IS-19900

Instruction Sheet
IS-19900
ELECTRIC FAN DRIVE COOLING SYSTEM CONVERSION WITH BOSCH
ALTERNATOR - H3 SERIES US10 COOLING SYSTEM
REVISION :
THIS DOCUMENT SUPERSEDES PREVIOUS VERSION.
NONE
MATERIAL
Kit IS19900 “H3 US10 electric fan drive retrofit with Bosch alternator” contains the following
parts:
Qty
Part No.
DESCRIPTION
050195
FAN SUPPORT PANEL
A1
1
050200
UPPER SHROUD TRANSITION
A6
1
050201
LEFT SHROUD TRANSITION
A7
1
050202
RIGHT SHROUD TRANSITION
A8
1
050203
LOWER SHROUD TRANSITION
A9
1
050204
UPPER LEFT SHROUD PANEL H3 US10+
A11
1
050229
ELECTRICAL CONNECTOR COVER
A15
1
050206
UPPER RIGHT SHROUD PANEL H3 US10+
A12
1
050213
LOWER SHROUD PANEL H3 US10+
A14
1
050208
LH SIDE SHROUD PANEL H3 US10+
A10
1
050255
RH SIDE SHROUD PANEL & WURTH BOX SUPPORT
H3 US10+
A13
1
Writer:
EL

IS-19900
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012349
IDLER PULLEY
Mechanical
1
012941
PULLEY, DRIVE
Mechanical
1
012942
L.H. ENGINE MOUNT
Mechanical
1
012943
SUPPORT, IDLER + TENSIONER
Mechanical
1
453076
CAP, DUST
Mechanical
1
506026
1x BELT, DRIVE POLY V 10PK1695
Mechanical
2
Mechanical
1
1x BELT, DRIVE POLY V 10PK1695 (for your spare kit)
510991
Writer: EL
TENSIONER, BELT

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564593
BOSCH HD10PLBH ALTERNATOR 28V-150AMP J180
Mechanical
1
0600265
PULLEY, ALTERNATOR 10PK, 73 DOB
Mechanical
1
050286
CAC INLET PIPE H3 US10+
Pipe
1
050406
CAC OUTLET PIPE H3 US10+
Pipe
1
050414
RADIATOR INLET COOLANT PIPE H3 US10+
Pipe
1
050288
RADIATOR OUTLET PIPE H3 US10+
Pipe
1
501027
FITTING, SAE 45º #4FL-Mx1/4NPT-M BR
Fitting
1
501308
ADAPTER / PIPE FITTING / 1/4NPT-Fx1/4NPT-M BR
Fitting
1
501329
ELBOW 45º / PIPE FITTING / 1/4NPT-Mx1/4NPT-F BR
Fitting
1
501332
ELBOW 90º / PIPE FITTING / 1/4NPT-Mx1/4NPT-F BR
Fitting
1
052366
HOSE 3/8 ID X 61 in LONG
hose
1
20550690
HOSE, FLEXIBLE - CHARGE AIR
Hose
2
Hose
1
Location: turbo outlet & engine intake
531469
HOSE, FLEXIBLE - CHARGE AIR
Location: CAC outlet
Writer: EL

IS-19900
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531471
HOSE, FLEXIBLE - CHARGE AIR
Hose
1
Hose
1
Hose
3
Clamps
8
Clamps
4
Clamps
16
Clamps
4
Location: CAC inlet
052889
HOSE, SILICONE 2 1/2" ID
Location : coolant pipes
053617
HOSE, SILICONE
Location : coolant pipes
21490616
CLAMPS, SPRING LOAD - CHARGE AIR
Location: CAC outlet & inlet
21490630
CLAMP, SPRING LOAD - CHARGE AIR
Location: turbo outlet & engine intake
992089
HOSE CLAMP CT CAILLAU 60mm-80mm
Location : coolant pipes
992081
HOSE CLAMP CT CAILLAU 12-22
Location : coolant filter
21185073
MOUNT, ANTI-VIBRATION
Support
/bracket
1
050305
BRACKET, RADIATOR INLET PIPE
Support
/bracket
1
050265
COOLANT FILTER SUPPORT H3
Support
/bracket
1
Writer: EL

IS-19900
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050266
ALTERNATOR BATTERY CABLE SUPPORT
Support
/bracket
1
050303
ALTERNATOR TELLTALE BRACKET
Support
/bracket
1
050214
UPPER RADIATOR SUPPORT H3
Support
/bracket
1
060102
ALTERNATOR BRACKET, LOWER
Support
/bracket
1
010060
DECAL, BELT ROUTING
Misc.
1
069205
DECAL, WARNING
Misc.
2
391028
INSERT, ALTERNATOR TELLTALE
Misc.
1
506025
RUBBER EXTRUSION, BLACK
Misc.
8 ft
060297
STUD ADAPTER, ALTERNATOR M/F-M8
Misc.
1
380360
GROUND STUD
Misc.
1
506040
TAPE, ADHESIVE AD1 EPDM CC GY 5/16"X3/4"X25'
Misc.
1
562113
TELLTALE LIGHT MODULE
Misc.
1
21937327
FILTER, COOLANT
Misc.
1
Writer: EL

