Trystan Casey
Electric fan relays are an essential component of any vehicle's cooling system, ensuring the engine maintains optimal temperatures. The process of wiring an electric fan relay involves several steps, including selecting a suitable location for the relay, away from excessive heat and moisture. The wiring process itself can vary depending on the type of electric fan cooling system and the specific relay kit used. Single and dual cooling fan systems are available, each with unique installation procedures. It is crucial to follow the manufacturer's wiring diagram and instructions for a safe and proper installation. This complex process requires careful attention to ensure the electric fan relay functions effectively to cool the radiator and engine.
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What You'll Learn
Where to place the relay
When placing the relay for an electric fan, it's important to choose a location that is away from excessive heat and not exposed to the elements, such as water splashing up from the road. This will help ensure the longevity and safe operation of the relay.
One recommended location is within the engine bay, where you can find an area that is largely free of significant moisture. This location provides easy access to the necessary wiring and connections. However, if you prefer a more discreet installation, you can choose to mount the relay within the inner fender well, which also offers protection from the elements.
It's important to note that you should avoid running a mechanical fan with an electric fan on the same side of the radiator. If you're replacing a mechanical fan, you can remove the fan spacer as well.
When it comes to wiring the relay, the positive wire (typically red) from the electric fan connects to the positive terminal on the relay, while the negative wire (typically black) needs to be grounded. The relay then draws power from the battery, and the ground wire from the relay is connected to the ground or "C" position on the switch, providing an ignition-controlled power source.
To ensure safety, it is recommended to run the constant 12-volt power through a circuit breaker or a fuse, rather than directly to the battery. This can be achieved by using a relay kit, which includes a circuit breaker or fuse to protect the circuit.
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How to connect the wires
To connect the wires of an electric fan, you will need to gather some tools and materials and follow a step-by-step process to ensure a secure and functional connection. Here is a detailed guide on how to proceed:
Firstly, you will need to gather the necessary tools and materials, including a wire stripper, screwdriver, electrical tape or heat shrink tubing, and of course, the electric fan relay kit. Ensure you have all these items at hand before beginning the process.
Now, let's begin the installation process:
Step 1: Start by locating the power source for your fan. Typically, this will be the battery or the fuse box. Identify a suitable location for the relay, preferably close to the battery to minimize voltage loss. Ensure that the relay is mounted securely and won't shift or vibrate during vehicle operation.
Step 2: With the relay securely mounted, it's time to connect the wires. You should have four wires to deal with: the power wire, ground wire, trigger wire, and output wire. Identify each wire by color or marking, as they should be clearly labeled.
Step 3: Connect the power wire (typically red) to the positive terminal of the battery or a suitable power source. Use an inline fuse holder with a 10-amp fuse to protect the circuit. This is an important safety measure to prevent short circuits and potential fires.
Step 4: Connect the ground wire (black) to a good metal ground. This can be a bolt on the vehicle's chassis or engine block. Ensure the connection is tight and secure to provide a proper grounding path.
Step 5: The trigger wire (usually blue or yellow) needs to be connected to a power source that is active when the ignition is turned on. This can be the ignition switch's power output or a keyed accessory wire. This ensures that the fan only operates when the ignition is on.
Step 6: Finally, connect the output wire (often green or purple) to the electric fan. This wire will provide power to the fan when the relay is triggered. Ensure that the connection is secure and that the wire is properly insulated.
Step 7: With all the wires connected, it's important to double-check your work. Ensure that all connections are tight and secure, and that there are no exposed wires that could short-circuit. Use electrical tape or heat shrink tubing to insulate any exposed wire connections.
Always refer to the manufacturer's instructions for your specific electric fan and relay kit, as there may be slight variations in the installation process. This guide provides a general framework, but specific models may have unique requirements.
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How to control the fan
To control an electric fan, you can wire it with a relay kit that is temperature-controlled. This is a more effective method than simply wiring the electric fan to run all the time. Firstly, you must install a temperature-controlled sending unit in one of the cooling passage ports on your intake manifold, using a high-temperature thread sealant to prevent leaks. The sending unit has two male spade connectors, one of which connects to the black wire on the relay, and the other to a ground.
The positive wire from the electric fan will connect to one of the two red wires on the relay, while the negative wire goes to the ground. The relay should be placed in an area that is largely free of significant moisture within the engine bay, or within the inner fender well if you want to hide the wiring.
The orange wire on the relay should see a 12-volt signal when the ignition switch is turned on. The yellow wire on the relay connects to the battery, along with a supplied fuse mounted within 12 inches of the battery. The fan relay #30 should be connected to the battery through a fuse, rather than through the ignition, to ensure the fan receives the power it requires without affecting ignition.
