Jr Fan Kit Installation Instructions
THE BLOWER KIT (P/NO. 8-94161-162-1) FOR JR MODEL
CONTENTS
ITEM PART NO. PART NAME
Q'TY
1 8-94161-163-0 BLOWER ASM. 1
2 9-03920-616-0 SCREW; BLOWER FIX (M6 x 16) 1
3 8-9416-1-168-0 DUCT; BLOWER, OUT 1
4 8-94161-169-0 DUCT; BLOWER, IN 1
5 8-94111-622-0 CLAMP; DUCT, IN 1
6 5-09707-030-0 1
CLIP; BAND, DUCT, IN, FIX
7 8-94110-539-0 CLAMP; DUCT, IN, FIX 1
8 8-94161-165-0 THERMO SWITCH 1
9 8-94161-166-0 BRACKET; THERMO SWITCH 1
10 9-01900-812-0 1
BOLT & WASHER ASM. (M8 X 12)
11 8-94161-164-0 CONTROLLER 1
12 8-94167-051-0 1
13 9-03920-512-0 BRACKET; CONTROLLER
SCREW; CONTROLLER FIX (M5 x 12) 2
14 8-94232-222-0 RELAY; BLOWER 1
15 8-94166-565-0 HARNESS ASM. 1
16 5-82690-214-0 1
CONNECTOR
17 8-94167-052-0 BRACKET; BLOWER FIX 1
9-03920-612-0 SCREW; BLOWER FIX (M6 X 12) 1
18
IMPORTANT: DISCONNECT NEGATIVEBATTERY CABLE BEFORE PROCEEDING
(1) Remove the evaporator fixing nut and washer, and the dropping resistor fixing screw. (See fig. 2)
(2) Attach the blower assembly as shown in fig. 3. Secure the blower assembly bracket with the nut and washer removed from the evaporator bolt. Tighten the other side of the bracket together with the dropping resistor using the screw supplied in the kit.
NOTE:
1984.5 and on JR production will not have the dropping resistor located as in fig. 3. In such cases, it will be necessary to use the bracket provided in the kit in order to secure the outboard end of the blower assembly bracket. (See fig. 4)
(3) Attach inlet duct to blower assembly. Secure it with clamp provided. Drape duct down inner fender panel, exiting engine compartment behind front cross member. Remove engine harness and speedometer cable clip from fender panel. Using existing screw, reverse this bracket and install together with duct bracket included in kit. Secure upper portion of duct to A/C pipe using tie wrap provided. (See fig. 5)
(4) Connect the duct securely to the exhaust side of the blower assembly. Outlet end of duct should face the four (4) fuel injection pipes, from the rear of the engine. (See fig. 6)
(5) Fasten the thermoswitch to the bracket provided. Fasten the bracket to the cylinder head cover using the bolt and washer provided. (See fig. 7)
(6) Remove the A/C condenser assembly bracket fixing nut and washer (upper right). (Sec fig. 8)
(7) Attach the controller to the mounting bracket supplied. (see fig. 9)
(8) Attach controller bracket to condenser stud using original nut and washer. (See fig. 10)
(9) Remove relay box cover (located on right inner fender panel). Attach relay from fan kit wiring harness to the unused space in the relay box. (See fig. 11)
(10) Remove WL (white/blue) wire terminal from main relay connector (brown). Replace it with the white/blue wire from fan kit wiring harness. (see fig. 11, 12, 13)
(11) Remove WR (white/red) wire terminal from charge relay connector (blue). Replace it with the white/red wire from fan kit wiring harness. (Sec fig. 11, 12, 13)
(12) Insert the WR and WL wires just removed from relay box into the fan kit connector. (See fig. 14)
NOTE:
Be sure white/blue wire is in the top (horizontal) slot of connector with white/red wire in the bottom (vertical) slot.
(13) Attach all fan harness connectors to blower assembly, controller, thermo switch and blower relay. At the controller, just behind headlights, make a loop in the wiring harness and secure with electrical tape. Using the existing vehicle harness, tie wrap to secure this bundle in place. (see fig. 1, 15)
(14) Remove the ignition coil fixing screw and fasten the grounding terminal together with the ignition coil. (See fig. 16)
(15) Bind necessary part (s) of the fan wiring harness with the existing harness clip (s).
(16) Reconnect negative battery lead.
(17) Reset multi-drive monitor functions for time and date. The last two instructions are omitted from instruction sheet packed with Fan Kit.