Uploaded by Travis Horning

Fan Drive Retrofit

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Instruction Sheet
HORTON DRIVEMASTER DIRECT FAN CLUTCH RETROFIT
4328244R2
Application
This Instruction Sheet depicts the necessary
procedures to retrofit a gear-driven fan drive with a
belt driven high mount fan drive.
Model: ProStar®, PayStar®
Engine Family: MaxxForce®13 (EPA 10)
Engine Family: Navistar® N13 (EPA 10) with SCR
Kit Contents
Table 1
Parts Information
Part Number
Description
Qty
2514165C94
KIT, FAN DRIVE,
RETROFIT, 2 SPE
1
Table 2
Kit Contents
Part Number
Description
Qty
7095182C91
Bracket Assy, Pulley Fan Drive
1
62917010904
Sleeve, Fan Drive
2
1817957C1
Bolt, Flange M8 X 25mm
4
1817959C1
Bolt, M8 X 1.25 X 40mm
1
6216490010
Plug (SK6 Oil Galley Rivet)
62019050092
Gasket, Cover Front
1
62015106008
Seal Assy, Radial Shaft
1
3012268C1
Gasket, Coolant Distribution Housing
1
6032158407
Hex Bolt, M10 X 35mm
9
3018590C1
Pulley, 10 Groove Crankshaft
1
6020990418
Screw, CYL M16 X 1.5 X 85mm
8
Drive, Fan, Journal Bracket
1
1817993C1
Bolt, M10 - 1.50 X 80mm
4
7095176C1
Support, Tensioner
1
HOR98A4710
2 (1 Required, 1 Extra)
1
Read all safety instructions in the "Safety Information" section of the appropriate Engine Service or Diagnostic Manual.
Follow all warnings, cautions, and notes.
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Table 2.
Kit Contents (cont.)
Kit Contents (cont.)
Part Number
Description
Qty
1824752C1
Bolt, M8 X 1.25
3
1818693C1
Bolt, M8 X 110
1
7095181C1
Belt, Tensioner
1
1841930C1
Pulley, Fan Drive
1
21378H
Bushing Reducer
1
1832771C1
Bushing, Idler Pulley Bracket
1
1832784C1
Cover, Dust Air Conditioner Compressor
Idler
1
1822018C1
Bolt, M10 X 90mm
1
HOR98A4707
Drive, Fan, Pulley
1
HOR98A4706
Drive, Fan, Clutch Two-Speed
1
Nut, Lock Flanged M8
6
3681266C1
Fan, Engine Cooling 32 in Borg Warner
1
934309R1
Washer, Lock 5/16 in
6
25520R1
Nut, Type 8 5/16 in
6
2017513C2
Fitting, Hose Connector Quick Connect 3/8
in
1
2017495C1
Fitting, “T” Tube Quick Connect 1/4 in NPT
1
3611896C1
Valve, Solenoid
1
417196C3
Tube, Black Nylon 1/4 in OD (Short)
1
2644094R1
Conduit Cable Electric, (Short)
1
2514162C91
Harness, Electrical Jumper (
1
2024440C1
Fitting, Elbow Quick Connect 1/4 in Tube X
1/4 in Stem
2
417196C3
Tube, Black Nylon 1/4 in OD (Long)
1
2644094R1
Conduit Cable Electric, (Long)
1
7096086C1
Belt, Fan, 10PK 1490
1
98985R91
Clamp, Pipe SGL - Cushioned 7/16 in
1
1840156C1
Bolt, M8 X 40 X 15 Stud
1
3014371C1
Tube, Extension DIA 41 X 35
2
3018586C1
Tube, Extension DIA 62 X 51
1
62069040039
Gasket, Housing Thermostat
1
3877737C1
Hose, Radiator Outlet
1
3006012C1
O-ring
1
40066R1
4328244R2
2
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Table 2.
Kit Contents (cont.)
Kit Contents (cont.)
Part Number
98959R1
Description
Qty
Clamp. Pipe Hose Cover
1
984153
Nut, Special Bearing
1
19140
Sleeve, Fan Drive Pulley
1
Procedure
WARNING: To prevent personal injury and /
or death, read all safety instructions in the “Safety
Information” section of the Engine Service Manual
or Engine Diagnostic Manual.
REMOVAL
NOTE: If vehicle you are working on has custom
programmable parameters, save a template of
all parameters before programming so custom
programmable parameters can be reset after
programing.
