Flex-a-Lite 475 User manual

Part# 475 JEEP WRANGLER FAN II (Nylon Shroud)
INSTALLATIONINSTRUCTIONS
1987-20034&6cylinderWranglers
REMOVE OLD FAN & SHROUD
1. Remove rubber splash guard (if so equipped) at
bottom of fan shroud.
2. Remove 4 screws holding shroud to radiator, and
remaining screw holding power steering
reservoir. Tuck reservoir out of way temporarily.
Save all bolts. (Note: Shroud will not come out until
fan and fan clutch are unbolted.)
3. Remove four nuts holding fan and fan clutch
assembly to water pump hub. Remove fan clutch
assembly in one piece, along with old shroud. Do
NOT remove water pump pulley. Replace nuts
onto water pump hub and tighten.
Assemblenewfanunit
1. Press plastic control knob onto the thermostat
shaft on Flex-a-lite fan shroud.
2. Screw left and right end brackets to fan as shown
with 3/8" bolts and flat washers supplied. Do not
tighten yet. See FIG. 1.
INSTALLNEWFAN UNIT
1. Lower Flex-a-lite electric fan unit into place. Fan will squeeze between radiator hose and power steering
reservoir. Be careful not to damage radiator core with mounting brackets during install.
2. Hold fan in place and, using original shroud bolts, fasten through new brackets and into original mounting
points on radiator flange. The power steering reservoir locates in its original
position.
3. Making sure that rubber seal contacts radiator all around, tighten 3/8" bolts holding
fan to brackets.
.
NOTE: 1997 AND UP Wranglers were produced with one or more fluid tanks mounted directly to the original
fan shroud. The shroud will be discarded in this installation. 4-cylinder models will require a Reservoir Bracket
Kit, Part# 30927, 6-cylinder models will require a Tank Bracket Kit, Part# 30928, to complete your installation.
FIG. 1
rev. 06-16-06 99939 Page 1 of 2
Insert the temperature probe into the radiator fins
Install temp. probe near inlet hose... then replace the insulator cap.
Locatetheinlet hose from the enginetothe radiator. Remove theblackinsulator cap and insert the
temp.probethroughthe radiator fins near the inlet hose. Reinstalltheblackinsulatorcap.

.
Before proceeding, disconnect battery ground cable! Otherwise,fancancomeonunexpectedly.
2.Runa length of heavy (10ga.)red wire (supplied) from batterytothe“B”terminal using thethickred
wireand in line fuseholder provided in the kit.
3.Run a length ofblack wire from Ground (oneof the screws holdingCircuit Breaker is good)toterminal
"G"on the controller,locatedonthefan shroud, using the blue electrical connectors
suppliedforterminalconnections.
4.Run a length ofthin (14 ga.) red wire to a12V pos(+) source.
(Ifyouwantthefantocontinuetorunaftervehicleis turned off and until radiator cools, run the wire
directlytothebattery.Otherwise,wireit to an ignition-switched source. Connect theotherendother
end to terminal "+" onthecontroller. Use the blue electrical connectors suppliedforterminalconnec-
tions.
Automatic A/C Relay Connection
Ifyou have airconditioning, tap into the air conditioner’spositivelead using the brown plastic wire
connector,andrunthe green wire from there to terminal "C" onthecontroller. To makethe
connection,snaptheA/Clead into the pass-thruchannelof the connector,and fit theotherendofthe
greenwire into the deadend channel in the connector. Use a pairofpliers to crimp themetalplateinto
place.Snap the plastic coverclosed.
Finish Up
Usenylon tiesto keep wires orderly andprevent them from contacting hotor moving parts.
Especially, don't allow extra slackinthewireat the fan controller; wires could contact
alternatorpulleyor drive belt. Reconnect battery.
Adjusting the Fan Activation Temperature
Start engine and run until warmedup.Adjustfan activating temperature by turning plastic controlknob.
Counterclockwisewillactivatefan at lower temps;clockwisefor higher temps.You may reset
theactivatingtemperature to suit different drivingconditionsas you see fit, withnoadverse effect
onthefanorcontrol unit.
WIRING INSTRUCTIONS
rev. 06-16-06 99939 Page 2 of 2
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 limitation 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.
B
CMG+
12 Volt Positive Source
12 Volt Positive Source
Fuse Holder
Control Box Terminals & Connections
Mandatory Connections
+ 12 volt positive source
G Ground
B 12 volt positive source
C Air conditioning relay
OptionalConnection
M Manual switch
12VoltSource
12 3
Ground
(Illuminateswitch)
A/C positive (+) wire from clutch
3-way
connector
optional
ControlBox Ground
*WARNING: If not using Flex-a-lite's
illuminated switch (PN #31148) you must
disconnect the switch ground.