Disconnect the battery while you install this kit. Remove the two intake air ducts. See Picture BDFK1. Remove two 10mm bolts at the top of the radiator, and lift off the upper radiator fan shroud. See Picture BDFK2.
Loosen and remove the Power Steering Belt. Two 13mm bolts and loosen the nut on the threaded adjuster if you have one. See Picture BDFK3. Loosen and remove the Air Pump/Fan belt. Two 13mm bolts, and loosen the nut on the threaded adjuster if you have one. See Picture BDFK4.
Remove three 13mm bolts that hold the Fan Assembly to the front of the engine, and lift out the fan assembly. See Picture BDFK5. Remove the two 6mm Allen bolts from the upper radiator mounts as shown in Picture BDFK7. This will allow the radiator to pivot on the lower mount a little bit. The radiator does not have to come out.
INSTALLING THE NEW FAN Note there are 4 mounting holes at the base of your new fan shroud. In the bag with your fan mounts, locate the neoprene foam squares. Place one square of neoprene foam anti-vibration material over each hole in the fan shroud, so that the foam will be trapped between the fan and the radiator when the radiator is mounted. Peel off the cover to expose the sticky surface. Be sure to line up the holes. Position the fan behind the radiator. It fits inside the lower shroud for the 928, and right up against the radiator core. There is a flat spot in the shroud that should be placed on top as shown.
Now attach the fan to the radiator. The fan mounts are installed from the engineside of the fan pointing forward to the front. Push a fan mount through the hole in the radiator shroud, through the foam square you previously placed, through the radiator, and secure on the other side with the clip on fastener. Cut off the extra so it does no interfere with the air conditioning core when we stand the radiator back up. INSTALLING THE TEMP SENSOR/FAN SWITCH Place the billet temp sender over the upper radiator hose and mark where you are going to cut it. See Picture BDFK12.
Jack up the car at the right front jacking point. This will make the upper radiator hose the high point in your cooling system and you will loose very little coolant when you cut the hose. Cut the upper radiator hose where you marked it - removing an amount equal in width to the center section of the billet temp sender unit. Slide the two hose clamps provided with the kit onto the hose, and insert the billet temp sender unit. Tighten the clamps. See Picture BDFK13. NOTE: Rubber hoses stretch with age, temperature, and pressure. If your upper radiator hose is a lot wider than our billet temp sender unit, it means it has weakened and stretched out. It needs to be replaced. If you notice this call us at 928 Motorsports, we keep this hose in stock just for this occurrence. Remove the plastic cover (s) from the forward battery post. See Picture BDFK13. Open about 2 inches of the wire loom as shown in Picture BDFK14.
Now we will install the fan relay and wiring harness supplied. The instructions on the following pages refer to this Picture and the notations below R = Relay SP = Switched Power TS = Temp Switch P = Power G= Ground Wires (2) FC = Fan Connector FH = Fuse Holder
Find the Red wire with a White stripe and place the blue electrical tap over it. Squeeze it shut with a pliers as shown to complete the connection. Insert a 12v test lamp into the end of the blue electrical tap you just installed and test it. It should have power when the ignition is ON, and no power when the ignition is OFF. Plug the White wire referred to as SP into the wire tap as shown in BDFK 16
Find the 2 black wires (G) with ring terminals on the end of them and place under the grounding bolt As shown in BDFK17. You may also use one of the headlamp adjustment nuts located in that vicinity To mount your ground wires. Confirm that the battery is still disconnected before this step. Then unthread the brass battery post as shown in BDFK 18 and place the red wire (P) under it. Re-install the brass battery post.
Confirm that there is a 25 amp fuse in the fuse holder FS. Form the wiring harness so that it lies down neatly next to the OEM wires and hold it in place with the small black cable ties provided. It is not necessary to mount the Relay. Re-install the plastic cover over the battery post area, if any. Plug the Fan Connector (FC) into the matching receptacle on the fan. Connect the two remaining bullet connectors to the Temp Switch TS as shown. They can connect to either post, in any order.
Tie the electrical wiring down with more of the small cable ties provided as in BFK21. Install the air pump belt provided with the kit and tighten. Put the two 6mm bolts back into the upper radiator mounts and tighten them down. Re-install the upper radiator shroud, taking care not to snag or cut the electric fan wiring you just installed. Top-off your radiator coolant to replace whatever dropped when you cut your hose, and re-connect your battery.
The finished installation should look like the picture below. TESTING THE INSTALL: Start your engine and check for leaks. Add radiator fluid to the coolant reservoir to replace any that may have come out when you cut the upper radiator hose. The new electric fan will not come on right away. It only comes on at 185 degrees F, and shuts off at temps below that also. The water enters the radiator through the upper radiator hose, so the temp sensor you have installed will be the first thing to notice the temperature rising. The new electric fan will come on only after the engine warms up. This may take several minutes at idle, or take the car for a short drive to warm it up faster. Call 920-485-0488 if you have any questions!