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
protection
Protect engine and area with blankets.
Blow area clean when completed.
Apply paint to protect the bare metal
FIGURE 34
32. Remove the water pump idler/tensioner
assembly from the former engine mount. To do
so, unscrew three (3) bolts at the back of the
engine mount.
FIGURE 35
EL
Writer:
IS-19910H
Page 27 / 75
33. Reinstall the idler/tensioner assembly as a unit
on the new L.H. engine mount #010090.
Mount the idler/tensioner assembly using
three (3) cap screws #5001643
Tighten to 14-17 lb-ft
FIGURE 36
FIGURE 37
EL
Writer:
IS-19910H
Page 28 / 75
34. Install the new engine mount #10090 using
seven (7) M14 screws saved from the former
engine support with the exception of:
•
Ground stud #012921 (1x) and nylon
insert NYRT nut #5001665 (1X)
•
•
Isolator cap screw #5001940 (2X)
Nut #5001761 (2X)
FIGURE 38
Seven (7) mounting screws torque : 90-94 lb-ft
(128 Nm)
FIGURE 39
Tighten ground stud to 94 lb-ft
Tighten stud nut to 94 lb-ft
EL
Writer:
IS-19910H
Page 29 / 75
FIGURE 40
Tighten isolator screws to 60 lb-ft
35. Install the new crank pulley using six new bolts
#5001296. Use blue Loctite on the bolt threads.
Torque to 26 lb-ft in the numerical order 1, 2,
3, 4, 5, 6, 1
Once done perform a final tightening to the
value of 66 lbf-ft.
FIGURE 41
36. Reinstall the water pump drive belt.
FIGURE 42: WATER PUMP DRIVEBELT
37. Reinstall the AC compressor drive belts.
38. Install alternator
#069891.
brackets
#069890
and
Note: Install the upper bracket #069891 with
short end towards bumper and long end towards turbo.
Use:
4x cap screws #5001308
Apply blue Loctite
Tighten to 48 lb-ft
FIGURE 43
EL
Writer:
IS-19910H
Page 30 / 75
39. Installing the LH alternator pulley. Place
#560720 alternator flat on a bench with the shaft
horizontal.
Required tools:
•
•
15-16” crowfoot adapter
8mm hex bit
Clean shaft and pulley with brake cleaner.
Slide pulley #069893 on shaft by hand.
Hand thread nut on shaft until snug.
Using thin wall15/16”adapter and 8mm hex bit to
block shaft rotation, tighten to 70-80 lbf-ft.
Never use power tools to install pulley and nut.
FIGURE 44
Note: Do not apply any pressure to end of the
shaft. Internal damage may occur if the shaft is
pushed back and turned.
40. Install alternator on support with four (4)
#5002091 M10x120 screws.
Apply blue Loctite
Tighten to 48 lb-ft
FIGURE 45
41. Install the idler support #011213 using:
3x screws #5001799
Tighten to 48 lb-ft
FIGURE 46
EL
Writer:
IS-19910H
Page 31 / 75
42. Install the new idler #012349 with screw
#5001786 and washer #5002008.
Tighten to 59 lb-ft
FIGURE 47
43. Install the dust cap #453076.
FIGURE 48
FIGURE 49
EL
Writer:
IS-19910H
Page 32 / 75
44. Install the new alternator tensioner #510991.
Secure with one screw #5001799 on which
blue Loctite is applied.
FIGURE 50: Tensioner mounting screw torque : 48 lb-ft
45. Install belt #506067. To do so, rotate the
automatic belt tensioner using a ½ square drive
breaker bar.
FIGURE 51
46. Remove former belt routing decal and replace
with decal #010111.
FIGURE 52
EL
Writer:
IS-19910H
Page 33 / 75
47. Install control harness #0610037 on alternator.
Connect circuit I to Indicator (I) post.
Connect circuit S to Sense (S) post.
Use the following hardware:
•
•
2x nylon lock nut #5001180
2x washer #5001137
Tighten to the following torque values:
Sense (S): 25-45 lb-in
Indicator (I): 25-45 lb-in
Apply Color Guard Rubber Coating on the
connections.
FIGURE 53
FIGURE 54
48. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
49. Weld the new coolant filter support #050265 on
the engine cradle.
23 ½ inches from the end of the cradle
FIGURE 55
EL
Writer:
IS-19910H
Page 34 / 75
FIGURE 56
FIGURE 57
FIGURE 58
EL
Writer:
IS-19910H
Page 35 / 75
50. As a preparation to welding, buff the paint to
reach bare metal. Weld the ground stud
#380360 centered in the beam and at 14 inches
from the beam end.
FIGURE 59
FIGURE 60: GROUND STUD #380360
51. Apply black paint to the area surrounding the
ground stud and also on the ground stud circular
base. DO NOT apply paint on the electrical
contact surfaces.
FIGURE 61: GROUND STUD #380360
52. Install a tie mount #504013 with one screw
#502686 at the back of the L.H. engine mount.
FIGURE 62
EL
Writer:
IS-19910H
Page 36 / 75
53. Install the alternator ground cable #0610035.
Use the ground screw and lock washer supplied
with alternator with the addition of a flat
washer #500411.
torque: 50-60 lbf-in
54. Secure the alternator ground cable to the
previously installed tie mount using one (1)
nylon tie #509491.
