Beatrice Lang
Mounting an electric fan on a radiator is a process that requires careful attention to detail. The first step is to measure the radiator and choose a suitable electric fan that will fit. The fan should be secured to the radiator using mounting brackets, with some kits providing pre-assembled brackets and others requiring assembly. It is important to ensure that the fan is not mounted directly onto the radiator surface to avoid leaks, and custom brackets can be fabricated for a unique installation. The fan should be placed against the radiator, with fibre washers and cone-shaped springs used to secure the brackets in place. Additionally, the cooling system should be drained, and the thermal switch and wiring should be properly connected and tested.
Characteristics and Values Table for Mounting an Electric Fan on a Radiator
| Characteristics | Values |
|---|---|
| Fan size | Depends on the engine size |
| Mounting method | Using brackets, zip ties, bolts, washers, and nuts |
| Bracket type | Custom-made or provided with the fan |
| Fan assembly | May require assembling the fan, motor, and brackets |
| Fan position | Front or rear side of the radiator, may be offset |
| Installation ease | Varies; universal fit fans are usually easier to install |
| Connection | Electrical connection to the fan motor |
| Sensor | Thermal sensor to control fan operation |
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What You'll Learn
Attaching the fan to the radiator
If you prefer a custom appearance, you can fabricate your own brackets. This requires some basic metalworking skills and materials like angled aluminum or sheet metal. Cut the material to length along the top and bottom or sides of the fan. Ensure the brackets are sturdy enough to support the fan and withstand vibrations. Drill three to four holes along the sides of the custom brackets and use bolts or rivets to attach them to the fan shroud. Align the brackets with the radiator frame or core support, marking and drilling holes as needed.
Before proceeding, ensure that the fans spin freely by hand and that there are no hoses that could come into contact with the blades. Place the assembled fan against the radiator. Hold it in place and fit a fibre washer between one of the fan brackets and the radiator face. Install a cone-shaped spring onto a plastic mount, then pass it through the bracket, washer, and radiator fins. Repeat this process for the remaining brackets.
Fit fibre washers to the ends of all four plastic mounts protruding from the radiator, followed by sponge pads. Secure each mount with a plastic 'nut'. Tighten these nuts with an open-ended spanner while simultaneously pulling the mount through the radiator with pliers.
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Preparing the fan and radiator
Once you have your fan, you will need to prepare the radiator. This involves disconnecting the battery and removing the existing fan, if there is one. You should also drain the cooling system and remove the top hose at the radiator end. Check your fitting instructions to see whether you need to remove the radiator to fit the fan.
The next step is to prepare the fan for mounting. If your fan did not come with assembled mounting brackets, you will need to attach the brackets to the fan using the provided screws. If you want a custom appearance, you can make your own brackets, but this will require some metalworking skills. Cut a length of angled aluminium or sheet metal to size, ensuring it is thick enough to support the fan and withstand vibrations. Align the brackets to the fan housing and drill holes to attach the brackets with bolts or rivets.
Before mounting the fan to the radiator, check that the fan spins freely and that there are no hoses that could come into contact with the blades.
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Wiring the fan
Wiring an electric fan to a radiator requires careful attention to safety and technical details. Here is a step-by-step guide to help you through the process:
Firstly, it is important to disconnect the battery's negative terminal before beginning any electrical work on your vehicle. This is a critical safety precaution to avoid any accidental electrical shorts or damage to sensitive components. Ensure that the negative wire does not come into contact with the positive terminal or any metal surfaces during the process.
Next, you will need to determine the wiring configuration for your specific fan. Consult the manufacturer's wiring diagram to identify the correct wires and their purposes. This diagram will guide you in connecting the wires correctly to the corresponding components.
Now, let's get into the wiring process:
- Power Wire Installation: Feed a suitable gauge power wire (typically 10-12 gauge) through a hole in your firewall. This wire will connect your fan's power wire to the switch, allowing control of the fan from within the vehicle's cabin. Securely connect these wires using a butt connection and protect the joint with electrical tape. Ensure that the wire is safely secured within the engine bay using zip ties.
- Positive Battery Connection: Identify the positive wire from your electric fan, usually indicated by red colour coding. Connect this wire to the positive terminal of your battery or a fused link, ensuring that it receives constant 12-volt power. It is important to note that you should not connect the positive wire directly to the battery's positive terminal. Instead, use a circuit breaker or fuse to mitigate potential electrical issues.
- Negative Battery Connection: Locate the negative wire from the electric fan, typically black in colour. Connect this wire to the negative terminal of the battery or ground. Ensure that all connections are properly sealed with electrical tape or heat shrink sleeves to prevent short circuits.
