Installation Tools Needed

17mm socket/wrench
¼ nut driver
10mm wrench
7mm socket/ratchet
Pliers
Pic or thin screwdriver
Wire cutters/Butt connector crimpers

                           Installation Instructions


1. Take the 17mm wrench remove the nut from the red battery junction box. (fig.1)

2. Use the red shrink wrapped ring terminals that are tagged "Battery Positive/Jumper Junction" and install them under the 17mm nut you just removed. Trimming of the junction box must be done to get it to close.(fig2)

3. Next, remove one of the two 10mm bolts on the Alternator/Accessory bracket that secure the junction box. Install the terminals that are tagged "Battery Negative/Alt Bracket. underneath the 10 mm bolt that you removed and re install the bolt.(fig.3)

4a. 99-02  A/C single pin Blue 42 triggered applications. Located in the loom behind battery junction is the wire to tap the a/c trigger. Locate the green wire. This wire may be light green or green w/ white stripe. Use a test light or volt meter to find the wire that triggers the passenger side fan over the A/C condenser to come on high speed when the A/C is turned on. CAUTION YOU MUST USE THE PROPER GUAGE WIRE TAP AND CONFIRM YOU HAVE THE RIGHT GREEN WIRE FIRST. FAILURE TO DO SO HERE WILL RESULT IN TROUBLE!. DO NOT TAP UNTIL YOU CAN CONFIRM YOU HAVE THE CORRECT  GREEN WIRE.  If the light dose not come on when you turn on the A/C, it not the correct green wire. Once you have located the correct green wire, then go ahead and tap it. Once you tap it, use your test light or volt meter to recheck and confirm proper operation (fig.4) Use pliers and a small flat head screwdriver, remove the grey harness retaining cover from the top of the blue PCM connector. Use the small flat head to pry the grey retaining tabs out. Flip the connector over and Remove the PCM. The black cover should pull off by pulling outward on the cover, releasing from the two plastic tabs. Take your 7mm socket remove the blue PCM connector closest to the engine. Use pliers and a thin pick or screwdriver, press on the white retaining tabs on each side of the blue-clear cover and pull it off. Lubricate the PCM pin and wire on the harness tagged BLUE 42 using vaseline or die electric grease. Gently push Blue 42 trigger through pin 42 on the PCM until it secures itself.  You can see it though the clear plastic. It should should line up and look uniform like the rest of the pins. GENTLY, pull on it blue42  fan harness wire to seat it and make sure it is secure to not back out when reinstalling the retaining covers. Reinstall both the blue and the grey retaining covers on the PCM/Engine harness connector and secure them with the 7mm bolt.(fig.5)

4.b 03-05 Dual Pin Triggered applications: Use pliers and a small flat head screwdriver, remove the grey harness retaining cover from the top of the blue PCM connector. Use the small flat head to pry the grey retaining tabs out. Flip the connector over and Remove the PCM. The black cover should pull off by pulling outward on the cover, releasing from the two plastic tabs. Take your 7mm socket remove the blue PCM connector closest to the engine. Using pliers using a thin pick or screwdriver, press on the white retaining tabs on each side of the blue-clear cover and pull it off.  Lubricate the PCM pins and wires on the harness tagged BLUE 42 and GREEN 33 using vaseline or die electric grease. Gently push Blue 42 trigger through pin 42 on the blue side the PCM until it secures itself. Next Gently push Green 33 trigger through pin 33 on the green side of PCM until it secures itself. You can see  both though the clear plastic. They both should line up and look uniform like the rest of the pins.   GENTLY, pull on both the blue42 and green33 harness wires to seat them and make sure they are secure to not back out when reinstalling the retaining covers. Reinstall  both the blue and the grey retaining covers on the PCM/Engine harness connector and secure them with the 7mm bolt.(fig.5)

5a. Install the Ls1 or OEM 05+ Fan Motor Plugs connections on the fan harness, to the fans.  Be sure to secure the wires using tie straps.(fig.6)

 5b.Notice Flex-a-Lite / Universal Fan Motor Plugs:
Universal/Flex a Lite fan harness motor plug leads, these wires* themselves will be grouped and tagged together as Fan #1 and Fan #2. Fan #1 will be the drivers side fan and fan #2 on the passenger side over the A/C condenser. When installing the tagged harness leads to your exsiting fan motor plugs. You must either solder them together and shrink wrap, or crip together using the supplied butt connectors and shrink wrap using the proper wire crimpers to crimp the leads. Tug them both to confirm they are tight. The integrity of these 4 connection(2 positive and 2 negative) will make or break the install of the harness.

 
*THESE ARE SPECIFICALLY ASSIGNED TO EACH FAN AND MUST BE INSTALLED ACCORDINGLY. FAILURE TO DO SO WILL RESULT IN HARNESS OPERATION FAILURE AND VOID YOUR WARRANTY

6. Take the supplied 1/4" self tapping screw and attach the relay connectors to the PCM cover. Be sure to clear the PCM when installing the screws, the upper right hand corner is usually the best spot just be sure they clear the PCM and NOT TO SCREW THEM IN TO TOUCH THE PCM .(fig.7)

     
Testing harness operation:

1. Start the truck.

2. Turn the AC on.  As soon as the A/C clutch engages, one fan will turn on high. If not, re trace your steps. If so go to step #3.

3.  Paying attention to the temp guage, when the engine coolant reaches the desired turn on value in the PCM set by the tuner that tuned the PCM, the other fan will turn on high and you will see 2 fans hi operation. If not retrace your steps, If so, got to step #4.

4.  Turn off the A/C. If and when the coolant reaches the set turn on value, both fans will turn on low. This is 2 fans low operation. If not retrace your steps, If so go to step #5.

5. Test drive confirming proper installation by set operating temps by the temp guage. If so, got to step #6.

6.   Enjoy your new much more quiet, smoother running, and more efficient running vehicle.