WARNING: To prevent property damage,
personal injury, and / or death, park vehicle on
a hard, flat surface, turn engine off, set parking
brake, and install wheel chocks to prevent vehicle
from moving in either direction.
1. Bring vehicle into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking
brake, and install wheel chocks.
WARNING: To prevent personal injury and /
or death, make sure the engine has cooled before
removing components.
3. Remove bumper from vehicle.
4. Remove hood from vehicle.
5. Remove air cleaner assembly.
WARNING: To prevent property damage,
personal injury, and /or death, remove ground
cable from negative terminal of main battery
before disconnecting or connecting electrical
components. Always connect ground cable last.
NOTE: Reposition A/C condensor; do not remove.
6. Remove cooling module / package, refer
to appropriate service manual for specific
procedures.
WARNING: To prevent personal injury and /
or death, keep flames or sparks away from vehicle
and do not smoke while servicing the vehicle’s
batteries. Batteries expel explosive gases.
WARNING: To prevent personal injury and /
or death, always wear safe eye protection when
performing vehicle maintenance.
CAUTION: To prevent engine / component
damage, ensure the kit-supplied rivet style plug
is correctly installed into the oil galley. If not
installed correctly, a low and / or no oil pressure
condition could occur causing severe damage to
various major engine components.
3
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
REMOVAL (cont.)
Figure 2.
Figure 1.
1.
2.
Fan Drive Assembly.
1.
2.
3.
4.
5.
6.
7.
Hex nut
Fan drive assembly
7. Remove fan drive as an assembly (Figure 1,
Item 2) at hex nut (Figure 1, Item 1). Refer
to appropriate service manual for specific
procedures.
Engine Cooling Components.
A/C compressor
Serpentine belt
Water pump pulley
Upper coolant tube
Upper fan shroud bracket
Belt tensioner
Idler pulley
8. Remove serpentine belt, belt tensioner and
idler pulley (Figure 2, Items 2, 6, 7). Refer
to appropriate service manual for specific
procedures.
9. Remove upper fan shroud bracket (Figure 2, Item
5).
10. Remove upper coolant tube (Figure 2, Item 4).
Refer to appropriate service manual for specific
procedures.
11. Remove water pump pulley (Figure 2, Item 3).
NOTE: Do not remove A/C compressor.
12. Remove A/C compressor mounting bolts and
reposition compressor (Figure 2, Item 1).
4328244R2
4
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
REMOVAL (cont.)
Figure 3.
1.
2.
Coolant Control Valve.
Figure 4. Upper Exhaust Gas Recirculation
Manifold.
Coolant control valve (CCV)
Engine harness
1.
13. Remove harness retainer from engine harness
(Figure 3, Item 2).
Upper exhaust gas recirculation (EGR) manifold
17. Remove upper EGR manifold (Figure 4, Item 1).
Refer to appropriate service manual for specific
procedures.
14. If equipped, disconnect engine block heater.
15. If equipped, disconnect SCR hoses.
16. Remove CCV (Figure 3, Item 1).
Refer
to appropriate service manual for specific
procedures.
5
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
REMOVAL (cont.)
Figure 5.
1.
2.
3.
4.
Water Distribution Case.
Figure 6.
Water distribution case
Thermostat housing
Vibration damper
Lower coolant tube
1.
2.
Front cover
Fan hub
20. Remove front cover (Figure 6, Item 1) and gasket.
Refer to appropriate service manual for specific
procedures. Save cover bolts for reuse. Discard
fan cover gasket.
18. Remove water distribution case (Figure 5, Item 1),
thermostat housing (Figure 5, Item 2), and lower
coolant tube (Figure 5, Item 4) as an assembly.
Refer to appropriate service manual for specific
procedures. Save mounting bolts for reuse.
21. Remove fan hub (Figure 6, Item 2) and discard
fan hub. Refer to appropriate service manual for
specific procedures.
19. Remove vibration damper (Figure 5, Item 3).
Refer to appropriate service manual for specific
procedures.
4328244R2
Front Cover With Original Fan Hub.
22. Clean front cover mating surfaces.
6
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
PREASSEMBLY
2. If necessary, install O-ring (Figure 8, Item 1) to kit
supplied fan bracket.
Figure 9.
Figure 7.
1.
2.
1.
2.
Fan Bracket Bushing.
Vibration damper
Crankshaft pulley
Bushing (2)
Fan bracket
3. Remove original crankshaft pulley (Figure 9,
Item 2) from vibration damper (Figure 9, Item 1).
Discard bolts and crankshaft pulley.
