Installing a ResistorPac

Installing a ResistorPac^™

ResistorPacs are made with different resistance values, depending on the requirements of the particular engine type and the desired increase in fan-on temperature.  A ResistorPac is connected in series with the coolant temperature sensor after Evans waterless coolant has been installed.  The connections must be secure, soldered and inspected to assure good conductivity and the connections must be protected with shrink-wrap tubing.  The following describes the recommended installation procedure:

A ResistorPac for elevating the fan-on temperature.

A.  Required parts and tools

1. A ResistorPac™ of the appropriate value available from Evans Cooling Systems.
2. Wire cutting pliers ("dykes").
3. Combination wire stripper and crimper that can crimp un-insulated butt connectors (e.g NAPA No. 726600).
4. Klenk DA76070 Cutter/Stripper 5".  Required for careful stripping of insulation from coolant temperature sensor (CTS) wires in crowded locations. Available from various sources incl. www.action-electronics.com .
5. Un-insulated butt connectors for #18-22 wire available from various sources incl. Allied Electronics www.alliedelec.com.   (Allied Stock No. 617-0156)
6. Small soldering iron (not a soldering gun).  Required for good solder flow into the butt connectors.
7. Solder, rosin core, .062 dia. (e.g. Radio Shack #64-007)
8. Soldering paste flux.
9. Shrink tubing 3/16" dia.
10. Heat gun for the shrink tubing.
11. Zip ties.

B.  Making the connections

1. Locate the coolant temperature sensor (CTS).  It should be a simple two-wire device.  If it is a three-wire device, do not proceed.

A Mack coolant temperature sensor (CTS) showing its two wires.

2. Cut just one of the CTS wires (either one) in the center of its exposed position.  Do not cut the other wire.  You will now have two wire ends for attachment.

3. Using the Klenk cutter/stripper, remove 5/16 inch of insulation from each of the two ends.  (Practice on non-critical wires before doing this.)

 

Using the Klenk DA76070 Cutter/Stripper

4. Find an appropriate location for the ResistorPac and cut the wires to the appropriate length for connection to the wire ends of the coolant temperature sensor.

5. Using a wire stripper appropriate for #18 wire and remove 5/16 inch of insulation from each of the two ResistorPac wires. 

 

The wires are Teflon coated, and the insulation is strongly attached and slippery.

6. Mount the ResistorPac using zip-ties.

7. Prepare two 1 1/2 inch lengths of shrink tubing.  Run them up the wires of the Resistor Pac as far as you can and tape them there. 

 

Keep the shrink tubing a safe distance from the soldering heat.

8. Press soldering flux into the ends of two un-insulated butt connectors made for #18 - 22 wire.

 

 

9. Crimp one end of each butt connector to each of the two #18 ResistorPac wires, leaving 1/16 inch of wire showing (for inspection).  Don't solder yet.

 

Left: Use the crimper made for non-insulated connectors. Right: Leave some wire showing for inspection.

10 The wires at the sensor end are often much thinner than #18 and an ordinary crimper can't squeeze enough for a good mechanical connection.  Use the special crimper.  Leave 1/16 inch of wire extending past the connector (for inspection).

 

 

11. Solder the wires in each of the two butt connectors.

 

Get the connectors hot enough for good solder flow.

12. Inspect the soldered joints.

 

To pass inspection, the solder must be seen to have flowed between the connector and both wires.

 

13. Move the shrink tubing over the connections and apply heat with a heat gun.

 

 

14. Use zip ties to make the installation neat.