- Temperature Control: If your electric fan setup includes a temperature-controlled sending unit or thermostatic switch, install it according to the manufacturer's instructions. This component will activate the fan when coolant temperatures reach a certain threshold and turn it off when temperatures drop below that point.
- Relay Connection: If your electric fan kit includes a relay, connect the corresponding wires. Typically, the relay's yellow wire connects to the positive wire on the electric fan, while the red wire from the relay connects to the battery or a fused link. The relay's black wire is spliced into the thermostatic switch or ground, and the white wire remains unused.
- Switch Connection: Connect the blue wire on the power link (middle link of the switch) to the main ignition wire of the vehicle, which is usually the large red wire connected to the ignition or the positive terminal of the battery.
- Final Checks: Once all the connections are made, carefully inspect your work. Ensure that all wires are securely connected, taped, and routed safely away from moving parts or high-temperature areas. Reattach the negative battery terminal and test the fan's operation by turning on the ignition and observing whether the fan functions as expected.
Remember, these steps provide a general guide, and the specific wiring process may vary depending on your vehicle's make and model, as well as the type of electric fan you are installing. Always refer to the manufacturer's instructions and diagrams for the most accurate and safe wiring procedure.
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Securing the fan
Firstly, it is important to determine the correct placement of the fan in relation to the radiator. The fan may need to be offset to clear any obstructions, such as a water pump, and in some cases, the radiator may need to be removed to fit the fan properly. Check the fitting instructions for your specific fan to ensure correct placement.
Once the fan is correctly positioned, it's time to attach the fan to the radiator. If using a kit, it should come with the necessary hardware, such as mounting brackets, screws, washers, and nuts. For universal fit fans, you may need to fabricate your own brackets, using angled aluminium or sheet metal, ensuring they are thick enough to support the fan and withstand vibrations. Drill holes and use bolts or rivets to attach the brackets to the fan shroud, and then align and attach the brackets to the radiator frame.
When using mounting brackets, place the assembled fan against the radiator and secure it with washers and nuts. Fibre washers and sponge pads can be used to provide a secure fit and protect the radiator and fan. Fit the washers and pads to the mounting brackets, and then tighten the plastic securing nuts with a spanner, pulling the mount through the radiator with pliers.
Another method of securing the fan involves using plastic mounting tabs and zip ties. Two sets of plastic mounting tabs can be attached to the top and bottom of the radiator, and then zip ties can be wrapped around the fan bracket and the tin straps of the radiator core to hold the fan in place. Ensure that the zip ties are tight and secure, and consider using heavier-duty zip ties for a stronger hold.
Finally, it is important to note that the fan should spin freely and not come into contact with any hoses or other components. Always double-check that the fan is securely mounted and that there are no obstructions before operating it.
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Testing the fan
Step 1: Check the Engine Temperature Gauge
Keep a close eye on the engine temperature gauge while driving. If the engine gets too hot, pull over and turn it off to let it cool down. This is important to prevent severe engine damage caused by a malfunctioning radiator fan.
Step 2: Turn On the Air Conditioning
One of the quickest ways to test the fan is to turn on the air conditioning. If your vehicle has two fans, both should operate as long as the AC is on. The main cooling fan is typically activated when the engine temperature exceeds a predetermined level, usually between 200 and 220 degrees Fahrenheit.
Step 3: Hotwire the Fan
If the fan doesn't operate with the AC on, you can hotwire it to test its functionality. Disconnect the electrical connector at the fan and use two jumper wires to jump the two terminals to the positive and negative terminals on the battery. If the fan runs, it is functioning properly.
Step 4: Check the Fuse and Relay
If the fan doesn't run with the jumper wires, the issue may lie with the fuse or relay. Check the fuse and engine cooling fan relay in the fuse/relay box. The location of these components may vary, so refer to the fuse box lid or your vehicle's owner's manual. A relay is a remotely controlled switch that should make an audible "click" when activated.
Step 5: Test Electrical Connectors
Inspect the electrical connectors for any signs of looseness or corrosion. Loose or corroded connectors can interfere with the fan's operation.
Step 6: Use a Multimeter (Advanced)
If you're comfortable with electrical testing, you can use a multimeter to test the radiator fan voltages. Locate the fuse boxes in your vehicle, which may include an under-dash and under-hood fuse box. Set your multimeter to Direct Current Voltage (DCV) as most cars have a 12V battery. Connect the black lead (negative) to an earth point, ensuring the engine is off but accessories are powered on.
Step 7: Observe Fan Activation
Start the engine and let it warm up. The radiator fan should activate once the engine temperature reaches the predetermined threshold. If the fan doesn't activate as expected, further troubleshooting or professional assistance may be required.
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