Wrangler Radiator & Fan Kit #60187
or Wrangler Radiator Kit #60087
Fits 1987-2006 Jeep Wranglers
Note: Manual transmission preferred; automatic transmission requires a remote cooler.
INSTALLATION INSTRUCTIONS
Remove Existing Fan, Shroud & Radiator
BE SURE THE ENGINE IS COOL BEFORE PROCEEDING!!
1.
Disconnect the negative (-) battery cable before proceeding with the installation.
2.
Drain the coolant from radiator utilizing the drain plug on bottom of the radiator. It may be necessary to
3.
remove the radiator cap to release vacuum inside the radiator for better draining.
Remove the upper and lower hoses from the radiator. It is not necessary to remove them completely from
4.
the vehicle for installation.
Remove coolant overflow bottle, from fan shroud, on driver’s side.
5.
Remove the 4ea. bolts (2 each per side) holding the fan shroud to radiator.
6.
Note: To remove the shroud you will need to remove the clutch fan at the same time.
Note: Consult your vehicle service manual for details on clutch fan removal.
Once the clutch fan has been separated from the pulley, lift the shroud and fan assembly out of the vehicle
simultaneously.
If vehicle is equipped with an automatic transmission, remove both inlet and outlet lines from bottom of
7.
radiator.
Note: A remote mount oil cooler will need to be used to cool transmission fluid.
Remove mounting bolts securing radiator to vehicle on both driver and passenger side.
8.
Note: Save removed bolts, you will be reusing these bolts later.
Remove the original radiator by lifting it straight up.
9.
Note: Use caution while removing the radiator, it may still contain coolant which can spill out.
Installation of Radiator and Fan Combo #60187
or Radiator only #60087
Utilizing the included T-bolts, washers, and lock nuts, mount bracket
1.
#61152 to the side tank on driver’s side of radiator. Attach bracket to
track of radiator side tank closest to what would be the front of the
vehicle when installed. Attach bracket so that it is 1.25” from top of
side tank. see Detail 1
Attach bracket #61151 on to the vehicle, on the passenger side, at
2.
original radiator mounting points utilizing the original mounting bolts
you removed in step #8 of the removal process.
Note: Top of bracket should be flush with the top surface on radiator
support.
Loosely attach T-bolts, washers, and lock nuts to bracket, leaving
3.
enough “gap” between T-bolts and bracket to allow the track of radiator
side tank to slide easily over T-bolts.
see Detail 2
see Detail 3
Driver’s Side
Side Tank
Bracket
#61152
Detail 1
Installation instructions continued on next page
Rev. 03-01-11 98187 Page 1 of 4
Bracket flush
to surface
Leave “gap”
for tank track
Detail 2
Once the brackets are attached, you will need to lower the radiator into the engine compartment.
4.
Detail 3
Lower / slide radiator along side of previously mounted passenger side bracket.
Note: Lower the radiator while sliding T-bolts up T-slots on side tank.
Loosely tighten locknuts but do not secure locknuts yet.
Return to driver’s side of radiator and insert 1ea. original mounting bolt through top of bracket into top
5.
mounting point on radiator support. Loosely attach but do not tighten securely yet.
Return to passenger’s side of radiator and adjust side tank offset height to be 1.125” from top of side tank
6.
to top of bracket. Securely tighten top T-bolt.
Return to driver’s side of radiator and insert remaining original mounting bolts through bracket into radiator
7.
support. Securely tighten all driver’s side mounting bolts.
see Detail 4
see Detail 5
Passenger’s Side Bracket
Driver’s Side Bracket
Overflow Bottle Bracket
Overflow Bottle Mounted
Detail 4 Detail 7Detail 5 Detail 6
Tighten any remaining mounting bolts or T-bolts making sure all mounting points are secure.
8.
Note: Flex-a-Fit® radiator tanks are made for maximum adjustability. Depending on space limitations within
your engine compartment, you will need to adjust bracket positioning by sliding the T-bolts up / down or
even select an alternate tank slot. Be sure all bracket mounting hardware has been sufficiently tightened
after proper positioning has been achieved.
Connect the upper and lower radiator hoses to the radiator. Make sure they are properly clamped to the
9.
inlet and outlet tubes.
Note: BE SURE that all moving parts of the engine and electric fan are clear of each other before
proceeding!!
Note: Due to outlet tube alignment difference on new radiator, you may need to trim bottom return hose
length ~2.5” to acquire proper fitment when securing.
If you are replacing the radiator only,(Kit #60087) reattach the clutch fan to water pump.
10.
Attach overflow bottle bracket #61153 to driver’s side utilizing T-bolts, washers, and lock nuts. Align top of
11.
overflow bottle bracket to top of driver’s side radiator mounting bracket.
see Detail 6
Rev. 03-01-11 98187 Page 2 of 4
Slide coolant overflow bottle onto new bracket in the same manor that the bottle was removed from fan
12.
shroud. see Detail 7
Install the pipe-nipple for the overflow tube to the filler neck of the radiator. Route and trim the overflow
13.
hose as needed. Note: Be sure that there is enough clearance between the hose and any moving engine
components.
Fill radiator/ cooling system with vehicle manufacturer recommended coolant. Remember to fill reservoir to
14.
cold fill level if equiped.
Note: For automatic transmission equipped cars.
We chose not to install a transmission cooler within our radiator’s side tank. This maximizes the cooling
efficiency of both your engine and transmission. If you do have an automatic transmission, you will need
to install an aftermarket transmission cooler. Flex-a-lite makes a full line of transmission coolers along with
customized mounting options.
