Flex-a-Lite Black Magic 175 Installation Instructions Manual
Black MagicBlack Magic
Black Magic
Black MagicBlack Magic
175
for the FORD MUSTANG 5.0 (1986-1993)
Prior to fan installation
1. Remove fan, fan clutch, shroud, and radiator overflow tank. Replace the bolts to the water pump pulley. Rotate the water
pump pulley to verify clearance of bolts to waterpump housing.
Note: Save the screws and clip-on nuts from the top of the radiator channel and from the shroud.
Installation Instructions
Overflow tank and bracket installation
2. Remove the clip-on nut from the top of the passenger side
radiator channel. Place the clip-on nut on the bottom of
the drivers side radiator channel. Use the original screws
to mount the overflow tank bracket to the radiator. (see
Diagram A)
3. Remove the 2 clip-on nuts from the original fan shroud,
attach them to the holes on the overflow tank bracket
provided in the kit. Use the original screws holding the
overflow tank to the original shroud to attach the overflow
tank to the new bracket. (see Diagram A)
Diagram A
175 Electric fan mounting instructions
4. Loosely fasten angle brackets to the ends of the square
tubing on the temperature sensor side of the shroud. (see
Diagram A) Hook the fan unit to the top of the radiator
channel. (see Diagram B)
5. Position the fan unit between the overflow tank and the
passenger side radiator tank.
6. Push the bottom of the fan unit towards the lower radiator
channel, while holding the fan unit to the radiator hook one
end of the angle bracket to the radiator and pass the lock
washer and bolt through the angle bracket and spacer ,
fastening it to the square tubing. Push the fan unit towards the
radiator and tighten the bolts until snug. (see Diagram B)
7. Tighten upper bracket bolts, check to see that the fan unit is secure.
8. See wiring instructions on back page.
Overflow
Tank
Bracket
Square Tube
Ø
Ø
Clip-on Nut
(From the top of the
passenger side of the
radiator.)
Upper
Channel
Angle
Bracket
Bolt
Diagram B
Lock
Top Angle
Bolt
Spacer
Lock
Washer
POSITION CAPILLARY TUBE
This temperature sensor sends engine coolant data to the
temperature control for more efficient cooling of your vehicle.
The temperature sensor needs to be carefully placed through the radiator core to
detect engine coolant temperature.
1. Locate your radiator inlet hose; one of two large hoses that attach to the radiator . The inlet hose from the engine should
be mounted higher than the other hose. Release the clip holding the thin capillary tube. Mount the fan so you can reach
the inlet hose with the temperature probe. Be careful not to kink or pinch the capillary tube.
2. With a small Phillips style screwdriver , gently separate the cooling fins on the radiator near the inlet hose. You will gently
push the screwdriver through the radiator to create a hole for the temperature sensor to rest. Move only the thin fins, do
not
disturb the thicker tubes which carry the coolant through the radiator.
3. Remove the protective cap and gently push the temperature sensor through the hole. The temperature sensor should fit
snug in the core.
4. After placing the sensor, replace the plastic cap. It is important to replace the cap to prevent the tube from pulling out of
the radiator. The cap also insulates the sensor from cool air passing though the grill.
5. Gently coil the extra capillary tube and place it out the way of moving objects. Be careful no to kink the tube. If you must
put a bend in the tube, bend the tube around a pen or small bolt to prevent pinching the tube.
Lower
Channel
rev. 06-21-05 part no. 99970 Page 1
Completed Installation
MANDATORY CONNECTIONS
1. Disconnect the battery . Negative terminal
2. Connect the “+” terminal of the control box to a 12V 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.
Note: Attach this wire to a non-ignition source to keep the fan running after the vehicle is shut off.
3. Connect the “B” terminal to a high amp 12V positive power source (i.e. battery , alternator) using the thick red
wire and in line fuse holder provided in the kit. (Do not install fuse at this time)
4. Connect the “G” terminal to ground (i.e. chassis, negative side of battery) using the thick black wire provided
in the kit.
5. If you have air conditioning: with 3-way connector provided, pass the A/C clutch positive(+) wire (connected 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
6. Insert probe in radiator core near upper hose. Install rubber cap over end of probe.
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
above normal, turn the control knob counterclockwise until the fan turns on. From here on the
fan should activate at this temperature setting.
Adjust as necessary according to your vehicle
needs.
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 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.
Control Box T erminals & Connections
Mandatory Connections
+ 12 volt positive source
G Ground
B 12 volt positive source
C Air conditioning relay
Optional Connection
M Manual switch
Ground
Control Box
G
+
12 Volt Positive Source
optional
12 Volt Source
Ground
(Illuminate switch)
3-way
connector
A/C positive (+)
wire from clutch
Fuse Holder
12 V olt Positive Source
C
M
B
*WARNING: IF NOT USING FLEX-A-LITE'S
ILLUMINATED
DISCONNECT
SWITCH (PN #31148) YOU MUST
THE SWITCH GROUND.
12 3
Note (optional): T o stop the fan from activating
thermostatically, omit the lead to the “+” terminal of
the control box. “B”, “G”, & “M” must remain
connected.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th 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 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 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. 06-21-05 part no. 99970 Page 2
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