Flex-a-Lite 678 Installation Instruction
Toyota Tacoma Electric Fan Kit;
'05–'09
#678 with controls
#688 without controls
———INSTALLATION INSTRUCTIONS———
REMOVAL OF EXISTING FAN AND SHROUD ASSEMBLY:
1. Make sure the engine is cool.
2. Disconnect negative (-) battery cable from battery.
3. Remove plastic protective cover from top of engine / intake manifold. Two acorn nuts
located in front are to be removed first. Lift front of cover and notice the cover is hinging
at back. Pull to disconnect at pivot point.
4. Remove plastic cover bridging shroud to top cross member. (9 ea) Push-type plastic
rivets need to be removed (see Detail 1). Prying each center post up with a flat-end
screwdriver will release fastener.
5. Remove overflow hose from radiator filler neck.
6. Remove top bolts (2ea.) holding fan shroud to radiator side tanks. Save bolts for installation of new shroud (see Detail 2).
7. Remove (4ea.) nuts securing fan-clutch assembly (see Detail 3); then pull fan-clutch
assembly and shroud out simultaneously.
8. Important: Re-secure pulley with new washers of kit bag #13615 and original pulley
nuts.
Plastic Cover
Save bolts for new installation
Detail 1
Detail 2
Plastic Rivets
rev. 04-20-09 part no. 99678 Page 1 of 4
Detail 3
Detail 4a
INSTALLATION OF NEW ELECTRIC FAN SHROUD:
1. Mount bracket #67802 to driver’s side of shroud. Use the hex bolts and washers provided. Note:
Leave the bracket loosely mounted for now; you will adjust and tighten them later (see Detail 4 &
4a).
2. Lower shroud, with one bracket only, into position inserting bottom of bracket into slot at bottom
of side tank (driver’s side). Loosely secure top of bracket using factory bolt, saved from step #6
of page 1
3. Attach overflow tank to bracket #67801 using supplied hardware included with overflow tank (see
Detail 4 & 4b).
4. Attach bracket #67801 to passenger’s side radiator tank and fan shroud;
a. Insert bottom of bracket into slot at bottom of side tank.
b. Loosely secure top of bracket using factory bolt, saved from step #6.
c. Mount bracket loosely to shroud using the hex bolts and washers provided (see Detail 4
& 4b).
5. After both brackets and shroud are attached; make final adjustments utilizing slots provided.
When tightening the brackets, adjust the fan so that the rubber seal is contacting the radiator
core and compress the seal about ~50%. Note: It may help to have a friend hold the fan against
the core while tightening brackets.
6. Mount rubber hose supplied to radiator filler neck and to the shorter of the two tubes protruding
from bottom of overflow tank (see Detail 4).
7. If you disconnected any hoses or drained coolant to install
the fan, reconnect the hoses and refill the radiator. At this
time fill overflow tank ~25% of capacity.
Detail 4b
Detail 5
Finished Installation
rev. 04-20-09 part no. 99678 Page 2 of 4
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