1. Install kit supplied bushings (Figure 7, Item 1) into
mounting side of kit supplied fan bracket (Figure
7, Item 2). Align bushings and lightly tap to install.
Figure 10.
Figure 8.
1.
Original Crankshaft Pulley.
1.
2.
3.
Fan Bracket O-ring.
O-ring
Belt Driven Crankshaft Pulley.
Vibration damper
Bolt (9)
Crankshaft pulley
7
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
PREASSEMBLY (cont.)
4. Install kit supplied crankshaft pulley (Figure 10,
Item 3) to vibration damper (Figure 10, Item 1)
using kit supplied bolts (Figure 10, Item 2). Using
torque wrench, tighten bolts to 33 lb-ft (45 N•m).
INSTALLATION
Figure 12.
1.
2.
Figure 11.
1.
2.
Fan Bracket.
Bolt (5)
Fan hub bracket
2. Using kit supplied bolts (Figure 12, Item 1), install
kit supplied fan hub bracket (Figure 12, Item 2).
Using torque wrench, tighten bolts to 25 lb-ft (34
N•m).
Oil Galley Plug.
Oil galley
Plug
3. Using petroleum jelly or equivalent, lubricate outer
diameter of fan bracket, over O-ring.
CAUTION: To prevent engine / component
damage, ensure the kit-supplied rivet style plug
is correctly installed into the oil galley. If not
installed correctly, a low and / or no oil pressure
condition could occur causing severe damage to
various major engine components.
NOTE: Ensure plug is flush with crankcase oil
galley.
1. Using a pneumatic rivet gun, install kit-supplied
rivet style plug (Figure 11, Item 2) into crankcase
oil galley (Figure 11, Item 1).
4328244R2
8
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
INSTALLATION (cont.)
Figure 14.
Figure 13.
1.
1.
2.
3.
Front Cover.
Front cover
4. Using previously removed bolts and kit supplied
gasket, install front cover (Figure 13, Item 1).
Refer to appropriate service manual for specific
procedures.
Water Distribution Case.
Water distribution case
Thermostat housing
Lower coolant tube
5. Using previously removed bolts, kit supplied
gasket and connectors; install water distribution
case (Figure 14, Item 1), thermostat housing
(Figure 14, Item 2), and lower coolant tube (Figure
14, Item 3) as an assembly. Refer to appropriate
service manual for specific procedures.
9
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
INSTALLATION (cont.)
Figure 15.
1.
2.
Front Crankshaft / Radial Seal.
Figure 16.
Front crankshaft / radial seal
Front crankshaft seal installer
1.
2.
6. Using Navistar® Front Crankshaft Seal Installer
ZTSE4873 (Figure 15, Item 2), install front
crankshaft / radial seal (Figure 15, Item 1).
Refer to appropriate service manual for specific
procedures.
Belt Driven Crank Pulley Assembly.
Belt driven crank pulley assembly
Bolt (8)
7. Position crank pulley assembly (Figure 16, Item
1) and loosely install kit supplied bolts (Figure 16,
Item 2).
8. Using torque wrench, torque bolts in a star pattern
type sequence:
A. Tighten bolts to 111 lb-ft (150 N•m).
B. Angle-tighten bolts an additional 90°.
4328244R2
10
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
INSTALLATION (cont.)
Figure 17.
1.
2.
Journal Bracket.
Figure 18.
Bolt (4) (one not shown)
Journal bracket
1.
2.
3.
9. Install kit supplied journal bracket (Figure 17, Item
2) to fan bracket with kit supplied bolts (Figure 17,
Item 1). Using torque wrench, tighten bolts to 45
lb-ft (61 N•m).
Tensioner Bracket.
Tensioner bracket
M8 X 55 bolt (3)
M8 X 110 bolt
NOTE: Record
locations.
tensioner
bracket
mounting
10. Position kit supplied tensioner bracket (Figure 18,
Item 1) to water distribution case. Mark / record
mounting locations and remove.
11. Clean threads on water distribution case / block in
tensioner bracket mounting locations.
12. Reposition tensioner bracket to water distribution
case and Install kit supplied M8 X 55 bolts (Figure
18, Item 2). Using torque wrench, tighten bolts to
24 lb-ft (33 N•m).
13. Install kit supplied M8 X 110 bolt (Figure 18, Item
3). Using torque wrench, tighten bolt to 24 lb-ft
(33 N•m).
11
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
INSTALLATION (cont.)
Figure 19.
1.
2.
Fan Belt Tensioner and Pulley.
Figure 20.
Fan drive belt tensioner
Fan drive idler pulley
1.
