Flex-a-Lite 345 User manual

345
Nissan 240SX
Fits 1989-1998
INSTALLATION INSTRUCTIONS
Remove the lower engine splash shield. This will allow you to easily ac-
cess the radiator drain valve and the lower fan shroud.
Drain the coolant from the radiator. Use a clean drain pan and set it in a
clean spot so that the coolant can be reused (see Detail 1)
Remove the air intake tube. It’s easiest to disconnect it at the connec-
tion to the air flow sensor block (see Detail 2).
Remove the radiator inlet hose and tie it back out of the way.
Remove the 2 bolts holding the lower portion of the fan shroud in place.
Remove the 2 clips holding the fan shroud ring in place.
Remove the bolt securing the air intake resonator/silencer located at the
bottom of the fan shroud.
Remove the hose and wire clips from the top of the fan shrou
Unplug the A/C fan wire harness (see Detail 3). This harness will be
used later when wiring the fan control unit. Remove and save the 2
bolts that attach the top of the A/C fan and the top of the shroud. These
will be used later to attach the new electric fan assembly. The factory
A/C fan will not be used and can be removed.
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NOTE: FOLLOW ALL INSTRUCTIONS CAREFULLY TO AVOID PERSONAL INJURY AND
DAMAGE TO THE FAN, CONTROL MODULE, AND YOUR VEHICLE!
Detail 1
Detail 2 Detail 3 Detail 4
The resonator/silencer box
can’t be used with this kit.
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Pull back the wires and hoses that run over the top of the shroud, then remove the top half of the shroud.
Remove the air resonator box. NOTE: The air resonator/silencer can’t be used with this electric fan.
Plug the hole in the air intake tube before reinstalling it to ensure no dirt or moisture enters the intake
tract (see Detail 4). Use the rubber cap included and secure it with a zip tie or hose clamp.
Remove the clutch fan. Replace the flange nuts that held the clutch fan on as these also hold the pulley onto
the water pump.
Remove the lower half of the shroud and ring.
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Peel the protective vinyl coating off of the top and bottom brackets and attach them to the fan shroud with the
screws provided as shown.
Hold the fan assembly so that it is approximately centered over the radiator core. The long 6mm bolts will be
used in the slots of the bottom bracket with the threaded end pointing down. The threaded end of the bolts,
with rubber caps placed over the ends, will slide into the holes on the bottom of the radiator. Determine which
set of slots you will use by looking at which slots line up over the holes. This fan kit is designed to accomodate
both the OEM radiator as well as popular aftermarket radiators. These bolts may go in the inside or outside
slots on the bottom brackets depending on which radiator you have. Leave these loose for now - you will need
to tighten them after you install the fan assembly.
Before installing the fan assembly on the radiator, install the A/C drier relocation bracket, #34584, as follows.
Remove the bolts that hold the drier bracket to the frame. Loosen the strap bolt so that the bracket is free to
move (see Detail 5 on next page).
The A/C drier unit will need to be
moved toward the rear of the car
about ¾” to move it away from the
fan blade. This can be accom-
plished by gently bending the hard
lines going to the drier unit (see
Detail 5).
Find the supplied relocation brack-
et. Swivel the strap bracket on the
drier canister out of the way and
slide the relocation bracket under-
neath. Use the two button head
6mm allen screws and washers to
attach this bracket to the frame.
Use the same bolt holes that the
OEM bracket used (see Detail 6).
Spin the strap bracket holes over
the two studs on the relocation
bracket. Use the ¼-20 lock nuts
and washers to secure it (see
Detail 7). When you’re finished,
there should be at least ¾” of clearance between the fan blade and the drier unit when you install
the fan assembly.
Find the fan controller. This controller can be mounted anywhere that is convenient in the engine
compartment that is no more than 3’ from the inlet tube of the radiator. For example, it can be
mounted in the center of the fan shroud. Use the two self-tapping screws in the kit to mount the
control module. NOTE: If washing your engine compartment, be sure to cover the wiring
connections and controller to avoid getting water in the controller.
With the A/C drier relocated, now the fan assembly can be installed. Lower the fan assembly into
place. Make sure the rubber caps fit into the tabs at the bottom of the radiator as shown (see
Detail 8). On automatic transmission models, it may be necessary to swivel the trans. oil line
clamps down so they clear the bottom bracket. First, tighten the top screws in place so that they
are supporting the weight of the fan. Then tighten the bottom bolts in place - use the lock nuts to
“sandwich” the bolt to the bracket (refer to detail above).
