3. Remove the OEM intercooler tube.
4. Unbolt the electrical module (14) from its mounting bracket on the
passenger side valve cover. Keep it plugged in and just move it out of
the way for now. Unbolt the mounting bracket. It will not be needed
again. See figure 6.
5. Remove the OEM belt. The tensioner has a spring to lock it open without
any tension. Remove two bolts mounting the tensioner. Just let it lay
against the shroud to allow room to mount the pump bracket.
6. Loosen the battery hold down clamps and slide the battery out toward the
fender. Tighten the hold down clamps. Tie the air conditioner line to the
positive battery cable running down the rear of the battery. See figure 7.
7. Slip the small hose insulation sheath (15) over the pressure hose. Slip
the large hose insulation sheath (16) over the suction hose. Place the
sheaths where the hoses run close to the exhaust to protect the hoses
from the heat. Route the hoses back to the firewall and down running
them outside the frame.
8. Mount pump (4) onto bracket (1) with the two 3/8 x 1 1/4 bolts (9) with
two 3/8 flat washers (10). Install the adapter into the inlet and outlet ports
in back of the pump. Connect the hoses to the pump. Mount the bracket
onto the engine with the four M10 x 45 bolts (7). Reattach OEM
tensioner with the OEM bolts.
9. Mount the DewEze electrical module bracket (2) onto the front of the
pump bracket at location G with the two 1/4 x 3/4 bolts (11). Attach the
electrical module (14) to its bracket with two 1/4 x 1 bolts (12) and two 1/4
nuts.(13)
10.
Mount the 3” diameter slotted-face idler pulley (6) to the boss on the
pump bracket at location F with an M10 x 40 Torx head shoulder bolt (8).
Mount the 2.50” diameter smooth-faced idler (18) to the boss at location
E with an M10 x 40 Torx head shoulder bolt.(8)
11.
Mount the clutch coil (5a) to the pump bracket with four 1/4 x ½ flange
bolts (5b). Mount the clutch pulley (5c) to the pump shaft with the 5/16 x
1 1/4 bolt (5d) and heavy flat washer (5e) making sure the key is in place
on the shaft.
12.
Install the belt as (19) shown in the diagram (Fig. 7). Release the lock on
the tensioner to tighten the belt.
13.
Slit the 4” long hose (17) lengthwise in one wall if it is not already slit.
Slip the hose over the top of the pump bracket. Install the DewEze
intercooler tube (3) into the same location as the OEM tube was. It may
be necessary to loosen the hose clamp on the rubber elbow on the turbo
(location H) so the elbow can be rotated to line up with the intercooler
tube. Secure the tube with the OEM hose clamps.
Truck Mounted Passenger Stair TMPS-200
Manual No. 307559
CHAPTER 2 MAINTENANCE
SEPTEMBER 30, 2008
3 REMOVAL AND INSTALLATION
PAGE 17
