Electric fan conversion

[saar]

I decided to take a chance and replace my fan clutch with an electric fan.
The electric fan has few advantages over the fan clutch, it saves fuel, reduces engine's overload and some would say they feel an increase in the power (I don't) but the most important thing is that is should work well on low speed/rpm = my kind of trips.

I used a Ford Taurus 16" electric fan which I bought with its shroud.
That fan is much bigger than the original 15" fan and its shroud is pretty huge, so most of the job here is fitting it. I choose that one since its spec is pretty impressive, it is rated as a 3000 cfm in low speed and 4500 cfm on its high speed, that is much better than the original mechanical fan!

1. Disconnect and remove the battery.
2. Remove the A/C electric fan.
3. Disconnect the radiator and remove it. Pay attention to the transmission hoses, you will need a "fuel line quick disconnect kit" use the 3/8" one.
4. Remove the fan clutch and the mechanic fan:

http://www.jeepsallover.com/attachment.php?attachmentid=69&d=1368005284

5. Remove the engine belt. Do that by releasing the tension pulley (under the power steering pulley)

6. Remove the A/C compressor (you will need to change its mount later)
7. Remove the A/C compressor mount:
http://www.jeepsallover.com/attachment.php?attachmentid=66&d=1368005090

http://www.jeepsallover.com/attachment.php?attachmentid=67&d=1368005120

Pay attention to the screw that is right above the alternator.

There is no room for the mechanic fan pulley so it has to be removed. I wanted to keep my mount in its original shape so I used an hydraulic press to remove the mechanical fan pivot. You may remove it that way or use a saw to remove it.
The final result should be like that:

http://www.jeepsallover.com/attachment.php?attachmentid=70&d=1368005488

Now you can put the A/C mount and compressor back in place.

8. Fitting the electric fan, I installed it vertically, so there is enough room for the original A/C e-fan., you will have to cut some parts of the shroud so it will fit, final result looks like:

http://www.jeepsallover.com/attachment.php?attachmentid=71&d=1368006215

I added a fiberglass part at the bottom of it so it will get the air through the radiator and not under it.

I used the original 2 holes on the top to mount it and added 3 more holes at the button so it will stay in place.
I installed the following part at the button, riveted to the chassis:

http://www.jeepsallover.com/attachment.php?attachmentid=72&d=1368006445

Next, you will need to grind the alternator mount a little, otherwise, it will touch the belt.

http://www.jeepsallover.com/attachment.php?attachmentid=73&d=1368006594

Since we removed one pulley, we will need another belt:
http://www.jeepsallover.com/attachment.php?attachmentid=74&d=1368006730

Install the new belt, make sure its tension is correct.

http://www.jeepsallover.com/attachment.php?attachmentid=75&d=1368006833

Now, you can install the radiator and the fans to their place

Next, wiring...
You can use a simple heat unit, a 95c - 105c one will probably fit.
I used a dixell temp controller with 2 70Amp relays, you may use 45 Amp relays, that would be fine too.

The controller I use:
http://www.jeepsallover.com/attachment.php?attachmentid=76&d=1368022531

That controller can operate 2 speeds fans, pay attention to its connection and programming, both are pretty simple.

I installed it instead of the ashtray (I do not smoke ) and added 2 switches:
1 - bypass the A/C vent and turn it on manually.
2 - bypass the high speed controller turn the high speed of the fan manually.

http://www.jeepsallover.com/attachment.php?attachmentid=78&d=1368023725

During the coming weekend there will be the off-road test for that and it is going to be very hot (~40c ) so I'll update later if it worth it :)
Saar

[4.3LXJ]

Thanks Saar. I like my Taurus fan a lot. Kudos for the belt rerouting job you did.

[Infidel Edition]

Next, wiring...
You can use a simple heat unit, a 95c - 105c one will probably fit.
I used a dixell temp controller with 2 70Amp relays, you may use 45 Amp relays, that would be fine too.


Hey, did you just swap the temp relay into the stock radiator sensor plug?
3106

...or did you use something different?

I'm thinking of using a multi-fan setup with 1 that simply kicks on with the engine (in front of the rad. push = air in - removing the AC rad and AC alltogether), 1 that is manual (left side pull), and 1 that is temp controlled (right side pull).
The combined push + pull should hit the 4000 cfm range.

[saar]

Hi,

No, I didn't use the radiator for that, I added my sensor on the hose which leads to the heater core, (it by passes the t-stat)
Saar.

[Infidel Edition]

Hi,

No, I didn't use the radiator for that, I added my sensor on the hose which leads to the heater core, (it by passes the t-stat)
Saar.

Do you have a pic of that?
...and where did you get it?

I'm trying to keep it clean ~ but functional.

[saar]

Hi,

Not at the moment, but I will take one and upload when I'll be next to the jeep.
I used the that controller (http://www.dixell.co.il/product/XT120C/_l1/621)
with its sensor.

Saar.