CYCLONE
POWER FAN INSTALLATION FORD F-Series POWER STROKE 1999 and Newer
CAUTION: Allow sufficient time for engine and engine
coolant to cool before starting installation.
Remove coolant reservoir cap to relieve coolant pressure.
Remove the lug nut wrench.
Remove the three hold down bolts on the water reserve tank and
place the tank out of the way along the passenger side of the
engine. It is necessary to disconnect the small overflow hose.
Plug the nipple or cover it with tape.
Place clean, large-capacity drain pan under drain cock of
radiator. Open the drain cock and allow all the fluid to drain
into the pan. Cover the pan to keep any contaminants from dropping
into the fluid. Remove the upper radiator hose.
WARNING: Do not drink antifreeze or solution. If swallowed,
give two glasses of water and induce vomiting. Call a physician.
Ethylene glycol base. Avoid inhaling mist or hot vapors. If
inhaled, remove to fresh air. Ethylene glycol base causes birth
defects in laboratory animals. Do not store in open or unlabeled
containers. Wash thoroughly after handling. Solution may taste
pleasant to animals, but is poisonous to them. KEEP OUT OF REACH
OF CHILDREN.
Remove the top bolts of the fan shroud and move the shroud
rearward a few inches.
Note: A large piece of cardboard between the fan and radiator
before fan removal will protect the radiator from damage. (This
step will be repeated in reinstallation of the assembly.)
Using
the fan tools available from U.S. Gear or the equivalent, remove
the stock fan assembly. Place the water pump tool on the hub bolts
and using the long fan tool on the large hex nut, loosen with
counter-clockwise rotation. (FIG. 1) (Right hand thread) A 1/2"
ratchet or breaker bar can be used on the water pump tool for
additional leverage. It is very tight, so you may need to help it
along with a brass or lead hammer.
Carefully remove the fan assembly.
Place the stock fan assembly on the work bench for installation of
the Cyclone Power Fan. On the bench, remove the stock fan blade
assembly from the factory viscous (FIG. 2) unit and install along
with the fan disk on the new electric clutch Power Fan, using the
split washers and bolts provided. Be sure the fan blades are
facing the same direction as they were on the original clutch.
Before installing the Power Fan assembly, an additional coolant
sending unit, anti-rotation stud, and wiring harness must be
installed and it is much easier without the fan in place. Locate
and remove the plug on the side of the water "gooseneck" area
(FIG. 3). Install engine coolant thermistor adaptor and tighten.
Do not use any silicone or sealant. Install thermistor and
tighten. Do not use any silicone or sealant. NOTE: Use of silicone
or sealant negatively effects the ground necessary for the
thermistor, and will cause a faulty signal to the Cyclone Power
Module. (If any anti-freeze is spilled, clean up the spill
immediately.)
Remove
the 8mm x 120mm water pump bolt from just below the "gooseneck"
area where the coolant sender assembly was installed. Place the
MN-7000 nut onto the anti-rotation stud and screw the nut all the
way to the end of the threads. Install the anti-rotation stud in
the place of the water pump bolt. You will back out the stud and
tighten the nut later. (FIG. 3)
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ENGINE COMPARTMENT WIRING
NOTE: A good ground is extremely important! Do not modify the
harness in any way.
Plan and lay out the wiring harness so that the 2-position clutch
connector will be in the fan clutch area, and the 6-position Power
Module connector will be able to run through the firewall on the
driver side.
As you complete the wiring in the engine compartment, use the wire
ties supplied to keep the wires away from belts, pulleys, and
other moving or hot parts.
We recommend that the harness be placed in the gap between the
alternator/power steering pump bracket and the engine.
Attach
the blue wire with the "bullet" connector to the engine coolant
sending assembly.
Attach the 2 black ground wires with the large ring terminal to
the bolt shown in FIG 3.
Run the clutch connector under the 90 degree water pump elbow to
protect the wire from the belt.
Note: The cardboard used during removal of the fan assembly should
be re-used in the following step.
