DewEze Clutch Pump Kit Dodge 6.7L, 2011+, AA Pump INSTALLATION INSTRUCTIONS

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5 DewEze Clutch Pump Kit Dodge 6.7L, 2011+, AA Pump INSTALLATION INSTRUCTIONS Record Pump Model No. and Serial No. for future reference. 1. The installation of this kit requires trained decisionmaking concerning clearances, tying components together, rerouting, or relocating OEM components, etc. It is impossible to describe all of the clearance and vibration points, etc. in the installation instructions. Therefore, the technician must exercise professional judgment to achieve the best quality installation. 2. Disconnect the battery. 3. Remove the left and right fan shroud mounting nuts. Fig. 4, Disconnect wiring plug-ins from air box. Remove air box. Fig Gently bend the steel hose ends slightly if needed to keep the hoses away. 6. Remove the OEM belt. Remove the fan shroud support bracket (13). 7. Remove the OEM grooved idler pulley (15) from the front of the engine at Location C. In its place, mount the DewEze grooved idler pulley (7) with the OEM idler bushing (2) and OEM bolt (18). 8. Install DewEze belt (27) on the OEM pulleys. It is easier to access the pulleys when the shroud can be pulled away and before the pump is installed. 9. Disconnect the ground wire attached to outside of battery post clamp on right side battery and reroute on top of existing truck hoses so pump hoses will go under wire. Reconnect. Fig Hold pump (7) onto back of pump plate (5) and clutch hub (8i) onto front of bracket, making sure anti-rotation pin (P) on front of hub is on top. Place two 3/8 x 1 1/4 socket head bolts (24) and 3/8 high collar lock washers (26) through pump, through mounting plate and thread into hub. Torque to 20 lb-ft. Left and right directions are standing in front of the truck looking at the engine. 11. Slide coil (9a) over hub, aligning hole in the back plate of coil with the anti-rotation pin in the hub. The wires from the coil should be on the same side as the pin. 12. Install large snap ring (9b) to hold coil in place. NOTE: THE BEVEL ON BOTH SNAP RINGS MUST FACE AWAY FROM THE PUMP. REFER TO INSTRUCTION SHEET FOR THE CLUTCH FOR CORRECT INSTALLATION OF SNAP RINGS. 13. Slide clutch pulley (9c) onto hub. Install small snap ring (9d) to hold pulley in place. 14. Place the key onto the pump shaft. Slide the hub/armature (9f) onto the pump shaft aligning the keyways. NOTE: SET THE AIR GAP BETWEEN THE HUB/ARMATURE AND THE PULLEY USING SHIMS (9e) ACCORDING TO INSTRUCTION SHEET FOR CLUTCH. 15. Run the hoses into the engine compartment. Pull them out far enough to attach them to the pump. Attach the top of the pump bracket (1) to the engine at Location A using two M10 x 40 bolts (14). Attach the bottom of the pump bracket to the power steering bracket at Location B with the 3/8 x 2 bolt (19), and the 3/8 lock washer (17) and 3/8 nut (25) on the back. 16. Finish installing the belt (27) onto the pump pulley as shown in the diagram (Fig. 1). 17. Install air box. Install intercooler cover. Connect battery. 18. Run the engine and check for any clearance or alignment problems. Re-examine the power steering lines for clearance as the engine torques. Adjust as needed. 1

6 Installing the Warner AA clutch Hub, Coil and Rotor/Pulley are preassembled by Warner. Armature is shipped loose along with Hardware Kit (consisting of center bolt, washer and shims) Step 1: Slide the Hub/Coil/Rotor/Pulley Assembly onto the pump shaft and secure to pump face using pump manufacturer supplied bolts through the two bolt holes. Step 2: Place two shims onto pump shaft on top of rotor face. Slide armature onto shaft and measure air gap between the Armature and Rotor. Repeat this step and add shims as needed (more or less than 2) to acquire air gap between the rotor and armature. Check air gap at 3 locations apart. Step 3: Fasten center bolt and washer to face of pump shaft and tighten to 25 ft. lbs. torque. Failing to set the air gap correctly will cause premature pump failure due to axial load placed on the pump shaft.

7 Installing the Ogura AA clutch Hub, Coil and Rotor/Pulley are preassembled by Ogura. Armature is shipped loose along with Hardware Kit (consisting of center bolt, washer and shims) Step 1: Slide the Hub/Coil/Rotor/Pulley Assembly onto the pump shaft and secure to pump face using pump manufacturer supplied bolts through the two bolt holes. Step 2: Place two shims onto pump shaft on top of rotor face. Slide armature onto shaft and measure air gap between the Armature and Rotor. Repeat this step and add shims as needed (more or less than 2) to acquire 0.3 to 0.6mm (.011 to.023 ) air gap between the rotor and armature. Check air gap at 3 locations apart. Step 3: Fasten center bolt and washer to face of pump shaft and tighten to 25 ft. lbs. torque. Failing to set the air gap correctly will cause premature pump failure due to axial load placed on the pump shaft.