Flex-a-Lite Black Magic Xtreme 485 Installation Instructions Manual
INSTALLATION INSTRUCTIONS
rev. 10-07-08 99485 Page 1 of 3
485
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.
171/2"
21
3
/8"
41/8" DEPTH
Jeep Wrangler
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. NOTE: Leave the brackets loosely mounted for now; you will
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.
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. NOTE: For
late model vehicles equipped with A/C, it
may be necessary to remove the knock-
out from the right hand bracket (33487)
for A/C line clearance. Smooth the edge
with a file after removing the knock-out.
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.
1987 - 2006
CONTINUE TO NEXT PAG E TO COMPLETE THE INSTALLATION
Yellow butt connector
Crimp the motor wires to the large
supplied wire.
Large red wire
Colored motor
wire
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) red wire to
the colored motor wire. Attach a length of the large diameter (10 AWG) black wire to the black
motor wire. Once the fan is in place, these will attach to the control module. Tip: Strip an additional
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. If mounting the control module to the fan shroud,
the motor wires can be connected now (see wiring diagram, next page). If mounting the control
somewhere else in the engine compartment, leave enough wire to reach the control module, but do
not connect yet.
Step 8: Wire the control module
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.
rev. 10-07-08 99485 Page 2 of 3
colored
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