Upper coolant tube
16. Install upper coolant tube (Figure 20, Item 1).
Refer to appropriate service manual for specific
procedures.
14. Install kit supplied fan drive belt tensioner (Figure
19, Item 1) to tensioner bracket. Using torque
wrench, tighten bolt to 45 lb-ft (61 N•m).
17. Install engine harness retainers.
18. Install idler pulley and belt tensioner. Refer
to appropriate service manual for specific
procedures.
15. Install kit supplied fan drive idler pulley (Figure
19, Item 2) to tensioner bracket. Using torque
wrench, tighten bolt to 45 lb-ft (61 N•m).
4328244R2
Upper Coolant Tube.
12
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
INSTALLATION (cont.)
Figure 21.
1.
2.
•
Using thumbs, align and push protective
bearing cap (Figure 21, Item 2) fully over
journal bracket threads.
•
With bearing cap fully seated onto journal
bracket threads, push fan drive pulley onto
journal bracket until fully seated.
•
Remove protective bearing cap.
Fan Drive Pulley.
Fan drive pulley
Protective bearing cap
19. Remove protective cover from journal bracket
threads.
CAUTION: To prevent property damage, do not
attempt to install fan drive bracket without bearing
cap, as damage to pulley and / or journal bracket
threads could occur. Fan drive pulley will be
shipped with a protective bearing cap.
Figure 22.
1.
2.
Fan Drive Bearing Nut.
Fan drive pulley
Bearing nut
20. Install fan drive pulley (Figure 21, Item 1):
•
Grasp fan drive pulley with hands on each
side of pulley.
•
Position center of fan drive pulley in front of
journal bracket threads.
21. Install bearing nut (Figure 22, Item 1) onto journal
bracket in center of fan drive pulley (Figure 22,
Item 1). Using torque wrench, tighten nut to 130
lb-ft (176 N•m).
13
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
INSTALLATION (cont.)
Figure 24.
Figure 23.
1.
2.
3.
1.
2.
3.
4.
Fan Drive Clutch Pack.
Fan drive pulley
Clutch pack
Nut (4) (2 not shown)
Fan Drive Belt Routing.
Serpentine belt
Water pump pulley
Fan drive belt
A/C compressor
27. Install water pump pulley (Figure 24, Item 2).
28. Position A/C compressor (Figure 24, Item 4)
and install mounting bolts. Refer to appropriate
service manual for specific procedures.
22. Install kit supplied clutch pack (Figure 23, Item 2)
using kit supplied nuts (Figure 23, Item 3) onto
fan drive pulley (Figure 23, Item 1). Using torque
wrench, tighten nuts to 24 lb-ft (32 N•m).
29. Install upper fan shroud bracket.
23. Install upper EGR manifold. Refer to appropriate
service manual for specific procedures.
30. Install serpentine belt (Figure 24, Item 1).
Refer to appropriate service manual for specific
procedures.
24. Install CCV. Refer to appropriate service manual
for specific procedures.
31. Install kit supplied fan drive belt (Figure 24, Item
3).
25. If equipped, connect SCR hoses.
26. If equipped, connect engine block heater.
4328244R2
14
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
INSTALLATION (cont.)
Figure 25.
1.
Bulkhead / Cowl Panel Stud.
Figure 26.
Bulkhead / cowl panel stud
1.
2.
32. Locate unused bulkhead / cowl panel stud (Figure
25, Item 1) near air brake manifold.
Fan Clutch Solenoid.
Fan clutch solenoid
90 degree air line fittings
33. Install kit supplied fan clutch solenoid (Figure 26,
Item 1) to unused bulkhead stud. Using torque
wrench, tighten solenoid retaining nut to 16 lb-ft
(22 N•m).
NOTE: Position air line fittings as depicted in
graphic.
34. Install kit supplied 90 degree air line fittings
(Figure 26, Item 2) to fan clutch solenoid.
15
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
INSTALLATION (cont.)
36. Remove fitting from air brake manifold.
Figure 27.
1.
2.
Air Brake Manifold.
Fitting
Air line
Figure 28.
1.
NOTE: Air seat equipped model shown. Non air
seat equipped model typical.
Air nozzle adapter fitting
37. Install kit supplied air nozzle adapter fitting (Figure
28, Item 1) to air brake manifold.
35. If equipped, disconnect air line (Figure 27, Item 2)
from fitting (Figure 27, Item 1) located on air brake
manifold.
4328244R2
Air Nozzle Adapter Fitting.
