Service Procedure

PART I - Installation of Relay and Jumper Harness Kit No. 25519237. Vehicles equipped with air conditioner or with heater only and heavy-duty cooling.

Some vehicles have a wire connected from the No. 4 terminal of the low speed-fan relay to ground at the radiator tie bar. This wire should be removed and discarded during the following procedure:

1. Raise hood and cover left fender.

2. Remove the two (2) screws that attach left sheet metal brace to radiator upper tie bar. Loosen the brace rear attaching screw and rotate brace inward to expose area over the battery.

3. Remove the positive cable from battery. Cover positive terminal on battery with electrical tape.

FIGURE 1 - REWORK OF PLASTIC PROTECTOR:

4. Remove plastic protector from upper tie bar and slot as shown in Figure 1.

5. Remove screw retaining forward lamp and battery ground terminals to tie bar. Retain screw for use in Step 7. If there is a wire from the low-speed relay which is grounded by this screw, this wire should be removed and discarded.

FIGURE 2 - LOCATION OF HOLES IN UPPER TIE BAR:

6. Drill two (2) 1/8" relay mounting holes in tie bar at locations shown in Figure 2. Use the new relay as a template, if required.

7. Drill one (1) 13/64" hole in tie bar and attach ground wire of the new jumper harness, along with forward lamp and battery ground wires, using screw removed in Step 5. Refer to Figure 2.

NOTICE: Electrical connectors are packed with special water resistant grease. Do not remove or wipe this grease from parts during installation of kit.

FIGURE 3 - INSTALLATION OF RELAY:

8. Reinstall plastic protector on tie bar, plug jumper harness connector on relay and attach relay to tie bar using furnished screws. Refer to Figure 3.

FIGURE 4 - REMOVING HIGH SPEED FAN RELAY:

9. Remove the fuel pump, high and low-speed relay mounting bracket, from left wheel house. Remove the fan high-speed (center) relay from bracket. Refer to Figure 4.

IF VEHICLE IS EQUIPPED WITH HEATER ONLY AND HEAVY-DUTY COOLING, PRIOR TO THE FOLLOWING STEP, INSTALL FAN SINGLE/LOW SPEED RELAY AS INSTRUCTED IN STEPS 3,4 AND 5 OF PART II OF SERVICE PROCEDURE.

10. Assemble relay mounting bracket to wheelhouse.

FIGURE 5 - REMOVAL & INSTALLATION OF WIRE TERMINALS:

11. Remove wiring connector from fan high-speed relay. Unlock this connector, remove the four wire terminals and discard connector. Refer to Figure 5.

FIGURE 6 - JUMPER HARNESS TO ENGINE HARNESS CONNECTIONS:

12. Install the four wire terminals removed in Step 10 into the three furnished connectors as shown, and plug the connectors into the jumper harness. Refer to Figure 6. Original wire color must match the wire colors in the jumper harness, except for the wire removed from cavity "C" of original connector on vehicles with heater only and heavy-duty cooling. Refer to important note on Figure 6.
13. Check cooling fan high speed relay operation by grounding the relay jumper harness dark green with yellow striped wire. Any change from the following procedure could result in damage to the new relay.

a. Insert a jumper wire probe in relay jumper harness connector cavity "B" so that probe contacts terminal of the dark green with yellow striped wire. Refer to Figure 6.

b. Attach the other end of jumper wire to a suitable ground (sheet metal screw, battery negative terminal, etc.).

c. Remove tape from battery positive terminal and reinstall positive cable.

d. Recheck to be sure you have a good connection between ground and jumper harness green wire with yellow stripe.

e. Place air conditioner selector lever in the "OFF" position.

f. Turn ignition switch to "ON". Fan should run at high speed. If fan does not operate, cause should be determined and corrected.

g. Allow fan to operate for a minimum of ten (10) seconds. Turn ignition off and remove jumper wire.
14. Reinstall left sheet metal brace front attaching screws and tighten the rear attaching screw. Be sure plastic conduit is on brace in area over battery.

15. Install campaign identification label as instructed in Part III.

PART II - Installation of Single/Low-Speed Relay Kit No. 25519249. Vehicles equipped
with heater only.

1. Raise vehicle hood, cover fender, and remove battery positive cable.

2. Remove the fuel pump and fan relay mounting bracket from the left wheelhouse.

FIGURE 4 - REMOVING HIGH SPEED FAN RELAY:

FIGURE 5 - REMOVAL & INSTALLATION OF WIRE TERMINALS:

3. Lift up tang on bracket and remove fan single/low-speed relay. Disconnect wiring connector from relay. Unlock connector and remove the four wire terminals and discard connector. Refer to Figures 4 and 5. (Figures 4 and 5 show procedure for high-speed fan relay. Procedure is the same for single/low-speed relay except for location of relay on bracket.)

FIGURE 7 - INSTALLATION OF COOLANT FAN SINGLE/LOW SPEED RELAY AND WIRING:

4. Insert the four wire terminals removed in Step 3 into the two connectors furnished in kit as shown in Figure 7. Plug these connectors onto new relay No. 25515230. Install relay on mounting bracket.

5. Check cooling fan single/low-speed relay operation by grounding the relay dark green with yellow striped wire.

Any change from the following procedure could result in damage to the new relay.

a. Insert a jumper wire probe in single/low-speed relay connector cavity so that probe contacts the terminal of the dark green with yellow striped wire. Refer to Figure 7.

b. Attach the other end of jumper wire to a suitable ground.

c. Connect battery positive cable.
d. Recheck to be sure you have a good connection between ground and relay green wire with yellow stripe.

e. Turn ignition switch to "ON". Fan should run at single/low-speed. If fan does not operate, cause should be determined and corrected.

f. Allow fan to operate for a minimum of ten (10) seconds. Turn ignition switch off and remove jumper wire.

6. Assemble relay mounting bracket to wheelhouse.

7. Install campaign identification label as instructed in Part III.

PART III - Install Campaign Identification Label

Each vehicle modified in accordance with the instruction outlined in this Service Procedure will require a Campaign Identification Label. Each label provides a space to include the campaign number, the five (5) digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the radiator upper mounting support and apply the campaign label where it is readily visible.