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Electrical
1
CONNECTOR HOUSING, PED WEATHER-PACK 4
WIRES
Electrical
1
561783
CAVITY PLUG, CONNECTOR
Electrical
4
22722850
I/O-B MULTIPLEX MODULE
Electrical
1
23499009_EFD
MCM, PROGRAMMED
Electrical
1
563593
CONNECTOR, WITH END-OF-LINE 120 OHMS
RESISTOR
Electrical
2
563750
FUSE HOLDER, AMG TYPE
Electrical
1
564520
FUSE, AMG 300A
Electrical
1
564612
CIRCUIT BREAKER BOX
Electrical
1
565191
FAN, ELECTRIC
Electrical
8
563533
HAND GUARD, FAN
Electrical
8
068820
HARNESS, FAN DRIVE
Harness
1
012921
GROUND STUD
561610
Writer: EL

IS-19900
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069246
GROUND CABLE, FAN DRIVE
Harness
1
069504
GROUND CABLE, LEFT ALTERNATOR
Harness
1
069511
CONTROL HARNESS, LEFT ALTERNATOR
Harness
1
23445869
MCM TO I/O-B INTERFACE HARNESS
Harness
1
23488790
FAN TO RJB INTERFACE HARNESS H3
Harness
1
23490553
VEHICLE INTERFACE HARNESS
Harness
1
23498450
MASTER RELAY TO 300A FUSE CABLE, 300mm
Harness
1
23498721
FAN DRIVE POWER CABLE, 4600mm
Harness
1
23498785
L.H. ALTERNATOR POWER CABLE, 4450mm
Harness
1
N37749
TIE, NYLON DOUBLE
hardware
15
504016
TIE, NYLON BLACK (LARGE)
hardware
58
504013
MOUNT, TIE HOLE 1/4"
hardware
25
504751
MOUNT, TIE SWIVEL
hardware
4
504750
MOUNT, TIE TREE
hardware
1
509490
MOUNT, TIE DOUBLE GRAY
hardware
15
Writer: EL

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509491
TIE, NYLON LARGE EXTRA STRONG 250 LBS
hardware
38
562679
MOUNT, SQUARE SELF-ADHESIVE BLACK
hardware
4
500449
WASHER, FLAT SS .687X1.5X0.078 (M16,5/8)
hardware
1
500482
WASHER, SPLIT LOCK Z050 .506X.873X.125
(M12,1/2)
hardware
1
500942
WASHER, SPLIT LOCK N500 8.1X14.8X2
(M8,5/16,#18)
hardware
4
502570
WASHER, SPLIT LOCK SS 6.1X11.8X1.6 (M6,#12)
hardware
62
502573
WASHER FL SS 6.4 X 12.0 X 1.6 (M6,1/4)
hardware
1
507657
WASHER, BANJO FITTING M14
hardware
8
5001341
WASHER, FLAT SS 8.4X17X1.6 (M8,5/16)
hardware
6
5001737
WASHER, SPLIT LOCK N500 10.2X18.1X2.2
(M10,3/8)
hardware
4
5001751
WASHER, FLAT N500 10.5X26X2 (M10,3/8)
hardware
10
5001833
WASHER, BELLEVILLE SPR SS 301
6.65X17.4X1.27(M6,1/4
hardware
32
5001868
WASHER, BELLEVILLE SS 8.4X18X2 (M8,5/16)
hardware
4
5001935
WASHER, FLAT SS 10.5X18X1.6 (M10,3/8)
hardware
1
5002008
WASHER, FLAT HARD N500 13X35X5 (M12,1/2)
hardware
1
500998
NUT HEX BR 1/2-13
hardware
1
502837
NUT HEXF STO N500 M8-1.25
hardware
2
502859
NUT HEX NYRT NX500 M10-1.5 G10
hardware
4
5001182
NUT HEX NYRT SS M6-1
hardware
1
5001665
NUT HEX NYRT NX500 M22-2.5
hardware
1
5001728
NUT HEXF STO N500 M12 CL10
hardware
1
5001761
NUT HEXF NYRT NX500 M12-1.75 G8
hardware
2
5001930
NUT HEXF NYRT NX500 M10-1.50 PC 10
hardware
2
5001983
NUT HEX NYRT NSS M8-1.25X9.5
hardware
3
21429955
NUT, FLANGED
hardware
1
Writer: EL