To turn the fan on at any time, you can connect 85 to 30. If you want manual control, you must first determine what kind of control you want, as this will determine the wiring.
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Avoiding common issues
To avoid common issues when hooking up an electric fan relay, there are several key considerations to keep in mind. Firstly, it is important to never run a mechanical fan and an electric fan on the same side of the radiator. This is due to space constraints and potential interference between the two fans.
Another critical factor is the location of the relay. Ensure that the relay is installed away from excessive heat and is not exposed to the elements, such as water splashing up from the road. This helps prevent damage to the relay and ensures its optimal performance.
When wiring the electric fan relay, it is recommended to use a proper crimp connector and follow the instructions provided by the manufacturer for a trouble-free installation. Additionally, pay attention to the wiring colours and their respective connections. For example, the red wire from the relay typically connects to the cooling fan, while the black wire from the fan connects to the ground.
It is also important to consider the amperage and voltage requirements of the fan. If the fan draws more than 15 amps, it is advisable to install a second relay kit. Additionally, ensure that there is a fuse as close as possible to the power source to prevent the potential risk of fire.
Finally, be cautious when dealing with a faulty cooling fan relay. A stuck closed relay or an electrical open circuit in the relay coil can cause issues with the fan's operation. Regularly check for faults and address them promptly to ensure the fan's optimal performance.
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Using a dual-activation fan relay
Understanding the Basics
Firstly, it's important to understand the purpose and functionality of a dual-activation fan relay. This setup allows you to control your electric cooling fans using two activation methods: a thermostatic switch and an A/C trigger. The thermostatic switch is mounted in the engine head and is set to a preset temperature. When the engine reaches this temperature, the cooling fan turns on to help regulate the engine temperature. Additionally, the A/C trigger allows the cooling fan to turn on when the air conditioning is activated, ensuring the system has the necessary cooling support.
Selecting the Right Kit
You'll need a dual fan-dual activation fan relay kit for this installation. Make sure to purchase a kit that includes all the necessary components, such as relays with mounting bases, a fuse with a fuse holder, a wire harness, and a thermostatic switch. Some kits, like the Painless Performance Dual Activation Electric Fan Relay Kit, come with detailed instructions and are designed for easy installation.
Installation Process
Now, let's get into the installation process:
- Find a Suitable Location for the Relay: It's important to mount the relay away from excessive heat and protect it from the elements, such as water.
- Connect the Temperature Sender: The temperature sender provides a ground signal at a specific temperature, triggering the relay. This is typically connected using a gray wire.
- Connect the Ignition Source: The orange wire on the relay should connect to your 12-volt ignition source. This ensures that the relay receives power when the ignition switch is turned on.
- Wire the Cooling Fans: The red wire from the relay connects to the cooling fan, and the black wire from the fan connects to the ground. Ensure you use a proper crimp connector for a secure connection.
- Fuse and Circuit Protection: Install the provided fuse within 12 inches of the battery. Additionally, ensure you have adequate circuit protection, typically around 30 amps, to safeguard the electrical system.
- Test and Adjust: Once the installation is complete, test the setup by running your engine and observing if the cooling fans activate at the preset temperature or when the A/C is turned on. Fine-tune any adjustments as needed.
Additional Considerations
- If you have dual cooling fans, consider their draw when wiring the relay. For larger fans with a higher amp draw, you may need to install a separate relay for each fan.
- Always follow the specific instructions provided with your relay kit, as wiring diagrams and connections may vary slightly between different kits.
- Ensure you have the necessary tools and safety equipment before beginning the installation process.
By following these steps and instructions, you'll be able to successfully install and use a dual-activation fan relay, keeping your engine cool and maintaining its performance.
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Frequently asked questions
A cooling fan relay controls when the electric radiator cooling fan turns on and off based on temperature information from your car's electronic control module or a thermostatically controlled sensor.
First, determine where you want to locate the relay, keeping the wires as short as possible. Second, connect a 12-volt power wire to the starter solenoid main post, then run the wire to relay terminal 30. Use a 10-12 gauge wire and add a fuse if desired. Third, connect the positive wire from the fan to one of the two red wires on the relay, and connect the negative wire to ground.
First, remove your car's mechanical fan and mount the dual electric fans onto your radiator. Second, install the activation fan relay kit in a heat- and moisture-free location. Third, install a 30-amp fuse on both wire 30s of the dual activation fan relay and splice them to a single wire before connecting to the battery. Fourth, splice both wires 85 from the dual activation relay and join them to a single conductor that connects to the thermostatic switch. Ensure a ground connection from both fans.
Avoid running a mechanical fan with an electric fan on the same side of the radiator. Do not run power for the fans through a switch under the dash, as this can burn up the switch and is unsafe. Do not run the positive wire from the relay directly to the positive terminal on the battery.
