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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•
15/16” crowfoot adapter
8 mm hex bit
Clean shaft and pulley with brake cleaner.
Slide pulley #069893 on the shaft by hand.
Hand thread nut on the shaft until snug.
Using thin wall15/16”adapter and 8 mm hex bit
to block shaft rotation, tighten to 70-80 lbf-ft.
Never use power tools to install pulley and nut.
Note: Do not apply any pressure to end of the
shaft. Internal damage may occur if the shaft is
pushed back and turned.
57. Install alternator on support with four (4)
#5002091 M10x120 screws.
FIGURE 64
Apply blue Loctite
Tighten to 48 lb-ft
FIGURE 65
58. Install the idler support #011213 using:
3x screws #5001799
Tighten to 48 lb-ft
FIGURE 66
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59. Install the new idler #012349 with one screw
(1) #5001786 and one (1) washer #5002008.
Tighten to 59 lb-ft
FIGURE 67
60. Install the dust cap #453076.
FIGURE 68
FIGURE 69
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61. Install the new alternator tensioner #510991.
Secure with one (1) screw #5001799 on which
blue Loctite is applied.
FIGURE 70: TENSIONER MOUNTING SCREW TORQUE : 48
LB-FT
62. Install belt #506067. To do so, rotate the
automatic belt tensioner using a ½ square
drive breaker bar.
NOTE: Use belt #506080 instead if the original
crank pulley is still in place (vehicle equipped
with a trailer hitch).
FIGURE 71
63. Remove former belt routing decal and replace
with decal #010111.
FIGURE 72
64. Perform the “Multiplex Modules Disconnection
Procedure Prior to Welding” found in your
vehicle Maintenance Manual, Section 00:
General.
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65. Weld the new coolant filter support #050265 on
the engine cradle.
23 1/2 inches (597 mm) from the end of the
cradle
FIGURE 73
FIGURE 74
FIGURE 75
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FIGURE 76
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66. As a preparation for welding, use a grinder
with abrasive disc to remove some paint to
reach bare metal. Weld the ground stud
#380360 centered on the beam, 16 inches (406
mm) from the vertical member beam end.
FIGURE 77
FIGURE 78
67. Apply black paint to the area surrounding the
ground stud and the ground stud circular base.
DO NOT apply paint on the electrical contact
surfaces.
FIGURE 79: GROUND STUD #380360
FIGURE 80: GROUND STUD #380360
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68. Install a tie mount #509490 with one screw
#502686 at the back of the L.H. engine mount.
FIGURE 81
69. 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
70. Secure the alternator ground cable to the
previously installed tie mount using one (1)
nylon tie #509491.
FIGURE 82
FIGURE 83
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71. 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
FIGURE 84
FIGURE 85
72. Protection against corrosion. Apply Color
Guard rubber coating on the alternator ground
screw and the ground stud once the ground
cable is hooked up.
FIGURE 86
FIGURE 87
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73. To the previously installed coolant filter
support, install the filter holder recovered from
the former installation.
FIGURE 88
74. Install a new coolant filter 21937327onto the
filter holder. Check the clearance between the
filter and the near-hose clamps of the coolant
pipe leading to the transmission oil cooler.
75. Transfer the drain plug and the coolant
extractor quick connect fitting saved from the
old radiator outlet pipe.
Apply Loctite 567 Thread Sealant prior
installation of the fittings
76. Install the new radiator outlet pipe #050331.
Reinstall with the flexible hose #053617 and
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
B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
77. Connect the elbow between the copper heater
line and the new radiator outlet pipe.
A: #992086 hose clamp (1x)
For proper clamp torque, refer to HOSE CLAMP
TORQUE on page 12.
FIGURE 89
FIGURE 90
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78. Using blue flexible hose #052366, prepare two
new short hoses for the coolant filter.
a) Cut two sections of blue flexible hose, one 13
inches long and a second one, 27 inches
long.
b) Use the banjo fittings recovered from the
previous installation.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)
FIGURE 91
hose clamp torque: 30 lbf-in
FIGURE 92
79. Install the 13″ and 27″ long hoses prepared at
the previous step as shown on the images.
