Molly Ayala
Converting a clutch fan to an electric fan is a popular modification for car enthusiasts. Electric fans are considered more efficient and energy-saving than clutch fans, which can limit the fan's speed and keep the engine cooler. This conversion can be done through a basic wiring/relay kit and an electric fan, or through a conversion kit from companies like Davies Craig, which offers Thermatic® Fans that can be mounted upstream or downstream of the radiator. However, some car owners have reported issues with electric fans, such as increased stress on the radiator and loud fan noise. Additionally, some have noted that the cooling system from the factory works perfectly and that the conversion may not offer any significant advantages.
| Characteristics | Values |
|---|---|
| Pros | Faster warm-up in winter, more effective in deep water crossings, increased MPG |
| Cons | May put stress on the radiator, plumbing and sensor, may cause inaccurate temperature gauge, reliability problems, loud fan noise, requires upgrade to alternator if you have a winch or lights |
| Parts required | Basic wiring/relay kit, Flex-a-Lite 180 fan, OEM thermal fan clutch, aftermarket thermal fan clutch |
| Tips | Measure radiator core area, width and height, ensure enough depth for fan, examine airflow (CFM) and maximum current draw, mount fan as close to hot water inlet as possible |
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What You'll Learn
Pros and cons of conversion
Converting a clutch fan to an electric fan has its pros and cons.
Pros
Firstly, an electric fan offers a more efficient, energy-saving alternative over a fan clutch or belt-driven mechanical fan. It releases parasitic power from the vehicle’s engine, which would otherwise be expended spinning a fan clutch or belt-driven mechanical fan. Electric fans are also lighter, which can improve fuel mileage.
Secondly, electric fans can improve cooling capability if sized correctly. They can be mounted offset from the radiator centre, and as close to the hot water inlet as possible, for maximum effect. Reversible electric fans can be mounted either upstream or downstream, for added flexibility.
Thirdly, electric fans allow you to hear the true engine noise, without the 'whomp, whomp, whomp' of the belt and fan.
Cons
Firstly, converting to an electric fan can put stress on the radiator, and plumbing the sensor and having an accurate temperature gauge can be challenging.
Secondly, electric fans can be noisy, and you may need to upgrade your alternator if you have a winch or lights. A good electric fan will pull 25-35 amps.
Thirdly, while an electric fan may improve cooling capability, it is not a simple swap, and you may need to adjust the fan engagement temperature.
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Engine swap considerations
Firstly, it is important to note that converting a clutch fan to an electric fan may not be a straightforward process. While some sources claim it is a simple swap, others have encountered challenges and issues with their engines overheating. It is also important to consider the specific make and model of your vehicle, as different engines may have unique requirements or complications.
One key consideration is the increased electrical demand that an electric fan will place on your system. Electric fans draw a significant amount of power, and this increased load on the electrical system may require an upgrade to your alternator. Ensuring a direct connection to the battery and using suitably thick conductors can help manage this increased demand.
The type of fan you choose is another important factor. Aftermarket, junkyard, and OE fans are all options, but you must ensure the fan is a “pusher” type designed to sit in front of the radiator. The size and mounting of the fan are critical, as there is limited space between the engine water pump pulley and the radiator. A heavy-duty fan with mounting brackets, such as the salvaged E21 320i auxiliary fan, could be a suitable choice.
Thermostatic control is essential for an electric fan. Commercially available electronic or electro-mechanical thermostats can be used, or you can design your own custom controller. The sensor location is critical, and it should be placed where the coolant is near the engine operating temperature, such as in the radiator's upper hose or on the coolant manifold. However, placing the sensor here means that the fan will either need to be triggered just before the engine overheats or will need to run almost constantly. A better location for the sensor is in the radiator tank, where the coolant exits the radiator, as this will allow more precise control of the fan activation temperature.
Finally, consider the potential benefits and drawbacks of the conversion. Electric fans offer advantages such as improved cooling at idle, increased power at high RPMs, quieter operation, and reduced stress on the engine. However, they may not provide more power overall and can be less reliable, especially in extreme conditions. Ensure you understand the specific advantages and disadvantages for your vehicle and usage patterns before proceeding with the conversion.
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Fan mounting for optimal performance
Fan mounting plays a crucial role in achieving optimal performance when converting a clutch fan to an electric fan. Here are some key considerations and instructions for effective fan mounting:
Choose the Right Fan Kit:
Firstly, select a suitable electric fan conversion kit that includes all the necessary components, such as a wiring/relay kit and an appropriate electric fan. Ensure the kit is compatible with your vehicle's make and model.
Measure Radiator Core Area:
Measure the width and height of your radiator core area, as well as the depth, which is the distance between the front of your engine block and the rear of the radiator. These dimensions will help you choose the right-sized electric fan for your vehicle.
