NHTSA ID Number: 10231097
Manufacturer Communication Number: IS-19912E
TSB/Document Date: 2023-02-04
Summary
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH DELCO REMY ALTERNATOR. REVISION: E Note added regarding power cable connection
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4. Open radiator door to access radiator
assembly. Unfasten upper arm assembly.
FIGURE 4
5. Remove radiator sealing frame.
FIGURE 5
6. Remove the rear bumper (undo three nuts
each side).
FIGURE 6
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7. Remove the fan drive casting.
FIGURE 7
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
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10. Remove the upper radiator assembly support
bracket.
FIGURE 10
11. Remove the radiator assembly protector tube.
FIGURE 11
12. Disconnect the radiator vent hose on top of
the radiator.
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13. Disconnect the 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
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
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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 16
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
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19. Remove the tripod from the radiator/CAC
assembly.
FIGURE 18
FIGURE 19
20. Remove the fan shroud.
FIGURE 20
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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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22. Drill two (2) new holes for both cooling pack
mounting supports at 1/2 inch (13 mm) from the
previous holes, towards the engine.
FIGURE 23: NEW HOLES FOR THE COOLING PACK MOUNTING SUPPORTS
FIGURE 24: NEW HOLE FOR THE COOLING PACK MOUNTING SUPPORTS (DETAIL VIEW)
23. Remove the exhaust pipe section located
between the DPF and the flexible section.
FIGURE 25: REMOVE THIS EXHAUST PIPE SECTION
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24. 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 26
25. Undo the two (2) V-band clamps and then
remove the engine intake elbow.
FIGURE 27: REMOVE THE INTAKE ELBOW
26. 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 28
27. On the engine hot side, remove the radiator
inlet pipe.
KEEP THE BLUE HOSE, IT WILL BE USED AS
PROTECTIVE SHEATH
FIGURE 29
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28. 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 30
FIGURE 31
FIGURE 32
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FIGURE 33
29. 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 34
A: REUSE EXISTING HARDWARE
FIGURE 35
A: REUSE EXISTING HARDWARE
B: NEW WASHER #500321, NEW NUT #5001983.
30. Depending on the vehicle model year, drilling
of the mounting hole shown might be
necessary (see image at right).
FIGURE 36
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31. 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 37
32. 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 38
33. Cut the sheet metal along the red lines as
shown on the image at right.
FIGURE 39
FIGURE 40
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34. Cut along the red line shown on the picture to
separate the sheet metal from the steel fold.
35. 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 41
36. Unscrew the bolt identified on the picture and
change it for screw #500594.
FIGURE 42
37. Cut the steel fold shown on the picture at right.
FIGURE 43
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38. Fold over the sheet metal as shown in the
picture and secure to the structure using the
following hardware:
•
rivet #504117 (5x)
39. Finally, apply sealant to assure water
tightness.
FIGURE 44
40. Remove all the drive belts mounted on the
crank pulley.
FIGURE 45
41. 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 46
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42. Remove the rust, clean and prepare the
surface on the vibration damper as shown.
Work the surface to achieve a smooth finish.
FIGURE 47
FIGURE 48
43. Properly support the engine as one of the
engine support will be interchanged in the
upcoming steps.
FIGURE 49
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44. Remove the two (2) coolant hoses shown on
the image. Keep the two (2) banjo fittings for
later use.
BANJO FITTING
FIGURE 50
45. 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 51: L.H. REAR ENGINE SUPPORT
46. 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
personal
protection
equipment.
Protect engine and area with blankets.
Blow area clean when completed.
Apply paint to protect the bare metal
FIGURE 52
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47. 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 53
48. 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 54
FIGURE 55
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49. Install the new engine mount #010090 using
seven (7) M14 screws saved from the former
engine support.
Use blue Loctite 243 on the bolt threads
FIGURE 56
FIGURE 57: FOUR (4) SCREWS UNDER THE
REINFORCEMENT CHANNEL
FIGURE 58: THREE (3) SCREWS ON THE SIDE OF THE
ENGINE MOUNT
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50. Install the ground stud. Use the following
hardware:
• ground stud #012921 (1x) and
• nylon insert NYRT nut #5001665 (1X)
Use blue Loctite 243 on the bolt threads
FIGURE 59
Tighten ground stud to 94 lb-ft
Tighten NYRT nut to 94 lb-ft
51. Install new isolator screws. Use the following
hardware:
•
•
Isolator screw #5001940 (2X)
Nut #5001761 (2X). Place the nuts to the
opposite of the side seen on the image.
Use blue Loctite 243 on the bolt threads
FIGURE 60
Tighten isolator screws to 60 lb-ft
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52. 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 61
53. Reinstall the water pump drive belt.
FIGURE 62: WATER PUMP DRIVE BELT
54. Reinstall the A/C compressor drive belts.
55. Install alternator brackets #069890 and
#069891.
Note: Install the upper bracket #069891 with
the short end towards bumper and long end
towards the turbo.
Use:
4x cap screws #5001308
Apply blue Loctite
Tighten to 48 lb-ft
FIGURE 63
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56. Installing the LH alternator pulley. Place
#560720 alternator flat on a bench with the
shaft horizontal.
Required tools:
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TSB/Document ID: IS-19912E
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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