3. Remove the fan shroud and fan. Repositioning the air cleaner, are for
the 5.4L engine only. Refer to fig. 8. If you have the 6.8L engine, discard
the DewEze air cleaner bracket (21).
4. Remove the air filter housing by releasing the large toggle clamp and
pulling the front filter housing up and to the rear. Tie the rear of the
housing and inlet tube to the rear of the engine compartment to keep it
out of the way.
5. Remove the rubber donuts from the OEM air cleaner support and place
them in the holes in the DewEze air cleaner bracket (21). Hold this
bracket on top of the OEM support placing the small holes in the DewEze
bracket in between the large holes in the OEM support. Run the 3/16 x
3/4 self-tapping screws (22) through the small holes into the OEM
support.
6. Remove OEM bolts from engine at locations A, B, and C. Lay the wiring
off to the side.
7. Remove the wiring harness from the attachment points on the valve
cover at the front corner and the stud bolt under the air tube. Push the
wiring harness back on top of the valve cover to clear the pump and
bracket.
8. Mount the crank pulley (16) to the damper using three M10 x 60 bolts
(17), 10mm lock washers (18), and 3/8 flat washers (19).
9. Bolt the pump (6) to the rear of the mounting bracket (1) using two 3/8 x 1
1/4 bolts (13) and two 3/8 flat washers (14). Attach the clutch coil (7) to
the front of the bracket using four flange bolts supplied with the clutch.
Insert the coil wire through the ½” hole right above the coil to keep it from
contacting the clutch pulley.
10.
Attach the flat idler pulley (3) to the tensioner arm (2) with the 7/16 x 1
3/16 flange bolt (10). Mount the tensioner assembly on the pump bracket
at location E with one ½ x 3 ½ bolt (12), inserting the bolt head on the
back of the tensioner into the small hole on the tensioner mounting pad.
11.
Insert an M10 x 60 bolt (11) through an idler bushing (15) and into a
serpentine idler also. Mount one idler onto the boss at location D and the
other idler on the boss at location G.
12.
Mount the pump bracket onto the engine at locations A, B, and C with the
three M10 x 110 bolts (8) with 3/8 flat washers (14). Torque these bolts
to 30-41 ft/lbs.
13.
Bolt the wiring harness holder to the back of the pump bracket at location
F using a 5/16 x 3/4 bolt (9).
14.
Mount the clutch pulley (7) onto the pump shaft using the bolt and washer
supplied with the clutch.
CHAPTER 2 MAINTENANCE
SEPTEMBER 30, 2008
3 REMOVAL AND INSTALLATION
PAGE 21
Truck Mounted Passenger Stair TMPS-200
Manual No. 307559