FIGURE 63
FIGURE 64
55. Secure the alternator ground cable to the
previously installed ground stud on the L.H.
engine mount.
Use screw #502719 & washer #5001935
Tighten to 20 lbf-ft
Protection against corrosion. Apply Color
Guard rubber coating on the ground stud
once the ground cable is hooked up.
FIGURE 65
56. To the previously installed coolant filter support,
install the filter holder recovered from the former
installation.
FIGURE 66
57. Install the new coolant filter onto the filter holder.
Check the clearance between the filter and the
close hose clamps of the coolant pipe leading to
the transmission oil cooler.
EL
Writer:
IS-19910H
Page 37 / 75
58. Transfer the drain plug and the coolant extractor
quick connect fitting saved from the old pump
inlet pipe.
Apply Loctite 567 Thread
installation of the fittings
Sealant
prior
59. Install the new radiator outlet pipe #050288.
Reinstall with the flexible hose #053617 and the
four (4) hose clamps #992089. Use steel wire to
hold the end of the pipe until the radiator is
installed if required.
A: # 992089 hose clamp (4x)torque: 30 lbf-in
FIGURE 67
B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
60. Reinstall the elbow between the copper heater
line and the new radiator outlet pipe.
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12.
FIGURE 68
61. Using blue flexible hose #052366, prepare two
new short hoses for the coolant filter.
a) Cut two sections of blue flexible hose, one 22
inches long and a second 38 inches long.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)
FIGURE 69
b) Use the banjo fittings recovered from the
previous installation.
hose clamp torque: 30 lbf-in
FIGURE 70
EL
Writer:
IS-19910H
Page 38 / 75
62. Install the 22” long and 38” long hoses prepared
at the previous step as shown on the images.
FIGURE 71
FIGURE 72
63. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657
FIGURE 73: DEF INJECTOR COOLANT LINE RETURN HOSE
EL
Writer:
IS-19910H
Page 39 / 75
64. Connect the coolant line coming from the surge
tank to the radiator outlet pipe.
TORQUES:
Constant-Torque with spring washers clamps :
90-100 lbf-in
Oetiker clamps – green spring : 12-18 lbf-in
FIGURE 74
Oetiker clamps – unpainted spring : 8-9 lbf-in
Caillau clamps : 30 lbf-in
65. Secure the coolant hoses together using nylon
ties.
A : handcuff nylon tie #N37749 (3x)
FIGURE 75
FIGURE 76
EL
Writer:
IS-19910H
Page 40 / 75
66. Secure the coolant hose near the engine block
«push-lok» fitting as shown.
B : nylon tie #504016 (1x)
FIGURE 77
EL
Writer:
IS-19910H
Page 41 / 75
67. Hook up the “L.H. alternator power cable”
#234524934 to the alternator positive (+) post.
Place the flash washer between the cable lug
and the nut.
1x nut #500685
torque: 80-125 lbf-in
1x flat washer #5001341
Apply Color Guard rubber coating at the alternator
ground (
) and positive (+) connections.
IMPORTANT NOTE
FIGURE 78
Early alternators are provided with a shorter positive
stud.
With the short stud, nut #500685 does not thread
fully to allow the locking nylon insert to grip on the
threads.
In this case, DO NOT use nut #500685. Use the nut
and lock washer provided with the alternator instead. Tighten to: 80-125 lb-po (9.0-14.0 N-m).
FIGURE 79:
EL
Writer:
-
NUT #500685 DOES NOT THREAD FULLY TO ALLOW
THE LOCKING NYLON INSERT TO GRIP ON THE
THREADS (UPPER IMAGE)
-
HARDWARE TO USE WITH SHORT STUD (LOWER
IMAGE)
IS-19910H
Page 42 / 75
68. Connect the “fan drive ground cable” #069246
to the ground stud previously welded to the
chassis.
A: split lock washer #500482
B: brass nut #500998
C: fan drive ground cable #069246
FIGURE 80
FIGURE 81
69. Apply Color Guard rubber coating on the ground
stud connection.
FIGURE 82: GROUND STUD WITH RUBBER COATING
EL
Writer:
- 💯【Conta.ct us for Support Directly】If you met any...
- 🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW...
- 🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS...
- 🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full...
- 🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE...
- 📌【We are Here for You】Dear valued customer, please be...
- 🚀【5X Faster Next-Level Hardware, Same as MK900/ MX...
- 🔥【3000+ Active Tests = MK900/MK900BT but...
- 📢【2026 U.S. Version, All-in-One as MK808S/ MK808Z...
- 🔥【28+ Hot Services for 150+ Brands】Same as MaxiCOM...
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
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:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission
, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU coding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations
- 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Programming): Allows for Ford, for Lincoln, and for Mazda ECU programming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- Cost-effective ECU Coding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 3 Years Software Update, Value for Money: With 3 years of software updates and 22+ languages(no IP restrictions), XTOOL D7S auto scanner code scanner ensures ongoing compatibility for the latest car models and improved diagnostic functions. This all system vehicle diagnostic scanner comes with a 30-day return policy and a 24-month repair for dependable performance. XTOOL are dedicated to your satisfaction, so enjoy seamless support and lifetime expert assistance. Should you encounter any issues or concerns, don’t hesitate to reach out XTOOL. D7S with newest update with 22 languages freely transfer without authorization, check details from setting-language or from XTOOL
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.