Select the Largest Diameter Fan:
Opt for the largest diameter fan that can fit the core of your vehicle's radiator. A larger fan will provide stronger airflow than multiple smaller fans. Ensure the fan can be mounted securely and sturdily to the radiator.
Mounting Direction:
Electric fans can be mounted either upstream or downstream of the radiator. Upstream mounting, in front of the radiator, is a common approach. However, some fans can also be mounted downstream, behind the radiator, depending on the airflow and current specifications.
Engage at Optimal Temperature:
Adjust the Thermatic® Fan Switch or similar control mechanism to engage the electric fan at your engine's optimal thermostat temperature for maximum cooling effect. This will ensure the fan operates efficiently and effectively.
Consider Alternator Upgrade:
Keep in mind that an electric fan may draw more power from your alternator, so consider upgrading to a more powerful alternator if needed. This will prevent excessive stress on your electrical system.
By following these guidelines and selecting suitable components, you can achieve optimal performance from your electric fan conversion, improving engine cooling and overall vehicle reliability.
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Thermatic® Fan Switch control
Converting a clutch fan to an electric fan offers a more efficient, energy-saving alternative. Automotive belt-driven fan clutches are viscous or "fluid" coupling devices with a built-in thermostat coil spring that detects the air temperature passing through the radiator. This utilizes the clutch to engage and disengage the fan at a specified engine speed or temperature. However, the fan clutch also limits how fast the fan can rotate, and it never fully disengages, always spinning at about 30% of the water pump speed.
The Davies Craig Thermatic® Fan Switch is a digital fan switch kit that can be used with Thermatic® Fans, EWPs (Electric Water Pumps), and competitors' fans. The switch kit includes two sensors with various installation options for coolant temperature sensing. The first sensor, the Temperature Probe, senses air temperature as it passes through the radiator, with the sensor placed in the radiator fin section. Alternatively, the sensor can be placed directly into the coolant system in combination with a Temperature Sensor Adaptor Kit. The second sensor, the ⅛ NPT Thermal Sensor Kit, can be placed into the thermostat housing, engine block, or directly into the radiator. If installing this sensor in the top radiator hose, use the Temperature Sensor Adaptor Kit.
The Thermatic® Fan Switch can run one or two fans and can be used for 12 or 24-volt applications. It has an adjustable temperature range of 40ºC to 110ºC (104ºF to 230ºF), which can be displayed in Centigrade or Fahrenheit. Fan #1 will start once the temperature reaches the set temperature, and Fan #2 (if applicable) will start operating 10 seconds after Fan #1 starts. It is recommended to wire the switch directly to the ignition source for optimal results.
When converting to a Thermatic® Electric Fan, it is important to measure the radiator core area, width, and height. Ensure there is enough depth between the engine block and the rear of the radiator by checking the dimensions against the appropriate Davies Craig Thermatic® Fan. Thermatic® Fans are reversible and can be mounted upstream (in front of the radiator) or downstream (behind the radiator). Examine the airflow (CFM) and maximum current draw specifications, as a higher current rating indicates a more powerful fan.
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Conversion kits and parts
Some sources suggest that a basic wiring/relay kit from Amazon ($30-$40) combined with a Flex-a-Lite 180 fan will do the trick. Another suggestion is to get an eFan from a V6, which is said to be more of a plug-and-play option, requiring less rewiring.
For those with a Toyota Tundra, a TOYOTA V8 TUNDRA 00-06 FFD EXTREME TWIN ELECTRIC COOLING FAN KIT is available on eBay.
LMC also makes two types of kits for 1973-1987 GM trucks: one is a basic single fan design, while the other is a dual fan design.
For those with a 1993 Chevy K3500 with a 454 engine, a Flex-A-Lite direct-fit dual fan with a controller set up is an option that has performed well for some.
For Jeep Wrangler TJ owners, a SPAL 19" 850-watt electric brushless fan is an option, but it is said to be loud and may require an alternator upgrade.
Davies Craig offers Thermatic® Fans, which are said to be more energy-efficient and can be mounted upstream or downstream.
It is important to note that some sources argue against converting to an electric fan, stating that belt-driven fans keep the engine cooler and that electric fans can cause reliability issues.
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Frequently asked questions
An electric fan offers a more efficient, energy-saving alternative over a fan clutch or belt-driven mechanical fan.
Electric fans can be unreliable and more prone to breaking down. They can also be noisier and place additional stress on the radiator.
You can purchase a wiring/relay kit and an electric fan to install. You can also purchase conversion kits from companies such as Horton, the industry leader in electromagnetic fan clutches.
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