IS-19900
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hardware
4
hardware
11
hardware
1
hardware
33
hardware
8
hardware
22
hardware
1
hardware
6
hardware
3
hardware
62
hardware
4
hardware
2
hardware
1
hardware
4
hardware
1
hardware
2
RIVET, POP DOME SS OE 3/16X1/4
hardware
41
504610
RIVET MGL PRDG SS 1/4X5/8
hardware
14
IS-19900
INSTRUCTION SHEET
FI-19900
FEUILLE D’INSTRUCTION
500119
SCREW, CAP HEX SS NSS M8X1.25X20
500658
SCREW TC PAN PH Z050 10-24X3/4
502719
SCREW, CAP HEX SS NSS M10X20 G8.8
502686
SCREW, CAP HEX SS NSS M6X30
502804
SCREW, CAP HEX N500 M10-1.5X25 G8.8
502848
SCREW TC HEX F N500 1/4-20X3/
502950
SCREW SHR HEXF N500 12.9X160LG CL10.9
5001296
SCREW, CAP HEXFN500 M12-1.75 X 80 CL10.9 PT
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
5001800
SCREW, CAP HEXF N500 M10X45 G10.9
5001940
SCREW CAP HEX N500 M12X1.75X140
504379
Writer: EL
1
1

PROCEDURE
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.
DIAGRAM OF ELECTRICAL CONNECTIONS
Writer:
EL

HOSE CLAMP TORQUE (coolant lines and charge air cooler)
HOSE CLAMPS
No
1
(Ø 2 ½ ” or
less)
2
(Ø 4 ¼ ”)
Writer:
EL
DESCRIPTION
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)
4.5-5.5 lbf-ft

IS-19900
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Writer: EL

1. Remove L.H. side rear fender.
FIGURE 1
Drain the cooling system
2. 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
3. Unfasten cap screws and remove access
panel located behind tag axle L.H. side wheel.
FIGURE 3
Writer:
EL

IS-19900
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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 clamps and then break hoses from
the front coolant and charge air pipes.
FIGURE 6
Writer: EL

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7. Remove rear coolant and charge air hose
clamps then break hoses loose.
FIGURE 7
8. Remove the upper radiator assembly support
bracket.
FIGURE 8
9. Remove the lower radiator assembly protector
tube.
FIGURE 9
Writer: EL

IS-19900
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10. Disconnect the radiator vent hose on top of
the radiator.
11. 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.
12. Remove fan drive shaft fasteners at the fan
clutch.
FIGURE 10
Writer: EL

IS-19900
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13. 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.
14. 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
15. Remove the fan drive casting.
FIGURE 14
Writer: EL

IS-19900
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16. Unscrew all lower radiator assembly mounting
fasteners (2 bolts on R.H. side, 2 bolts on L.H.
side).
FIGURE 15
17. 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
Writer: EL

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18. Remove the tripod from the radiator/CAC
assembly.
FIGURE 17
FIGURE 18
19. Remove the fan shroud.
FIGURE 19
Writer: EL

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20. 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 20: MOUNTING SUPPORT IN INITIAL POSITION
AFTER
FIGURE 21: MOUNTING SUPPORT AFTER 180° ROTATION
21. Remove the rear bumper (undo three nuts and
one attachment plate each side).
FIGURE 22
Writer: EL

IS-19900
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22. On the engine hot side, remove the following
pipes:
•
•
radiator inlet & outlet pipes
CAC inlet and outlet pipes
Keep the fittings found on the radiator outlet
pipe for reuse
FIGURE 23
FIGURE 24
23. Remove all the drive belts mounted on the
crank pulley.
FIGURE 25
Writer: EL

IS-19900
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24. Remove the drive pulley. Discard the 6 bolts.
FIGURE 26
25. Remove the rust, clean and prepare the
surface on the vibration damper as shown.
Work the surface to achieve a smooth finish.
FIGURE 27
FIGURE 28
Writer: EL

IS-19900
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26. Properly support the engine as one of the
engine support will be interchanged in the
upcoming steps.
FIGURE 29
27. Remove the two (2) coolant hoses shown on
the image. Keep the two (2) banjo fittings for
later use.
BANJO FITTING
FIGURE 30
28. 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 31: L.H. REAR ENGINE SUPPORT
Writer: EL

