Flex-a-Lite 67100 Cherokee XJ Radiator Only Kit Fits 1987-2001 Jeep Cherokee XJ - Manual (Page 3)

Installation instructions continued from previous page
Rev. 06-12-13 98108 Page 3 of 6
Reattach the long “L-bracket” with previously removed Torx bolts and 10 mm nuts. 5.
Reattach the center hood latch bar with previously removed Torx bolts to top center of radiator support. 6.
Attach and secure top and bottom radiator hoses to new radiator. 7.
Attach barbed fitting to threaded hole on filler neck. Note: using Teflon tape will help to ensure a better seal. 8.
Attach overflow hose to barbed fitting. Secure hose along radiator support with stock plastic clamps and 9.
bolts.
Fill radiator / cooling system with vehicle manufacturer recommended coolant.
10.
Note: BE SURE that all moving parts of the engine and electrical fan assembly are clear of each
other before proceeding!
Locate a mounting point for the VSC (variable speed control) unit: 1.
Locate a mounting point for the VSC near inlet (upper hose) side of the radiator. The control unit should be
placed close to radiator inlet (upper hose) if possible. On the passenger side, upper fire wall, next to hood
hinge may be a convenient location. Attach the control unit using the screws provided.
Wire the fan motors (refer to Wiring Diagram, on page 4): 2.
After the VSC has been mounted, route a length of the thick (10 AWG) red wire and a length of the thick
(10 AWG) black wire from the VSC to the fan motor wires. The motor wires have pre attached yellow butt
connectors. Connect the butt connector with the three red motor wires to the thick red wire. Connect the
butt connector with the three black motor wires to the thick black wire.
Connect the fan wires to the VSC: 3.
Using the yellow butt connectors provided, connect the red wire you attached to the fan motor wires to the
yellow wire on the VSC. Connect the black wire from the motor wires to the purple wire on the VSC.
(see wiring diagram)
NOTE: Failure to do this will result in incorrect operation and damage to fan motors!
Connect power leads: 4.
Determine the length needed to run thick red and black wire from the VSC to the battery terminals and trim
appropriately. Crimp a large yellow ring connector to one end of the each wire and connect the black wire
to the negative (-) battery terminal, but
Do Not connect the red wire yet. Using butt connectors, connect the
fuse holder provided in line with the red wire. The fuse and fuse holder will protect the fan motors and your
vehicles electrical system from damage.
Ignition controlled power source: 5.
Locate fuse box. Find a circuit that is “hot” when the key is in the “ON” position. NOTE: DO NOT use
the DRL or brake/taillight fuse, or any fuse directly related to the fuel or ignition system. Attach
the included fuse tap to fuse. Attach a female connector to the thin red wire provided and connect to the
fuse tap. Trim the wire so that it will reach the VSC. Attach pink female connector to other end of wire and
connect to terminal #9 on VSC.
Fan operation with air conditioning: 6.
Locate the wires coming from the A/C compressor. Determine which wire is ground and which is positive
by using a volt meter. Connect or splice the thin green wire to the positive (+) wire of the A/C compressor
using the blue “Piggy-Back” connector. Determine length of wire needed to reach VSC. Route green wire
then trim to length. Attach a pink female connector to the wire. Connect this wire to terminal #8 on VSC.
Temperature sensor: 7.
Determine the length of wire needed to reach the VSC. IMPORTANT: Strip the
insulation back about 1” and fold the wire onto itself to effectively double the
thickness of the wire before connecting the pink female connectors as shown.
(see Detail F) Attach temp probe wires to terminals #10 & 11 on the VSC. Both
wires need to be connected but it doesn’t matter which wire goes to each terminal.
Manual Switch: (Optional Purchase Part #31148) 8.
If manual switches (Flex-a-lite #31148) have been purchased, attach them as follows: To override engine
temperature signal and turn fans off, connect the switch to terminal #5 on VSC to send a negative (-) signal.
To override engine temperature signal and turn fans on, connect the switch to terminal #6 on the VSC so
that a negative (-) signal is sent.
Reattach negative (-) battery cable to battery. 9.
FOLLOW THESE INSTRUCTIONS CAREFULLY TO AVOID DAMAGING THE CONTROL UNIT,
FAN MOTORS, AND YOUR VEHICLE! WHEN CRIMPING WIRES, ALWAYS USE A QUALITY
CRIMPING TOOL (DO NOT USE PLIERS OR OTHER DEVICES).
Wiring Instructions Model #67108
(Detail F)