With the plastic fan blade assembled on the new Power Fan, start
the assembly and shroud on the water pump hub, but do not tighten
at this time. Swing the anti-rotation arm to the three o’clock
position so that the anti-rotation stud can be backed out through
the slot to hold the arm in position.
Finish threading the fan assembly onto the water pump and, with
the installation tools, tighten in place. Be sure the
anti-rotation arm is not touching any belts or moving parts.
Unscrew the anti-rotation stud through the slot in the
anti-rotation arm so 1/4" of the shoulder end of the stud is
showing in front of the arm. Tighten the MN-7000 nut to secure the
anti-rotation stud.
Plug in the fan clutch.
Re-install the shroud bolts and lug nut wrench. Re-install the
water reserve tank and overflow hose.
Refill the reservoir with anti-freeze up to "full" line marking on
the side of the reservoir.
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ELECTRICAL AND TRANSMISSION TEMPERATURE
(Refer to the diagram at the bottom of this page.)
Place the two-button control switch on the lower left side of the
dash. Run the wire harness from the switch, around the corner and
under the dash. Place the power module box under the dash, find a
convenient spot and "wire tie", then plug in the switch harness
connector. On vehicles with automatic transmissions, run the
engine compartment harness into the cab through the large plastic
cover behind the power distribution box. On vehicles with manual
transmissions, the engine compartment harness will run through the
small plastic cover in the tunnel area. Plug the engine
compartment harness into the Power Module. The red 12 volt wire
and yellow idle validation wire will remain under the dash. All
other wires should be on the engine side of the firewall.
Drop the green transmission fluid wire down to the trans cooling
return line.
After the transmission oil has cooled, locate the transmission
return (cool) line. For automatic transmissions, there are two
transmission fluid lines running parallel from the front of the
truck. The return farthest back on the transmission. Install the
hex manifold a couple inches behind the starter.
For manual transmissions, install the hex manifold in the line
which crosses under the radiator from driver side to passenger
side.
Cut the hard lines and install the compression fittings. NOTE: In
each application, the hex manifold relies on the hard cooling line
for proper grounding.
Assemble the Housing Assembly as shown in the diagram in the
center of this booklet. NOTE: Use sealant designed for electrical
sending units. Do not use teflon tape or teflon sealant.
Referring to the diagram in the center of this booklet, note that
the cooling lines are installed on the ends of the hex manifold,
and the Cyclone thermistor and plug (for optional transmission
temperature gauge) install into the hex sides of the manifold.
Under
the dash, find the idle validation switch and using the diagram
provided, (FIG. 4) attach the yellow wire from the harness to the
red wire with light green stripe (This wire should be "hot" when
the throttle is depressed and "cold" when the throttle is off.).
Find a 12 volt switched source (position 27 in the fuse block) and
attach the red wire using the mini fuse tap provided. NOTE: If the
truck is equipped with any aftermarket addition which allows the
engine to run with the key off (remote starters, turbo savers,
etc.) you will need to determine an alternate fuse location which
will allow the fan to run any time the engine is running.
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SYSTEM CHECK
Start the truck and check for leaks at engine coolant sender,
transmission temperature sender, and at all hoses.
Verify that the controller and clutch are working properly. When
the truck is started, the Green (Automatic mode) LED should light
up if the cab of the truck is cool.
If the cab temperature is warm and the throttle is not depressed,
the Red (Engaged mode) LED should light up and the fan should
engage. If the Red LED is lighted, and then the throttle is
depressed, the Green (Automatic mode) LED should light and the fan
should disengage.
To test the Super Cooling feature, press the Blue button. The fan
should engage and the Blue LED should light up. Press the Red
(Power) button to disengage Super Cooling.
Refer to the
Operating Instructions in the Customer Information packet for
more information on the operation and safety features of the
Cyclone Power Fan.
WARNING: When the fan is off (disengaged), the fan will
still spin slowly due to bearing drag (approx. 150 RPM). Under NO
circumstances should you place your hand, or any object, in the
fan while the engine is running.