IS-19900
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29. Remove the water pump idler/tensioner
assembly from the former engine mount. To do
so, unscrew three (3) bolts from the back of the
engine mount.
FIGURE 32
30. Reinstall idler/tensioner assembly as a unit on
the new L.H. engine mount #012942.
Mount the idler/tensioner assembly using
three (3) cap screws #5001643
Tighten to 14-17 lb-ft
FIGURE 33
31. Install the new engine mount #012942 using
seven (7) M14 screws saved from the former
engine support with this exception of:
•
Ground stud #012921 (1x) and nylon
insert NYRT nut #5001665 (1X)
•
Isolator cap screw #5001940 (2X)
•
Nut #5001761 (2X)
FIGURE 34
Seven (7) mounting screws torque : 90-94 lb-ft
(128 Nm)
Writer: EL

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FIGURE 35: REAR VIEW – GROUND STUD
FIGURE 36
FIGURE 37
Writer: EL

IS-19900
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32. Install the new crank pulley using six new bolts
#5001296. Use blue Loctite on the bolt threads.
Torque to 36 lbf-ft in a star pattern. Once
done perform a final tightening to the value
of 66 lbf-ft.
FIGURE 38
33. Reinstall the water pump drive belt.
FIGURE 39: WATER PUMP DRIVEBELT
34. Reinstall the AC compressor drive belts.
35. Install the idler support #012943 using three (3)
screws #5001799. At the same time, install the
alternator lower bracket #060102.
screws #5001799 prescribed torque:48 lbf-ft
FIGURE 40: BRACKET #060102
Writer: EL

IS-19900
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36. Make a smooth round clearance in the engine
cradle to allow required space for the alternator
lower bracket #060102 installed at the previous
step. Carefully work the edge to achieve a
smooth finish and coutour.
Measurements: ↔ 2″, ↕¾″
Apply paint to protect the metal against
corrosion
FIGURE 41
37. Install the new idler #012349 with screw
#5001786 and washer #5002008.
Tighten to 82 lb-ft
FIGURE 42
Writer: EL

IS-19900
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38. Install the dust cap #453076.
FIGURE 43
FIGURE 44
39. Install the new alternator belt tensioner
#510991. Secure with one screw #5001799 on
which blue Loctite is applied on the threads.
FIGURE 45: TENSIONER MOUNTING SCREW TORQUE : 48
lb-ft
Writer: EL

IS-19900
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40. Apply anti-seize compound (Prevost p/n:
680335) inside the alternator mounting ears
and inside the sleeves found on the support
attached to the engine.
FIGURE 46
FIGURE 47
41. Install the alternator.
A: screw #502950 & nut #5001728 (torque: 82
lbf-ft)
B: screw #5001800 & nut #5001930 (torque:
48lbf-ft)
C: apply blue Loctite and then torque to 48 lbf-ft
FIGURE 48
Simultaneously, install the alternator
“power cable” support #050266 to the
alternator as shown on the picture.
FIGURE 49
Writer: EL

IS-19900
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42. Install the alternator pulley #0600265 (for
further
details,
refer
to
Maintenance
Information IM16-17).
Use washer #500449 and flanged nut #21429955
torque: 75 lbf-ft
FIGURE 50
43. Install the alternator drive belt #506026.
FIGURE 51
44. On the alternator, install the stud adapter
#060297 at B1+ stud terminal.
torque: 11 lbf-ft
FIGURE 52
Writer: EL

IS-19900
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45. Weld the new coolant filter support #050265 on
the engine cradle.
24 inches from the end of the cradle
FIGURE 53
3 inches above the flat surface of the cradle
FIGURE 54
FIGURE 55
Writer: EL

IS-19900
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46. As a preparation to welding, use a grinder with
abrasive disc to remove some paint to reach
bare metal. Weld the ground stud #380360
centered in the beam and at 14 inches from the
beam end.
FIGURE 56
FIGURE 57: GROUND STUD #380360
47. 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 58: GROUND STUD #380360
48. Install a tie mount #509490 with one screw
#502686 at the back of the L.H. engine mount.
FIGURE 59
Writer: EL

IS-19900
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49. Install the alternator ground cable #069504.
Secure to the ground stud on the alternator
using washer #502573 and nut #5001182.
torque: 6 lbf-ft
50. Secure the alternator ground cable to the
previously installed tie mount using one nylon
tie #509491.
FIGURE 60
51. Secure the alternator ground cable #069504 to
the previously installed ground stud on the L.H.
engine mount.
Use screw #502719 & washer #5001935
Protection against corrosion. Apply Color
Guard rubber coating on the ground stud once
the ground cable is hooked up.
FIGURE 61
52. To the previously installed coolant filter
support, install the filter holder recovered from
the former installation.
FIGURE 62
53. Install a new coolant filter onto the filter holder.
Check the clearance between the filter and the
near hose clamps of the coolant pipe leading to
the transmission oil cooler.
Writer: EL