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WARNING! THE VEHICLE MAY NEED TO BE RAISED ON A JACK AND SUPPORTED ON
JACK STANDS TO PERFORM THIS INSTALLATION. USE A HEAVY DUTY HYDRAULIC
JACK AND ALWAYS SUPPORT THE VEHICLE ON AT LEAST THREE POINTS BEFORE
GETTING UNDERNEATH. USE ONLY APPROVED LIFTING POINTS THAT ARE CALLED
OUT IN YOUR OWNER’S MANUAL!
Installation of the Electric Fan Assembly
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With the A/C drier relocated, now the fan assembly can be installed.
Lower the fan assembly into place. Make sure the rubber caps fit into
the tabs at the bottom of the radiator as shown (see Detail 8). On au-
tomatic transmission models, it may be necessary to swivel the trans.
oil line clamps down so they clear the bottom bracket. First, tighten the
top screws in place so that they are supporting the weight of the fan.
Then tighten the bottom bolts in place - use the lock nuts to “sandwich”
the bolt to the bracket (refer to detail on previous page).
Before you begin wiring, disconnect the battery negative terminal. First, connect the main power and ground
leads to the fan control unit. Find the fuse holder in the wiring kit. Use a large ring connector to connect the
fuse holder to the positive (+) battery terminal. For your safety, DO NOT INSTALL THE FUSE UNTIL ALL
THE WIRING IS COMPLETE. Use a blue butt connector to connect the thick red wire to the other end of the
fuse holder. Use a blue female connector to attach this wire to the “B” terminal on the fan control unit (see wir-
ing diagram, next page). Use the thick black wire to run a ground wire directly from the battery negative (-)
terminal to the “G” terminal on the fan control unit.
Using the thick red and black wire and the connectors provided, connect the motor wires to the control unit
as described next.
Place both red motor wires side by side and smoothly twist together. Completely insert pair of wires into one
end of a yellow insulated butt connector. Crimp connector to secure. Repeat with black motor wires to anoth-
er yellow insulated butt connector. Insert thick black wire into the open end of butt connector containing the
two red motor wires and crimp connector securely. Insert thick red wire into the open end of butt connector
containing the two black motor wires and crimp connector securely. NOTE: THE BLACK MOTOR WIRES
ARE POSITIVE (+) AND THE RED MOTOR WIRES ARE NEGATIVE (-). FAILURE TO CONNECT THESE
WIRES PROPERLY WILL RESULT IN DAMAGE TO THE FAN MOTORS AND YOUR ENGINE! Connect
the joined red motor wires to the “M-” terminal on the control unit. Connect the joined black motor wires to the
“M+” terminal on the control unit (see wiring diagram, next page).
Find a fused circuit in the engine compartment fuse box that is “hot” (reads 12 volts) when the ignition is turned
on. Use the supplied fuse tap and connectors to run a length of the thin red wire from the fuse to the “+” ter-
minal on the control unit. This will provide ignition-controlled activation - the fan control unit will only be active
when the ignition is turned on.
Find the A/C fan connector you unplugged earlier. Use the wire tap connector to connect the supplied green
wire to the orange/white wire in this harness. Connect the other end of the green wire to the “C” terminal on
the fan control unit.
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CONTINUED FROM PREVIOUS PAGE
Detail 5
Detail 6 Detail 7
Detail 8
Wiring the Electric Fan
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Find the temperature probe attached to the control unit. Insert the temp. probe through the hole in the top
bracket that is directly below the radiator inlet hose. Gently push the probe through the radiator fins. Push the
rubber cap over the end of the temp. probe to insulate it. You may have to loosen the top radiator bracket to
install the rubber cap. Zip-tie loose wires and vacuum lines to to the top bracket to keep them clear of the fan
blades.
Connect the radiator hose and refill the radiator with coolant. Be sure to remove the air bleed bolt before refill-
ing (located where the top radiator hose connects to the engine). Reinstall the air bleed bolt, the lower engine
cover, and the air intake tube. Insert the fuse for the electric fan into the fuse holder and reconnect the battery
terminals.
Start the engine and allow it to warm up completely. It is best to use a digital thermocouple or infrared heat
gun to read the temperature as the vehicle’s temperature gauge is not accurate enough. Feel the top radiator
hose - there should be hot coolant flowing through it. The engine is completely warmed up when it reaches
about 185° F.
If the fans have not already cycled on, turn the temperature control knob counterclockwise just until the fans
come on. The fans should cycle on and off to keep your engine at this temperature.
Turn on the air conditioning. The fans should cycle on and off with the A/C compressor. If not, check to see
that the A/C signal wire is connected correctly.
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CONTINUED FROM PREVIOUS PAGE
WIRING DIAGRAM
Initial Start-up and Adjustment Procedure
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.
Page 4 of 4 #98345 Rev. 05-17-10