Beatrice Lang
Electric fan relays are an important component of a car's cooling system, controlling when the electric radiator cooling fan turns on and off based on temperature readings. Wiring an electric fan with a relay involves connecting the positive and negative wires from the fan to the relay, and then connecting the relay to the car's electrical system. This process can vary depending on the type of electric fan cooling system, with single and dual cooling fans requiring different wiring setups. Additionally, it's important to consider the location of the relay, ensuring it is away from excessive heat and moisture to prevent damage and maintain functionality.
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What You'll Learn
Where to place the relay
When deciding where to place the relay, it is important to consider the function of the relay and the environment in which it will operate. The relay should be placed in an area that is away from excessive heat and is not exposed to the elements, such as water splashing up from the road. It should also be placed in an area that is largely free of significant moisture within the engine bay.
One option for placing the relay is to mount it within the inner fender well, which can help to hide the wiring. This location can provide easy access for maintenance and repairs. It is also important to consider the orientation of the relay, ensuring that the wires are routed in a way that minimizes their exposure to heat and moisture.
Another factor to consider when placing the relay is the length of the wires and the ease of connection to the other components in the system. The relay should be placed in a location that allows for neat and efficient routing of the wires, minimizing the risk of damage or short circuits. The wires should be secured and protected to prevent chafing and insulation faults.
Additionally, the relay should be placed in an area that provides adequate ventilation to ensure proper cooling of the relay and surrounding components. This can help to extend the lifespan of the relay and prevent overheating. It is also important to ensure that the relay is easily accessible for future maintenance, repairs, or upgrades.
Overall, the placement of the relay should take into account the specific characteristics of the vehicle, the environment in which it will operate, and the functionality of the relay itself. By considering these factors, you can ensure that the relay is placed in an optimal location that balances performance, durability, and ease of maintenance.
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Connecting the wires
The exact wiring setup will depend on the make and model of your car, as well as the type of electric fan cooling system you are using. It is recommended to consult the manufacturer's supplied wiring diagram for specific instructions.
However, as a general guide, the following steps can be taken to connect the wires when installing an electric fan relay:
Firstly, determine a suitable location for the relay, ensuring it is away from excessive heat and moisture. Keep the wires as short as possible.
Next, connect the wires according to the wiring diagram. The positive wire from the electric fan will connect to the red wire on the relay, while the negative wire will need to be grounded. The ground wire from the relay should be connected to the ""C" position on the switch, providing an ignition-controlled power source.
For dual cooling fans, there are two methods for wiring the relay kit. This depends on the draw of the fans. If the fans are larger and draw more than 15 amps each, a second relay kit is recommended. For smaller fans, both fans can be connected to a single relay, and a proper fuse should be installed to protect the circuit.
When connecting the wires, it is important to use proper crimp connectors and follow the directions provided in the instructions for a trouble-free installation. Additionally, ensure that all connections are correct and secure, and double-check your wiring before attaching the relay.
Finally, test the setup by allowing the car to warm up to temperature. Once the fan kicks on, you should be able to feel if it is pulling air from the front of the car. If not, turn off the car, swap the wires, and try again.
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Using a fuse
Fuses are an essential component when wiring an electric fan relay to ensure the system functions effectively and safely. The wiring process for an electric fan relay involves connecting the relay to the fan, power source, and various sensors or switches, and fuses play a critical role in protecting the circuit.
When wiring an electric fan relay, it is important to use the correct type and size of fuse. The fuse should be installed close to the power source, typically the battery, to protect the circuit. For dual cooling fans, a higher amperage fuse may be required, such as a 30-amp fuse for each relay connection to the battery. This ensures that the fuse can handle the current draw from both fans without blowing.
In some cases, it is recommended to connect the fan relay to the battery through a fuse rather than the ignition. This is because some fans may draw more power than the ignition circuit can supply, and wiring it directly to the battery ensures the fan receives the required power without affecting ignition. It is also important to ensure that battery power is isolated from ignition power to prevent issues with the car's electrical system.