IS-19900
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54. Transfer the drain plug and the coolant
extractor quick connect fitting saved from the
old radiator outlet pipe.
Apply Loctite 567 Thread
installation of the fittings
Sealant
prior
55. Install the new radiator outlet pipe #050288.
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
FIGURE 63
B: drain plug
C: coolant extractor quick connect valve
D: # 053617 silicone hose
56. 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 64
57. 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 one, 38 inches
long.
A : hose clamp #992081 (4x)
B: banjo fitting copper washer #507657 (6x)
FIGURE 65
b) Use the banjo fittings recovered from the
previous installation.
hose clamp torque: 30 lbf-in
FIGURE 66
Writer: EL

IS-19900
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58. Install the 20” long and 36” long hoses
prepared at the previous step as shown on the
images.
FIGURE 67
FIGURE 68
59. Connect the DEF injector coolant line return
hose to the radiator outlet pipe.
Use two (2) new banjo fitting copper washer
#507657
FIGURE 69: DEF INJECTOR COOLANT LINE RETURN HOSE
Writer: EL

IS-19900
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60. Connect the coolant line that comes 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 70
Oetiker clamps – unpainted spring : 8-9 lbf-in
Caillau clamps : 30 lbf-in
61. Secure the coolant hoses together using nylon
ties.
A : nylon tie (handcuff type) #N37749 (about 3
to 6, as required)
FIGURE 71
FIGURE 72
Writer: EL

IS-19900
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62. Secure the coolant hose near the engine block
«push-lok» fitting as shown.
B : nylon tie #504016 (1x)
FIGURE 73
63. Hook up the “L.H. alternator power cable”
#23498785 to the alternator (+) terminal which
is the stud adapter.
A: nut M8 #5001983
torque: 11 lbf-ft
B: flat washer #5001341
C: nylon tie #504016 (2x)
D: tie mount #504013 (2x)
E: rivet #504379 (2x)
FIGURE 74
FIGURE 75
Writer: EL

IS-19900
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64. 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 76
FIGURE 77
65. Apply Color Guard rubber coating on the
ground stud connection.
FIGURE 78: GROUND STUD WITH RUBBER COATING
Writer: EL

IS-19900
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66. Apply Color Guard rubber coating at the
alternator ground
connections.
(
)
and
positive
(+)
FIGURE 79: GROUND CONNECTION ON THE ALTERNATOR
FIGURE 80: POSITIVE (+) CONNECTION ON THE
ALTERNATOR
Writer: EL

