NHTSA ID Number: 10231096
Manufacturer Communication Number: IS-19910i
TSB/Document Date: 2023-02-04
Summary
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH DELCO REMY ALTERNATOR. REVISION : i Note added regarding power cable connection
IS-19910H
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502848
SCREW TC HEX F N500 1/4-20X3/
5001296
5001308
SCREW, CAP HEXFN500 M12-1.75 X 80 CL10.9 PT
SCR CAP HEXF N500 M10-1.5X40 G10.9
hardware
22
hardware
6
hardware
hardware
4
3
hardware
62
hardware
4
hardware
2
hardware
1
hardware
4
hardware
2
5001643
SCREW, CAP HEXF G500 M8-1.25X25 G8.8 PT
5001697
SCREW, CAP HEX SS NSS M6X16
5001738
SCREW, CAP HEX N500 M8X30 G8.8 FT
5001745
SCREW, CAP HEX N500 M8-1.25X25 G8.8
5001786
SCREW, CAP HEXF AD N500 M12-1.75X30 G8.8
5001799
SCREW, CAP HEXF N500 M10-1.5 X 70 G10.9
5001940
SCREW CAP HEX N500 M12X1.75X140
5002091
SCR CAP HEXF N500 M10-1.5X120 G10.9
hardware
504379
RIVET, POP DOME SS OE 3/16X1/4
hardware
4
41
504610
RIVET MGL PRDG SS 1/4X5/8
hardware
14
IS-19910
INSTRUCTION SHEET
1
Other parts or products that may be required:
Part No.
DESCRIPTION
680459
Loctite 404, INSTANT ADHESIVE 9.3gr
680098
LOCTITE 567 THREAD SEALANT 250ML
680038
LOCTITE 243, BLUE THREADLOCKER 50ML
NOTE
Material can be obtained through regular channels.
PROCEDURE
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Writer:
IS-19910H
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DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the
ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button.
ELECTRICAL CABLES & HARNESSES DIAGRAM
HOSE CLAMP TORQUE (coolant lines and charge air cooler)
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HOSE CLAMPS
No
DESCRIPTION
1
(Ø 2 ½ ” or
lower)
2
(Ø 4 ¼ ”)
EL
TORQUE
Constant-Torque hose clamps - coolant lines
90-100 lbf-in
Oetiker hose clamps – Green spring - coolant lines
12-18 lbf-in
Oetiker hose clamps – unpainted spring - coolant lines
8-9 lbf-in
Caillau hose clamps - coolant lines
30 lbf-in
Constant-Torque hose clamps 4.25in - charge air cooler
(CAC)
Writer:
4.5-5.5 lbf-ft
IS-19910H
Page 13 / 75
EL
Writer:
1. In the main power compartment, place the
battery master switch to the OFF position. Trip
all the main breakers that have a manual trip
(CB2,
CB4,
CB6,
lever
or
button
etc…depending on the year model).
2. Remove L.H. side rear fender.
FIGURE 1
Drain the cooling system
3. 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
Writer:
EL
IS-19910H
Page 15 / 75
4. Unfasten cap screws and remove access panel
located behind tag axle L.H. side wheel.
FIGURE 3
5. Open radiator door to access radiator assembly.
Unfasten upper arm assembly.
FIGURE 4
6. Remove radiator sealing frame.
FIGURE 5
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7. Remove clamps and then break hoses from the
front coolant and charge air pipes.
FIGURE 6
8. Remove rear coolant and charge air hose
clamps then break hoses loose.
FIGURE 7
9. Remove the upper radiator assembly support
bracket.
Keep the three small (3) rectangular plates for
reuse
FIGURE 8
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10. Remove the lower radiator assembly protector
tube.
FIGURE 9
11. Disconnect the radiator vent hose on top of the
radiator.
12. Cut the cable tie and disconnect electrical
connector from the fan clutch. The remaining
connector on the chassis cable will be capped
and left in place.
13. Remove fan drive shaft fasteners at the fan
clutch.
FIGURE 10
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IS-19910H
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14. 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.
15. Cap the chassis fan clutch cable with this
connector. Secure the connector on the inner
wall above the radiator using:
•
•
1x tree mount #504750
1x nylon tie #504016
FIGURE 11
FIGURE 12
FIGURE 13
16. Remove the fan drive casting.
FIGURE 14
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IS-19910H
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17. Unscrew all lower radiator assembly mounting
fasteners (2 bolts on R.H. side, 2 bolts on L.H.
side).
FIGURE 15
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 16
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19. Remove the tripod from the radiator/CAC
assembly.
FIGURE 17
FIGURE 18
20. Remove the fan shroud.
FIGURE 19
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Writer:
IS-19910H
Page 21 / 75
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 cooling
pack assembly mounting supports 180° and
reinstall.
BEFORE
FIGURE 20: MOUNTING SUPPORT IN INITIAL POSITION
AFTER
FIGURE 21: MOUNTING SUPPORT AFTER 180° ROTATION
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22. Drill two (2) new holes for both cooling pack
mounting supports at ¾ inch (19 mm) from the
previous holes, towards the engine.
FIGURE 22: NEW HOLES FOR THE COOLING PACK MOUNTING SUPPORTS
FIGURE 23: NEW HOLE FOR THE COOLING PACK MOUNTING SUPPORTS (DETAIL VIEW)
23. Remove the rear bumper (undo three nuts and
one attachment plate each side).
FIGURE 24
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IS-19910H
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24. On the engine hot side, remove the following
pipes:
•
•
radiator inlet & outlet pipes
CAC inlet and outlet pipes
Keep the hose clamps, the flexible hoses for
later reuse
Keep the fittings found on the pump inlet pipe
for later reuse
FIGURE 25
FIGURE 26
25. Remove all the drive belts mounted on the crank
pulley.
FIGURE 27
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IS-19910H
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26. Remove the drive pulley. Discard the 6 bolts.
FIGURE 28
27. Remove the rust, clean and prepare the surface
on the vibration damper as shown. Make a
smooth surface for the pulley that will be
reinstalled later on.
FIGURE 29
FIGURE 30
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IS-19910H
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28. Properly support the engine as one of the
engine support will be interchanged.
FIGURE 31
29. Remove the two (2) coolant hoses shown on the
image. Keep the two (2) banjo fittings for later
use.
BANJO FITTING
FIGURE 32
30. Remove the L.H. rear engine support on which
the coolant filter is installed (10 bolts). Keep the
hardware for reuse.
Take note that the water pump belt
idler/tensioner assemble will be reused as is.
Do not take apart tensioner or idler.
FIGURE 33: L.H. REAR ENGINE SUPPORT
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Writer:
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31. Cut the engine cradle rail as shown to increase
the clearance between the cradle and the
alternator. Carefully work the edge to achieve a
smooth finish and contour.
Wear
appropriate
equipment.
personal
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TSB/Document ID: IS-19910i
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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