE 163
133. Route and secure the fan harnesses as shown
on the images.
Secure with the following parts:
A= nylon tie mount #504013 + rivet
#504379 + nylon tie #504016
(11x)
B= nylon tie #504016 (4x)
Do not tighten the nylon ties at this moment
FIGURE 164
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FIGURE 165
134. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 166
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135. Using the blue hose previously saved, make a
protective sheath. Cut to an appropriate size
and secure around the cables using nylon ties.
FIGURE 167
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136. Complete the connection to the fan circuit
breaker box (three connectors: gray, black
and red).
A: fan drive ground cable (black connector)
B: fan drive power cable (red connector)
C: “fan to RJB interface” harness (gray
connector)
NOTE
TRICK: Pre-twist the red and black cables counter-clockwise then insert the cables in their connector and lock. This will ensure that there’s
some pre-tension in the locking (clockwise) direction. This pre-tension will help the cables to
stays in place(locked position).
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TSB/Document ID: IS-19901E
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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