IS-19900
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67. Install a tie mount #509490 at the location
shown on the picture. Secure the tie mount
with a rivet.
A: tie mount #509490
B: rivet #504610
C: nylon tie #509491
D: fan drive power cable #23498721
FIGURE 81
68. Secure the “fan drive power cable” #23498721
onto the tie mount using a nylon tie. Make sure
to leave 26 inches long from the tie mount up
to the end of the “fan drive power cable” red
connector.
FIGURE 82
FIGURE 83
FIGURE 84
69. Install six (6) tie mounts to secure the “fan
drive power cable” and the “L.H. alternator
power cable” as shown on the picture.
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FIGURE 85
A: tie mount #509490
B: rivet #504610
C: nylon tie #509491
FIGURE 86
70. Route the “fan drive power cable” and the
“L.H. alternator power cable” up to the main
power compartment. Refer to the pictures at
right as a guide for the installation.
71. Secure both cables using five (5) tie mounts
#509490 fixed with five (5) rivets #504610.
Secure the cables on the tie mounts as
previously done with ten (10) nylon ties #
509491.
A: tie mount #509490
B: rivet #504610
C: nylon tie #509491
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FIGURE 88
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72. INSTALLATION OF THE “FAN TO RJB
INTERFACE” HARNESS #23488790
a) Route the “fan to RJB interface” harness
#23488790 up to the main power
compartment. Secure this harness to the
fan drive power cable using nylon ties
#504016.
b) This harness will be connected close to the
fan drive power cable, thus it also requires
26 inches of free length.
FIGURE 89
A: FAN TO RJB INTERFACE” HARNESS #23488790
B: FAN DRIVE POWER CABLE
C: NYLON TIES #504016 (23x approx.)
FIGURE 90
FIGURE 91
FIGURE 92
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73. INSTALLATION OF THE ALTERNATOR
CONTROL HARNESS #069511
a) Connect the harness #069511 to the
alternator.
b) Secure the harness with nylon ties as
shown on the pictures.
FIGURE 93: C: NYLON TIES #504016 (2x)
FIGURE 94: C: NYLON TIES #504016 (2x)
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74. Connect the new CAC outlet pipe #050406 to
the engine intake elbow.
A: #20550690 hose (1x)
B: #21490630 spring loaded clamp (2X)
FIGURE 95
Constant Torque hose clamps 4.25in - charge
air cooler (CAC) 4.5-5.5 lbf-ft
FIGURE 96: CONNECTION AT THE ENGINE INTAKE ELBOW
FIGURE 97
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75. If your vehicle is equipped with AFSS
(Automatic Fire Suppression System), the new
CAC outlet pipe #050406 is likely to come into
interference with a AFSS extinguishing agent
hose (see image) near the end of the pipe that
connects with the Charge Air Cooler.
If this is the case, move the hose the other side
of the bracket shown, to prevent rubbing
between the hose and the CAC outlet pipe.
FIGURE 98
76. On the diagonal member, change the existing
radiator inlet pipe bracket for the new bracket
#050305. Use the existing hardware.
FIGURE 99
77. Install the new radiator inlet pipe #050414.
A: #052889 silicone hose
B: # 992089 hose clamp (4x); torque: 30 lbf-in
FIGURE 100
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78. Install the new CAC inlet pipe #050286. Use
one new #20550690 CAC flexible hose.
Secure the hose using two (2) spring loaded
clamps #21490630.
A: #20550690 hose
B: #21490630 spring loaded clamp (2X), torque:
5 lbf-ft
FIGURE 101: CONNECTION AT THE TURBO OUTLET
ELBOW
79. Reinstall the cooling pack.
FIGURE 102
80. Secure the cooling pack base with the following
parts:
A: 4x screw #502804
B: 8x washer #5001751
C: 4x nut #502859
FIGURE 103
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81. Using parts #501332, #501308, #501329,
#501027, mount the brass fitting assembly
shown on the image at right.
Apply Loctite 567 Thread Sealant on the
threads
A: #501027
B: #501329
C: #501308
FIGURE 104: BRASS FITTING ASSEMBLY
D: #501332
82. Remove the vent hose fitting found on the
radiator.
FIGURE 105
83.
Install the brass fitting assembly in place of
the former vent hose fitting and then connect
the radiator vent hose.
84. 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 #050214
C: 2x screw #5001738 , 2x nut #502837
D: 2x screw #5001738 , 2x washer #500942
E: 2x screw #5001745 , 2x washer #500942
FIGURE 106
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One end of the upper attachment is
mounted on the radiator frame (image at
right)
FIGURE 107
Bolt the anti-vibration mount onto the
vehicle chassis
FIGURE 108
85. Reinstall all the blue flexible hoses at the CAC
and radiator (at the lower connections of the
cooling pack). Install with the following parts:
A: #21490616 clamp (4x)
B: #531471 flexible hose
C: #053617 silicone hose
D: #992089 (4x)
FIGURE 109
86. Reinstall all the blue flexible hoses at the CAC
and radiator (at the upper connections of the
cooling pack). Use the following parts::
A: 1x flex hose #531469
B: 1x silicone hose #053617
C: 4x clamp #21490616
D: 4x clamp #992089
FIGURE 110
For proper clamp torque, refer to HOSE CLAMP
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TORQUE on page 12
87.
Reinstall the lower cooling pack protector
tube with the following hardware:
4x Screw #502804
4x split lock washer #5001737
FIGURE 111
88.
Install the sealing element #050200. Screw it
on the existing threaded holes on the upper
part of the radiator. Secure with the following
hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 112
FIGURE 113