FIGURE 93
FIGURE 94
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80. Secure the 24″ long hose as shown on the
image.
A : nylon tie # 509491
FIGURE 95
81. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657
FIGURE 96: DEF INJECTOR COOLANT LINE RETURN HOSE
82. Connect the coolant line that comes from the
surge tank to the radiator outlet pipe. Use one
(1) hose clamp #992086.
TORQUES:
Caillau clamps : 30 lbf-in
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FIGURE 97
IS-19912E
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83. Secure the coolant hoses together using the
following hardware.
A : nylon tie # 509491 (2x)
B:swivel mount #504751 (1x)
FIGURE 98
84. Secure the coolant hoses together using nylon
ties.
A: « handcuff » nylon tie #N37749 (2x)
FIGURE 99
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85. Hang the engine intake pipe #050308 in place.
FIGURE 100
FIGURE 101: ENGINE INTAKE PIPE SUPPORT
FIGURE 102: PIPE SUPPORT
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86. Reinstall the intake elbow and adapter. Use the
following hardware:
A: V-band clamp #20592783 (2x)
B: Gasket #1675066 (2x)
FIGURE 103: ENGINE INTAKE PIPE SUPPORT
FIGURE 104
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87. Connect the new CAC outlet pipe #050308 to
the engine intake elbow.
A: #030096 hose (1x)
B: #21490630 spring loaded clamp (2X)
FIGURE 105
Constant Torque hose clamps 4.25″- charge air
cooler (CAC) 4.5-5.5 lbf-ft
FIGURE 106: CONNECTION AT THE ENGINE INTAKE
ELBOW
88. Reinstall the pipe (item A) section located
downstream the engine air filter. Connect the
air compressor fresh-air inlet pipe (item B)
connected to pipe A.
FIGURE 107
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89. Reinstall the exhaust pipe section located
between the DPF and the flexible section. Use
the following hardware:
•
V-band clamp #21021850 (2x)
•
Gasket #21095726 (2x)
FIGURE 108: REINSTALL THIS EXHAUST PIPE SECTION
90. Pre-install the new radiator inlet pipe #050309.
A: #052889 silicone hose
B: # 992089 hose clamp (4x); final torque: 30
lbf-in
FIGURE 109
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91. Install seven (7) nylon tie mounts centered
on the beam, as shown in the picture. Drill Ø ¼
in. Use the following hardware:
•
Tie mount #509490 (7x)
•
Rivet #504610 (7x)
Spacing between
approximately.
each
tie
mount:
6½″
FIGURE 110
FIGURE 111
FIGURE 112
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92. Install five (5) nylon tie mounts as shown in
the picture. Drill Ø ¼″. Use the following
hardware:
Tie mount #509490 (5x)
Rivet #504610 (5x)
•
•
FIGURE 113
FIGURE 114
FIGURE 115: TIE MOUNT 3 & 4 SHALL NOT BE PLACED
BETWEEN THE BULKHEAD AND THE VALVE COVER.
93. On the bracket shown on the image, drill a hole
of Ø 11/32″. and then install a nylon tie with fir
tree #504750.
FIGURE 116: BRACKET ON THE ENGINE HOT SIDE
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DIAGRAM OF ELECTRICAL CONNECTIONS
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94. Hook up the “alternator power cable” #0610053
to the alternator positive (+) post. Place the flash
washer between the cable lug and the nut.
1x nut #500685torque: 80-125 lbf-in
1x flat washer #5001341
Apply Color Guard rubber coating at the alternator
ground (
) and positive (+) connections.
IMPORTANT NOTE
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 117
FIGURE 118:
-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)
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95. Secure the alternator power cable with the nylon
tie with fir tree previously installed.
FIGURE 119
96. Secure the alternator power cable to the tie
mounts previously installed using nylon ties:
nylon tie #509491 (7x)
•
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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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