Page 1
21 3/8"
17 1/2"
485
4 1/8" DEPTH
Jeep W rangler
1987 - 2006
2000-2006 may require modification to brackets
INSTALLATION INSTRUCTIONS
Step 1: Remove Existing Fan & Shroud
If radiator overflow bottle is connected to the fan shroud, remove it and set it aside. This will
be installed with the new shroud.
Step 2: Mount Side Brackets to Shroud
Mount bracket number 33485 to left side of shroud, and bracket number 33487 to the right side.
Use the bolts and washers provided.
adjust and tighten them in Step 6.
Step 3: Overflow Bracket
If your radiator overflow bottle was mounted to
the O.E. shroud, you may use an optional
bracket kit to mount the overflow bottle to the
new shroud. Flex-a-lite p/n 30927 mounts
overflow bottles on '97-up 4-cylinder models,
and Flex-a-lite p/n 30928 for '97-up 6-cylinder
models.
Call 800-851-1510 to order.
Step 4: Locate mounting point for control
Locate a mounting point for control near passenger side of radiator. Control needs to be placed
within 18" of radiator inlet hose on passenger side. You may want to mount next to radiator on
fender well or the corner of the fan shroud. Mount control using screws provided.
Step 5: Wire fan
Route the motor wires through shroud. Drill a ¼" hole to
pass the wires through.
NOTE: Leave the brackets loosely mounted for now; you will
Step 6: Mount fan assembly
You will use the mounting bolts from your
O.E. fan shroud. Mount fan assembly to the
radiator and tighten the bolts that hold the
brackets to the radiator first.
model vehicles equipped with A/C, it may be
necessary to remove ½" - ¾" of material from
the right side bracket (33487) cut-out for A/C
line clearance.
Put the fan into place. Before tightening the
brackets, adjust the fan so that the rubber
seal is contacting the radiator core and
compress the seal about 50%. It may help to
have a friend hold the fan against the core
while tightening brackets.
NOTE: For late
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Step 7: Wire the fan motors (refer to Wiring Diagram, below)
Using the yellow butt connectors provided, attach a length of the large diameter (10 AWG)
the
blue
motor wire. Attach a length of the large diameter (10 AWG)
wire. Once the fan is in place, these will attach to the control module.
black
wire to the
Tip: Strip an additional
black
red
motor
wire to
1/8
of insulation from the motor wires and fold them over to increase the thickness of the wire
where it will slide into the butt connector.
motor wires can be connected now (
see wiring diagram, next page
If mounting the control module to the fan shroud, the
). If mounting the control somewhere else in the engine compartment, leave enough wire to reach the control module, but do not
connect yet.
"
Blue motor wire
Step 8: Wire the control module
Crimp the motor wires to the large
supplied wire.
Large red wire
Y ellow butt connector
Step 8a: Connect the motor wires to the control module
(Red wire to the "M+" terminal and black wire to the "M-" terminal).
Step 8b: Disconnect the negative battery lead for safety while finishing the wiring. Use the large
diameter red (10 GA) wire to run power directly from the battery positive (+) terminal to the "B" terminal on the control module. Connect the fuse holder in-line with this wire, as shown, but do not insert
the fuse yet. Use the yellow female, ring, and butt connectors provided.
CONTINUE TO NEXT PAGE TO COMPLETE THE INSTALLATION.
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Step 8c: Use the large diameter black (10 GA) wire to run from the negative (-) battery terminal
to the "G" terminal on the control module. Use the yellow female connector and ring connector
provided.
Step 8d: Use the small diameter red wire (14 GA) to connect the "+" terminal on the control module to a positive power source.
NOTE: Attaching this wire to an ignition-controlled source will shut off the fan when the engine is turned off. Attach this wire to
an uninterrupted (always hot) power source to allow the fan to continue running after
the engine is shut off.
Use the blue female connector and fuse taps (included) if neces-
sary.
Step 8e: (Optional) For air conditioning control (if desired) connect the "C" terminal on the
control module to the
positive
wire that triggers the A/C compressor using the small diameter
green (14 GA) wire. Using a voltmeter, determine which wire coming from the compressor is the
positive
trigger wire. Use the 3-way connector (included) to tap into this wire and send a signal
to the fan control module. The fan will cycle on and off with the A/C clutch when the A/C is
turned on.
Step 8f: (Optional) For manual switch operation, use Flex-a-lite p/n 31148. Connect the switch
as shown on the wiring diagram (previous page). Connect the "M" terminal on the control module
to the "1" terminal on the switch. Connect the "2" terminal on the switch to a positive 12v power
source. Connect terminal "3" on the switch to a good ground (for switch illumination).
NOTE: To
prevent thermostatic activation (if only manual switch operation is desired), omit the lead
to the "+" terminal of the control box. "B", "G", "M+" and "M-" must remain connected. If
not using a Flex-a-lite manual switch, do not connect a ground wire to the switch!
Note: You must use a diode protected switch, such a as Flex-a-lite part # 31148, failure to
do this will cause circuit board failure.
Step 8g: Use the zip ties provided to secure the wires and prevent them from interfering with
fan blades, belts, and pulleys in the engine compartment. Reconnect the battery and insert
the fuse provided.
Step 9: Insert the temperature probe into the radiator fins
Install temp. probe near inlet hose...
then replace the insulator cap.
Locate the inlet hose from the engine to the radiator. Remove the black insulator cap and insert
the temp. probe through the radiator fins near the inlet hose. Reinstall the black insulator cap.
Step 10: Adjust the temperature control knob on the control box
If you disconnected any hoses or drained coolant to install the fan, reconnect the hoses and refill the
radiator. Press the control knob (included in wiring kit) onto the control box shaft. Turn the knob
clockwise until it stops. Start the engine and allow it to idle. Using a hand held thermometer (positioned near the inlet hose) or the vehicle's temperature guage, monitor the temperature. When the
coolant temp. is slightly above normal (or desired temp.), turn the knob counter-clockwise just until
the fan turns on. From now on, the fan should activate at this temperature setting. Adjust as necessary to maintain desired temperature.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th St. Ct. E. Fife, W A 98424, Telephone No. 253-922-2700, warrants to the original purchasing user, that all Flex-a-lite products to be free of defects in material and
workmanship for a period of 365 days (1 year) from date of purchase. Flex-a-lite products failing within 365 days (1 year) from date of purchase may be returned to the factory through the point of
purchase, transportation charges prepaid. If, on inspection, cause of failure is determined to be defective material or workmanship and not by misuse, accidental or improper installation, Flex-a-lite will
replace the fan free of charge, transportation prepaid. Flex-a-lite will not be liable for incidental, progressive or consequential damages. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may have other right s, which vary from state to state.
The Flex-a-lite warranty is in compliance with the Magnuson-Moss Warranty Act of 1975.
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