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89.
Install the sealing element #050203. Screw it
on the existing threaded holes on the bottom
of the radiator. Secure with the following
hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 114
90.
Prepare the sealing elements #050201 and
#050202. On both parts, apply foam tape
#506040 on the edges as shown on the
image.
FIGURE 115
91.
Install the sealing elements #050201 and
#050202. Screw them onto the upper and
lower sealing elements installed at the
previous steps. Secure with the following
hardware:
8x bolt #5001697
8x lock washer #502570
A: #050201
B: #050202
FIGURE 116
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92.
Cut two pieces of 39 inches (990 mm) long
of rubber extrusion #506025.
93.
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
#050195.
FIGURE 117
FIGURE 118
94.
Install panel #050195. Secure with the
following hardware:
19x bolt #5001697
19x lock washer #502570
FIGURE 119
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95.
Install the upper left #050204 and upper right
#050206 sealing elements.
Secure with the following hardware:
6x bolt #5001697
6x lock washer #502570
FIGURE 120
96.
Install the lower sealing element #050213.
Secure with the following hardware:
5x bolt #5001697
5x lock washer #502570
FIGURE 121
97.
Install the
#050208.
L.H.
side
sealing
element
Secure with the following hardware:
4 bolts #5001697
4 lock washers #502570
FIGURE 122
98.
Install the
#050255.
R.H.
side
sealing
element
Secure with the following hardware:
4x bolt #5001697
4x lock washer #502570
FIGURE 123
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99.
With a paint marker, identify the fans from 1
to 8 in accordance with number found on a
label on their respective blue connector.
100. Install the fans and fan hand guards on the
panel in the same arrangement shown on
the image. Be sure to place the fan so that
the cable is at the proper location, 3
O’clock, 6 O’clock or 12 O’clock. Refer to the
image at right.
FAN HAND GUARD
FIGURE 124
Install with the following hardware:
32x bolts #502686
32x lock washers #5001833
Prescribed torque:30 lbf-in
101. Snap the fan blue connector in the holes
punched on the panel for that matter.
FIGURE 125
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102. Route and secure the fan cables as shown
on the images.
Secure with the following parts:
A= nylon tie mount #504013 + rivet
#504379 + nylon tie #504016
B= nylon tie #504016
Do not tighten the nylon ties at this moment
FIGURE 126
FIGURE 127
103. Install the circuit breaker box #564520.
Install with the following hardware:
4x bolt #500119
4x lock washer #5001868
FIGURE 128
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A: 2x bolt #500119 + 2x lock washer
#5001868
FIGURE 129
A: 2x bolt #500119 + 2x lock washer
#5001868
104. Connect each fan to the corresponding
connection port on the circuit breaker box.
FIGURE 130
105. Tighten the nylon ties previously installed
while routing the fan cables.
106. Use two (2) additional nylon ties #504016 to
secure the extra-length of cables together
close to the circuit breaker box as shown on
the image at right.
FIGURE 131
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107. Install the electrical connector cover #
050229.
Fasten with the following hardware:
4x bolt #5001697
4x lock washer #502570
108. Using good industrial glue (Loctite 404 or
similar product), glue three (3) pieces of
rubber extrusion #506025 as shown on the
connector cover.
FIGURE 132
FIGURE 133
109. Complete the installation of the sealing
elements. Screw the panels to the chassis
threaded holes where shown on the image.
Use the following hardware:
22x bolt #502848
FIGURE 134
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110. Complete the connection of the to the fan
circuit breaker box (three connectors: gray,
black and red).
A: fan drive ground cable (black connector)
B: fan drive power cable (red connector)
C: “fan to RJB interface” harness (gray
connector)
FIGURE 135
111. Secure the fan drive ground cable and the
fan drive power cable connected to the fan
drive circuit breakers box as shown on the
pictures.
A: rivet #504379 (6x)
B: tie mount #504013 (6x)
C: nylon tie #504016 (6x)
D: handcuff nylon tie #N37749 (1x)
FIGURE 136
FIGURE 137
112. Connect the alternator control harness
connector C-ALT3 to connector C-ALT3 of
the “fan to RJB interface” harness. Secure
the extra length of harness as shown with
nylon ties.
A: handcuff nylon tie #N37749 (3x)
B:nylon tie #504016 (4x)
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FIGURE 138
FIGURE 139
INSTALLATION OF ELECTRIC COMPONENTS AND HARNESS
CONNECTIONS IN THE MAIN POWER COMPARTMENT
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DIAGRAM OF ELECTRICAL CONNECTIONS
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113. In the battery compartment, disconnect the
battery ground cable from the chassis
ground stud.
FIGURE 140
114. Most of the electric components will be
installed on the bulkhead at the right of
master relay R1 (when facing it). Locate the
master relay R1 (refer to the image at right).
FIGURE 141
115. If the situation applies to the vehicle on
which you are working on, remove the two
(2) useless studs found on the bulkhead and
then smooth the surface.
FIGURE 142
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FIGURE 143
116. Make sure this is no voltage applied to the
master relay R1 posts and then, remove the
master relay R1 cover.
FIGURE 144
117. Disconnect the four (4) cable lugs connected
