Derale Performance Direct Fit Jeep Wrangler Performance Electric Fan Kit - Manual

20161-InstructionSheet
INSTALLATION INSTRUCTIONS
DIRECT FIT ELECTRIC FAN KIT
PART # 20161
KIT CONTENTS
QTY. DESCRIPTION
1 Electric Fan Assembly
4 Angled Mounting Brackets
1 Rubber Seal
1 Bracket-Radiator
Overflow Reservoir
1 Bracket-Power
Steering Reservoir
1 Clamping Bracket-Power
Steering Reservoir
1 Thermostat Switch
1 3/8” NPT Brass Tee
1 3/8” x 1/8” Reducer Bushing
1 Relay Wire Harness
1 7ft. extra Wire
QTY. DESCRIPTION
1 6ft. Convoluted Tubing
8 1/4-20 x 1/2” Hex Bolts
2 1/4-20 x 3/4” Hex Bolts
21 1/4” Flat Washers
11 1/4-20 Lock Nuts
3 #10 Sheet Metal Screws
2 Blue Female Connectors
2 Blue Butt Connectors
1 Yellow Butt Connector
2 Blue Wire Tap Connectors
1 Blue 5/16” Ring Terminal
1 Blue #10 Ring Terminal
1 Red #10 Ring Terminal
2 6” Zip Ties
12 4” Zip Ties
Derale Performance, Los Angeles, CA 800.421.6288 www.derale.com
Please read these instructions completely before beginning installation
TOOLS NEEDED
7/16” Socket & Ratchet
7/16” Box End Wrench
5/16” Nut Driver
Flat head Screw Driver
1/2” Open End Wrench
5/8” Open End Wrench
11/16” Open End Wrench
3/4” Open End Wrench
13/16” Open End Wrench
Drill
5/32” Drill Bit
Wire Stripper
Wire Crimping Tool
Dyke Pliers
Teflon Tape
APPLICATIONS
1987-1996
Jeep
Wrangler YJ
1997-2006
Jeep
Wrangler TJ
ALL 4 & 6
Cylinder Engines
IMPORTANT
These instructions refer to components that are application specific and may
not apply to your specific vehicle. Refer to application details below for
Radiator Overflow and Power Steering Reservoir relocating information.
All brackets are included.
(Page 1)
PRE-INSTALLATION
1. Using a table or workbench, lay the Electric Fan Assembly on a flat surface,
Electric Fan assembly facing down.
2. Identify the four Angled Mounting Brackets, 1/4-20 x 1/2” Hex Bolts,
1/4” Flat Washers & 1/4-20 Lock Nuts. Attach the Mounting Brackets to
the Shroud using two bolts per bracket. (See Diagram #1)
3. Using a 7/16” Open End Wrench and 7/16” Socket/Ratchet, tighten the
Angled Mounting Brackets in place.
4. Take the supplied Rubber Seal and install it onto the bottom edge of the
Fan Shroud Assembly. (See Diagram #1)
5. Cut off excess Rubber Seal.
VEHICLE PREPARATION
1. Park vehicle on a solid, level surface and allow vehicle to completely cool before beginning installation.
2. Engage the parking brake.
3. Disconnect the Negative (-) terminal on the vehicles battery.
REMOVAL OF FACTORY COMPONENTS
These instructions refer to components that are application specific and may not apply to your specific vehicle. Refer to
application details below for Radiator Overflow and Power Steering Reservoir relocating information.
1987-1996 JEEP WRANGLER YJ
4 & 6 Cylinder – No relocating of reservoirs will be necessary.
1997-2006 JEEP WRANGLER TJ
4 Cylinder – Both Radiator Overflow and Power Steering Reservoirs will be relocated.
6 Cylinder – Radiator Overflow Reservoir will be relocated.
1.
Remove the Radiator Overflow Reservoir (1997-2006 Models only).
2. Without disconnecting the oil lines, remove the Power Steering Reservoir and temporarily zip tie it out of the way.
3. Remove the four factory shroud mounting bolts on both sides of the fan shroud.
Warning: Do not disregard the factory shroud mounting bolts; these will be used to install your new Electric Fan Assembly. In
Most cases you will not be able to remove the fan shroud until the fan clutch and fan assembly are removed.
4.
On Automatic Transmissions, remove the transmission cooler hose attached to the bottom of the factory fan shroud.
5. Remove the four factory nuts holding the fan clutch and fan to the water pump flange/pulley.
6. Remove the fan clutch, fan and fan shroud from the engine compartment. Do not remove the water pump pulley.
7. Reinstall four nuts onto the water pump flange/pulley and tighten.
Diagram #1
Electric Fan
Assembly
Angled
Mounting
Brackets
1/4-20
x 1/2”
Hex Bolts
1/4-20
Lock Nuts
1/4-20
Lock Nuts
Rubber
Seal
1/4”
Flat
Washers
1/4”
Flat
Washers