16
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
INSTALLATION (cont.)
Figure 29. Fan Clutch Solenoid Air Nozzle - Air
Seat Equipped.
1.
2.
3.
4.
Figure 30. Fan Clutch Solenoid Air Nozzle - Non
Air Seat Equipped.
Air line (kit supplied)
Air nozzle
Air line (vehicle equipped)
Fitting adapter
1.
2.
3.
Air line
Air nozzle
Fitting adapter
NOTE: Steps 41 — 42 depict NON AIR SEAT
EQUIPPED model installation.
NOTE: Steps 38 – 40 depict AIR SEAT EQUIPPED
model installation.
41. Install kit supplied air nozzle (Figure 30, Item 2) to
fitting adapter (Figure 30, Item 3).
38. Install kit supplied air nozzle (Figure 29, Item 2) to
fitting adapter (Figure 29, Item 4).
42. Connect kit supplied air line (Figure 30, Item 1) to
air nozzle.
39. Connect vehicle equipped air line (Figure 29, Item
3) to air nozzle.
40. Connect kit supplied air line (Figure 29, Item 1) to
air nozzle.
17
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
INSTALLATION (cont.)
Figure 31.
Connect.
1.
2.
Fan Clutch Solenoid - Air Line
Figure 32.
Connect.
Air line - fan clutch solenoid outlet to journal bracket
Air line - air brake manifold to fan clutch solenoid inlet
1.
Fan Clutch Solenoid - Harness
Harness - fan clutch solenoid to engine harness
45. Connect kit supplied harness (Figure 32, Item 1)
to fan clutch solenoid.
43. Connect kit supplied air line (Figure 31, Item
2) leading from air brake manifold to fan clutch
solenoid inlet.
44. Connect kit supplied air line (Figure 31, Item 1) to
fan clutch solenoid outlet.
4328244R2
18
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
INSTALLATION (cont.)
Figure 33.
1.
2.
Routing - Air Line and Harness.
Figure 34.
Harness / air line - fan clutch solenoid to front of
engine
Tie straps (5)
1.
2.
3.
4.
5.
6.
46. Route harness / air line (Figure 33, Item 1)
alongside existing engine harness towards journal
bracket located at front of engine.
Air Line Retainer.
2-way stud
Air line
Engine harness
Harness (kit supplied)
Tie strap
P-clip retainer
NOTE: Belt removed from graphic for clarity.
47. Using tie straps (Figure 33, Item 2) at evenly
spaced locations, secure harness / air line to
existing engine harness.
48. Remove upper water pump mounting bolt.
49. Install 2-way stud (Figure 34, Item 1). Using
torque wrench, tighten stud to 26 lb-ft (35 N•m).
50. Remove protective sleeve from journal bracket
and connect air line (Figure 34, Item 2).
51. Position kit supplied P-clip retainer (Figure 34,
Item 6) onto 2-way stud and retain air line. Install
kit supplied retainer nut.
52. Connect kit supplied harness (Figure 34, Item 4)
to engine harness fan clutch take off (Figure 34,
Item 3).
53. Secure air line and harness accordingly with tie
strap (Figure 34, Item 5).
19
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4328244R2
INSTALLATION (cont.)
57. Perform engine control module (ECM)
programming steps.
Refer to iKNow article
IK0900105 13L V-Master (Stratus) Fan Drive
Retrofit to Horton 2-Spd Air Operated Fan Drive
for template download.
58. Perform
body
control
module
(BCM)
programming steps using Diamond Logic Builder
(DLB) E-Fix:
Figure 35.
1.
2.
3.
Fan Blade.
•
Launch DLB connected to internet
•
Connect the vehicle to DLB
•
Click on SELECT tab
•
Verify VIN selected is correct
•
Click on CAMPAIGN tab
•
Verify FIX1067 TWO SPEED FAN CONVERSION
is shown
•
Click on APPLY SELECTED CAMPAIGN button
•
Click on FEATURE tab
•
Verify parameter 595BPB is NOT selected
•
Verify parameter 595BBB IS selected
59. Install hood to vehicle.
Fan blade
Washer (6)
Nut (6)
60. Remove wheel chocks.
54. Install kit supplied fan blade (Figure 35, Item
1) with kit supplied nuts and washers (Figure
35, Items 2 and 3) to clutch pack. Using torque
wrench, tighten nuts to 26 lb-ft (35 N•m).
55. Install cooling module / package, refer to
appropriate service manual for specific
procedures.
56. Install air cleaner assembly.
4328244R2
20
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
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