to the master relay R1 upper post.
118. Momentarily, connect the angled lug of the
“master relay R1 to 300A fuse” cable
#23498450.
FIGURE 145
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119. Find the best location where to install the
fuse holder #563750 on the bulkhead. Take
note that the fuse holder must be installed at
a distance that allows cable #23498450 to
reach it.
120. Drill two 11/64 pilot holes for the installation
of the fuse holder on the main power
compartment bulkhead. Secure with the
following hardware:
A: tapping screw #500658 (2x) + flat
washer #5001341 (2x)
FIGURE 146
121. Reinstall the four (4) other cable lugs to the
master relay R1 upper post.
Being the largest lug at R1, the cable #23498450
lug should be placed first on the post (behind
all the other lugs) (or second if rubbing is likely
to happen).
Master relay R1- Port 30 – M10-1.5 stud nut
torque: 160-195 lb-in (18-22 Nm)
FIGURE 147: ON THIS PICTURE, CABLE #23498450 LUG IS
IN SECOND (2ND) POSITION BECAUSE IT WAS LIKELY TO
RUB ON THE HEAD OF ONE OF THE FOUR SCREWS.
122. Reinstall the master relay R1 cover.
FIGURE 148
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123. Place the 300A fuse #564520 in the fuse
holder underneath the cable lugs.
124. Connect to the free post of the fuse holder
the two (2) following cables that are routed
from the alternator and the fan drive circuit
breakers box:
•
•
Fan drive power cable #23498721
L.H. alternator power cable #23498785
A: nut #5001983 (2x)
B: washer #5001341 (2x)
Thread the nuts and tighten to a torque of 96
lbf-in (11Nm).
FIGURE 149: TAKE NOTE THAT THE 300A FUSE IS NOT
SEEN ON THE PICTURE ABOVE BUT IT SHOULD BE
INSTALLED AT THIS STEP
125. Secure the “fan drive power” cable and the
“L.H. alternator power” cable as shown on
the pictures at right using the following parts:
A: tie mount #509490 (2x)
B: rivet #504610 (2x)
C:nylon tie #509491 (3x)
FIGURE 150
FIGURE 151
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126. Install the MCM #23499009_EFD and the
I/O-B module #22722850 on the bulkhead.
•
•
Spacing between the I/O-B and the MCM=1
inch
Pilot holes diameter: 11/64”
Install with the following hardware:
Tapping screws #500658,
3x for the MCM
4x for the I/O-B module
FIGURE 152: MAIN POWER COMPARTMENT
127. In the main power compartment, connect the
“fan to RJB interface harness” to the “MCM
to I/O-B interface harness” #23445869 by
means of connector C-EFD1.
128. Connect the MCM and the I/O-B module
together using the “MCM to I/O-B interface
harness” #23445869.
129. Connect the OEL resistors connector RES1F
and RES2F (part #563593) to the “MCM to
I/O-B interface harness”. See the image at
right and the following pictures for reference.
FIGURE 153
FIGURE 154
FIGURE 155
A:nylon tie #504016 (3x)
A:nylon tie #504016 (2x)
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FIGURE 156
A:nylon tie #504016 (3x)
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)
FIGURE 157
B:nylon tie #509491 (2x)
C:swivel mount #504751 (1x)
130. In the main power compartment, connect the
“vehicle interface harness” #23490553 to
the “MCM to I/O-B interface harness” by
means of connector C-EFD2.
FIGURE 158
131. Connect circuit 24VI, 24VD & GND2 to post
1, 2 & 5 respectively of the junction block.
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FIGURE 159
132. Get the J1939 signal. To do so, locate
connector C193 among the existing
harnesses of the main power compartment.
133. Disconnect connector C193 and connect
with C193FS and C193FP of the “vehicle
interface harness” #23490553.
FIGURE 160
134. In the main power compartment, locate I/O-B
module A52 (alternately named AE52).
135. At A52 (or AE52), remove existing circuit 291
and 292 from connector J1:1 (pin 1) and J1:2
(pin 2).
136. For each circuit, cut the terminal and put a
heat shrinking sleeve at the end of the wire.
Those circuits won’t be used anymore.
137. Insert circuit 291 and 292 of the “vehicle
interface
harness”
#23490553
into
connector J1 pin 1 and J1 pin 2 respectively.
FIGURE 161
138. On the bulkhead, install the alternator
telltale bracket #050303. Fasten to the
bulkhead using two (2) rivets #504379.
139. Place the alternator telltale insert #391028
in the telltale light module #562113.
140. Connect the appropriate branch of the “fan to
RJB interface harness” to the telltale light
module.
FIGURE 162
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FIGURE 163
FIGURE 164
141. There are remaining nylon ties and tie
mounts in the kit. Use them to secure the
harnesses and cables that may seem loose.
The goal is to prevent rubbing of the cables
and harnesses.
FIGURE 165
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142. Place one (1) warning decal #069205 as
shown on the image.
FIGURE 166
143. Install a second warning decal #069205 as
shown on the radiator door.
FIGURE 167
144. Fasten the
assembly.
radiator
door
upper
arm
FIGURE 168
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145. Refill the cooling system. Connect coolant
extractor. Use coolant extractor to refill the
coolant from the engine.
FIGURE 169
146. Reinstall the bumper.
FIGURE 170
147. Reinstall the access panel located behind
tag axle L.H. side wheel.
FIGURE 171
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148. Reinstall the L.H. side rear fender.
FIGURE 172
149. In the battery compartment, connect the
battery ground cable to the chassis ground
stud.
FIGURE 173
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/
Federal)
Writer: EL