For more mounting options, call Customer Assistance at: 1-877-767-0554 or FAX: (253) 922-0226.
or visit “www.flex-a-lite.com”
Wiring the Fan: Radiator and Fan Combo #60187 only
Wiring Diagram
1.
Connect the “B” terminal on the control to the 12 volt positive (+) battery terminal using the thick red wire
and fuse holder provided in the kit.
2.
(Do not install fuse at this time) Connect the “G” terminal on the control to battery negative (ground - )
terminal using the thick black wire provided in the kit.
Note: Failure to connect ground wire directly to negative battery terminal may lead to premature failure of
control module.
3.
Connect the “+” terminal of the control box to a keyed 12 volt positive (+) power source (i.e. fuse box), using
the thin red wire and fuse taps (if necessary) provided in the kit.
Note: Attach this wire to an ignition controlled source to stop the fan when the vehicle is shut off. Attach
this wire to a constant source to keep the fan running after the vehicle is shut off.
4.
If you have air conditioning: With the 3-way connector provided, pass the A/C clutch positive(+) wire (con
nected to the A/C compressor) through the connector. Place the green wire provided into the closed end of
the connector. Crimp metal plate. Snap plastic cover into place. Attach green wire to the “C” terminal of the
control box. Air Conditioning Relay activates fan when A/C is turned on.
5.
Insert temp. probe through radiator core near the upper (inlet) hose. Install rubber cap over end of probe.
Note: To maintain position of temp probe the cap must be installed onto probe end.
WIRING DIAGRAM - MODEL #60187
*WARNING: If not using
Flex-a-lite’s optional
illuminated switch (PN
#31148), you must
disconnect the switch
ground.
-
Note: To stop the fan from activating thermostatically, omit the lead to the “+” terminal of the control box.
“B”, “G”, & “M” must remain connected.
ADJUSTING THE TEMPERATURE CONTROL
1. Attach the temperature control knob to the control box.
2. Turn the knob clockwise completely.
3. Idle the vehicle, observe the temperature of the vehicle. (Use the vehicles gauge)
4. When the temperature of the vehicle reaches slightly above normal, turn the control knob counter-clockwise
until the fan turns on. From here on, the fan should activate at this temperature setting. Adjust as necessary ac
cording to your vehicle needs.
Rev. 03-01-11 98187 Page 3 of 4
-
OPTIONAL CONNECTIONS
Manual Switch (not included) - Allows manual operation of the fan.
(This step is based on Flex-a-lite’s manual switch part #31148, other switches will cause this unit to fail).
1. Connect the “M” terminal to terminal 1 on the switch.
2. Attach terminal 2 of the switch to a 12V positive (+) source.
3. Attach terminal 3 of the switch to ground, in order to illuminate the switch.
Limited Radiator Warranty
Flex-a-lite Consolidated warrants its aluminum radiators to be free from defects in materials and workmanship
for a period of one year from the date of purchase at retail by the original purchaser. This warranty is extended
only to the first purchaser of any such radiator at retail. If the Flex-a-lite radiator is used in any racing application,
repaired or altered, this warranty is considered null and void, it also does not cover any radiator repaired or
altered in any way. If products such as transmission cooler or electric fan are attached with cable ties or similar
fasteners that run through the radiator core, the warranty is voided.
This warranty does not cover labor, materials not manufactured by Flex-a-lite, or shipping charges. The retail
purchaser is responsible for the appropriate use and application of the product. This warranty does not cover the
effects of physical or chemical properties of water, steam, or other liquids used in the radiator. Radiators used
without an adequate proportion of premium quality antifreeze/coolant are not covered by this warranty. Flex-a-lite
aluminum radiators require a correct proportion of quality coolant, which contains aluminum corrosion inhibitors
in the formula.
Claims for internal damage of the engine, components, or user’s vehicles are not covered by this warranty. It is
the responsibility of the Flex-a-lite product user to monitor engine operation and have proper detection devices
installed to warn the user of overheating. Specific exemptions to the warranty include tube damage, ballooning
or bursting from excessive engine operating temperature, internal corrosion due to inadequate proportions of
antifreeze/coolant, or damage to radiator resulting from a collision damage.
Flex-a-lite shall not be responsible for damages to its product or injury to persons using the product when
improperly opening radiator pressure caps, burst hoses, etc. Flex-a-lite shall not be responsible for injury or harm
to persons or property caused by persons or vehicles using our products.
The purchaser’s remedy for breach of this warranty, exclusive of all other remedies provided by law, is expressly
limited to repair or replacement of any part or parts. All products returned for warranty consideration must be
returned through the point of purchase with all transportation expenses prepaid. Upon receipt of the product,
Flex-a-lite will examine the product to determine the condition and validity of the claim.
Radiators or products received, which were damaged in shipping, should immediately be reported to the shipping
carrier as damaged, and claims of damage filed accordingly. Contact the transport carrier (UPS, truck line, etc.)
for procedures in filing damage claim with the carrier or their agent. Do not return product damaged in shipping
to Flex-a-lite.
Some states may not allow a limitation on the duration of any implied warranty. The above warranty may not
apply to you. This warranty grants you specific legal rights, and you may have other rights, which vary from state
to state.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7009-45th St. Ct. E. Fife, WA 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
product 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 limitaion 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 rights, which vary from state to state. The Flex-a-lite warranty is in compliance with the Magnuson-Moss
Warranty Act of 1975.
Rev. 03-03-11 98187 Page 4 of 4
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