The specific wiring configuration may vary depending on the make and model of the vehicle, as well as the type of relay and temperature sensors or switches being used. It is important to consult the manufacturer's wiring diagram or seek guidance from a professional if you are unsure about the wiring process.
When using a fuse in an electric fan relay system, it is crucial to select the appropriate wire gauge that can handle the current draw of the fan. This ensures that the wire can safely carry the electrical load and prevents overheating or damage to the system. Proper wire sizing, along with the use of fuses, helps protect the circuit and ensures the safe operation of the electric fan relay.
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Grounding the wires
Firstly, identify the ground wire in your wiring setup. The ground wire is typically black and connects to the negative terminal of the power source. This wire should be connected to a clean and corrosion-free grounding location on your vehicle's chassis or engine block. This location should provide a good electrical connection to the vehicle's ground. If the grounding location has a protective coating, it is recommended to use a star washer to ensure a better connection.
For electric fan relays, the ground wire plays a crucial role in the circuit. It provides a return path for the electrical current, completing the circuit and allowing the fan to operate. A proper ground connection ensures that the electric fan relay functions efficiently and safely.
In some cases, you may need to extend the ground wire to reach the grounding location. It is important to use a wire of the same gauge and type as the original ground wire. Ensure that all connections are soldered and insulated with heat-shrink tubing or electrical tape to prevent short circuits.
When grounding the wires, it is important to consider the location of the relay. The relay should be placed in a dry and protected area, away from excessive heat and moisture. This will help prevent any potential damage to the relay and ensure the longevity of the wiring setup.
Additionally, it is recommended to use a relay kit that includes a fuse. This adds an extra layer of protection to the circuit. The fuse should be installed close to the power source, typically within 12 inches of the battery, to protect the wiring and prevent excessive current flow in case of a short circuit.
By following these instructions and paying close attention to the wiring diagram provided with your electric fan relay kit, you can ensure that the ground wires are properly connected and the electric fan operates safely and effectively.
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Troubleshooting
One issue that can occur is that the electric fan continues to run even after the ignition is turned off. This could be due to a blockage within the fan relay system, causing the switch to malfunction. To fix this, check for any blockages or damage to the wiring and ensure that the relay is installed in a location away from excessive heat and moisture, as this can compromise the system's functionality.
Another issue could be that the fan is not turning on when the key is on. This could be due to the engine having cooled down sufficiently, causing the thermostat to turn off the fan. Adjusting the thermostat settings can help ensure the fan turns on when desired. Additionally, check the wiring, especially the ground wire, to ensure it is connected correctly and is not damaged.
If you have a dual-fan setup, you may need to install a second relay kit if the fans draw more than 15 amps each. This will ensure the system has enough power and protect the circuit.
For those who have previously used a switch under the dash to control the fan, it is recommended to move away from this method. This is because the switch may not be able to handle the current required to power the fan, which can lead to various issues and is not electrically safe.
Finally, ensure that the temperature settings for the fan to turn on and off are appropriate for your needs. For example, if you have air conditioning, you may want the fan to turn on when the AC clutch is engaged, regardless of the motor temperature. Adjusting these settings can help ensure the fan operates when desired.
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Frequently asked questions
The exact steps depend on the make and model of your car, but here is a general overview:
- Find a suitable location for the relay that is away from excessive heat and moisture.
- Connect the wires as per the wiring diagram. For example, wire 30 only connects to the fan's positive terminal.
- Ensure that you have a ground connection from the fan.
- If all connections are correct, your engine should receive sufficient airflow to cool it.
Here are some common mistakes to avoid:
- Running a mechanical fan with an electrical fan on the same side of the radiator.
- Not following the manufacturer's wiring diagram.
- Running power for the fans through the switch, which can burn up the switch.
Once you've completed all the wiring, let the car warm up to temperature. Once the fan kicks in, you should be able to feel if it is pulling air from the front of the car. If it's not, turn the car off, swap the two wires, and try again.
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