E Fan Installation Instructions
04 & 05 HEMI Dodge Ram 1500
1. Disconnect the electrical plugs from the coolant and washer tanks, unplug the washer tank hose at the splice point before the pump, this will keep you from having to drain the tank.
Remove the two 10 mm bolts that mount the coolant, washer fluid reservoir tanks, pull the tanks up and out from the radiator shroud look at the design of the tanks they will only fit one way, move the tanks out of the way.
2. Remove the two 13mm bolts that hold the fan shroud 1 on each side, turn the fan where the shroud can be removed and set aside, be careful not to puncture the radiator with the shroud during removal.
3. With the shroud removed you can now gain access to remove the fan nut, several people have done it differently, basically you have to get the water pump pulley still and loosen the fan nut. I used a chain and wrapped it around the front sway bar, then used a Ό x 20 nut bolt and flat washer to hold it together, then put another Ό x 20 bolt into the pulley from the backside with the nut and flat washer on the front. Use the pipe wrench to remove the fan nut.
fan to the shroud:
Your new Viper fan will need to be modified to fit inside the shroud, set the shroud on the floor like it would be mounted in the truck, test fit the fan with wiring plug at the bottom left while sitting inside the shroud. The left side of the fan housing will need to be trimmed 1& 1/8 to fit inside the shroud. Once you have the fan housing trimmed set it inside the shroud, you will need to drill 4 Ό holes in the fan housing along the edge (approximately ½ from the edge), you will need to drill 4 more Ό holes in the fan shroud make sure they are aligned with the fan housing holes. Use your large ty-wraps (8) to secure the fan housing to the shroud, the top and bottom ty-wraps will go around the fan housing opening at the wind flaps on both sides top and bottom. Drill a 1 Ό hole in the lower part of your shroud to run your pigtail wiring through. Your pigtail will need to be put together, use the three larger green wires. Test fit the plug to the fan connection, disconnect the plug remove the black end clip and the blue insert. Attach your green leads into the back of the plug ( they will only fit one way), once all three are in put the blue insert back by sliding the wires through the provided holes, put the black end clip back on. Connect the plug back on the fan connector. Now is a good time to mark these leads, with the plug connected the bottom wire is ground make it #3, the middle green wire will be #2 and the top #1.
the shroud with the fan attached:
The shroud will need to be reinstalled in reverse
manner from removal, install the washer and coolant reservoir, and
tighten mounting bolts, reconnect electrical connections and washer
Mounting your Temp Controller:
Your options to mount this controller are somewhat limited due to the length of the probe lead wire, a good position is to the right front of the AC/ Transmission cooler fan on the post directly behind the drivers headlight. Mount the relay directly below the temp controller.
the Temp Probe:
The probe is designed to go into the radiator fins
in the upper right side count 9 rows down from the top right of the
radiator, then 5 from the right side. Insert probe between the fins and
slowly apply pressure while slightly rocking the probe back and forth,
be careful here if you get too rough you could end up with a radiator
leak. Once the probe is through put on the black cap provided in the
Relay and Temp Controller:
Relay tabs (3) will need to be filed down to fit
the Sta- Kon connectors
Look at the bottom of the relay to become familiar with the connection numbering.
Connect the fan lead #2 to position 87 on the relay
Connect a jumper wire from 87A to the top connection on the Temp controller.
Connect 85 & 30 together with a butt splice, then to the positive side of the battery ( do not connect to the battery yet)
Connect the #1 lead from the fan to the Temp controller lower connection
Ground the #3 lead - if you choose to use the optional toggle switch, you will need to connect one side to ground and the other to #86 on the relay, this will allow a manual override that will turn the fan on low speed continuously. Use wire loom and small ty-wraps to clean up the wiring.
Connect the fuseholder to the Positive battery post and install the 60 amp fuse.
If the optional toggle switch is used turn on to verify low speed operation, turn the switch off after test.
Start the truck and let the engine warm up, once operating temp is reached the fan will turn on high speed, shut the engine down and let the fan run to cool the radiator. The first time it will run until the radiator is completely cool ( approx 10-15 minutes). Once the fan turns off, start the engine again and let it run until the fan comes on again this time it will run 1-2 minutes then turn off and on intermittently. Shut the engine down again, the fan should turn on and off 1-2 minutes at a time until the radiator and engine are cool. Installation complete!
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