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
FIGURE 120
FIGURE 121
97. On the diagonal member located under the
previously welded ground stud, install a nylon tie
mount. Use:
Tie mount #509490 (1x)
Rivet #504610 (1x)
•
•
FIGURE 122
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98. Partially install the “fan drive power cable”
#0610563. Secure the tie mount using a nylon
tie. Keep the nylon tie loose.
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
A: nylon tie #509491 (1x)
B: fan drive power cable #0610563
FIGURE 123
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99. Install the “fan drive ground cable” #069246 and
connect to the ground stud previously welded to
the chassis.
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
A: fan drive ground cable #069246
B: fan drive power cable #0610563
FIGURE 124
C: split lock washer #500482 + brass nut #500998
D: tie mount #509490 (1x) + rivet #504610 (1x) +
nylon tie #509491 (1x)
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
FIGURE 125
A: fan drive ground cable #069246
B: fan drive power cable #0610563
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 126
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100.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.
101.Once properly adjusted, tighten the nylon ties
previously installed.
FIGURE 127
102.Apply Loctite Color Guard Rubber Coating on
the ground stud connection.
FIGURE 128: GROUND STUD WITH RUBBER COATING
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103.Connect the “alternator control cable” #0610037
on the alternator.
Connect circuit I to Indicator (I) post.
Connect circuit S to Sense (S) post.
Use the following hardware:
2x nut with nylon insert #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
connections.
on
FIGURE 129
FIGURE 130
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104.Partially route the “alternator control cable”
#0610037 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” #0610037
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 131
FIGURE 132
FIGURE 133
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FIGURE 134
FIGURE 135
105.Route the “fan drive power cable” and the
“alternator power cable” towards 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
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FIGURE 136
IS-19912E
Page 64 / 92
106.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 137
107.Secure harness #23488790 along the fan drive
power cable, placing a nylon tie #504016 every
6 ″ (150 mm).
DO NOT TIGHTEN THE NYLON TIES AT THIS
MOMENT
FIGURE 138
108.Secure connector C-ALT3 as shown on the
image with one (1) nylon tie #504016 and then
connect to the alternator control cable #0610037
previously installed.
FIGURE 139
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109.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 140: CONNECTION AT THE TURBO OUTLET
ELBOW
110.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 12
FIGURE 141
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111.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 142:
FIGURE 143
112.Install the upper attachment on the cooling pack.
FIGURE 144
113.Reinstall the cooling pack in its compartment.
FIGURE 145
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114.Secure the cooling pack base with the following
parts:
A: screw #502804 (4x)
B: washer #5001751 (8x)
C: nut #502859 (4x)
FIGURE 146
115.Bolt the anti-vibration mount onto the vehicle
chassis
FIGURE 147
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116.Complete the connection with
the cooling pack.
For proper clamp torque, refer to
HOSE CLAMP TORQUE on page
12
FIGURE 148
117.Connect the radiator vent hose on top of the
radiator.
FIGURE 149
118. 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 150
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119.Remove all the old spring nuts on the cooling
pack and replace with new spring nuts.
•
spring nut #5001965 (18x)
FIGURE 151
120. 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 152
FIGURE 153
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121. 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 154
122. 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 155
123. Install the sealing element #050380. Secure
with the following hardware:
5x bolt #5001697
5x lock washer #502570
B: #050380
FIGURE 156
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124. Install the sealing element #050359. Secure
with the following hardware:
6x bolt #5001697
6x lock washer #502570
C: #050359
FIGURE 157
125. Cut two pieces of 39 /8 ″ (1000 mm) long of
rubber extrusion #506025.
3
126. 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 158
FIGURE 159
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127. Install panel #050343. Secure with the
following hardware:
22 x bolt #5001697
22 x lock washer #502570
FIGURE 160
128.Install the circuit breaker box #564612.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 161
129. Install the upper sealing element #050366.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 162
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130. Install the pull-rod box #050369.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 163
131. Install the lower sealing element #050365.
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 164
132. Install the R.H. side sealing element #050367.
Secure with the following hardware:
bolts #5001697 (5x)
lock washers #502570 (5x)
FIGURE 165
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133. 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 166
134. 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 167
135.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 168
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FIGURE 169
136. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 170
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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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