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-   -   DIY Manual radiator fans control (http://986forum.com/forums/diy-project-guides/61513-diy-manual-radiator-fans-control.html)

Ben006 05-05-2016 03:07 PM

DIY Manual radiator fans control
 
Hi guys!

I've wanted to do this for a while, and finally did it!
A manual control of the radiator fan, nothing new, but I didn't find any "good" DIY for it... I'll do my best.

I wanted it to be plug and play, without messing any original part, and without any soldering inside the car.

So here is what I used:

-These relay sockets (actually I just found those... half as much of what I paid!):
Amazon.com: Absolute USA 5-Pin 12 VDC Interlocking Relay Socket, 5 Set: Car Electronics

-Some 14AWG wire, you can find here: Electrical Wire/Primary wire 85732R- ReadReviews onElectrical Wire #85732R

-Those male quick disconnect terminals: Tyco Electronics 250 Series 16-14 AWG 10/Clam Male Disconnect Fully Insulated Nylon-CPGI-3-520107-2-10 - The Home Depot
They are the thickest I found.

-A 3 positions switch: CARQUEST by BWD Multi Purpose Switch URS83: Advance Auto Parts

And you'll need a soldering iron (the 18w one at Home Depot is pretty good), heat shrink and solder.

Here is the final part:
http://nsa37.casimages.com/img/2016/...4202205925.jpg
http://nsa37.casimages.com/img/2016/...4204702071.jpg
http://nsa37.casimages.com/img/2016/...4201957030.jpg
http://nsa37.casimages.com/img/2016/...4204435741.jpg

Hard to see anything with all these wires...

What we want is a mean to ground the pin 85 of the 4 fan relays manually.
This is done with the three positions switch, one position for low, one position for high, and the middle position is off.

The PCM still controls the fans, and even if you forget to turn the fans off, they will shut off when you turn the key off after 5sec.

Two relays are for high speed and two are for low speed (and I just realized that on the picture I got the wires wrong!)

You can do the ghetto version by simply wrapping a wire around the pin directly on the relay... but I don't like it!

I measured 11.5A at high speed and 7.8A at low speed when the car is stationary. 14AWG should be alright for that.

The relay are positioned like this from right to left: [low speed right] [high speed right] [low speed left] [high speed left].

I replaced the wires going to the pins 87 and 30 with the 14AWG wire since the are the power wires, the other are only for control (low current).

I'll draw a clear schematic after... pictures are pretty useless here.

I hope it helps!
I haven't put the final assembly in the car yet.

Ben

Ben006 05-05-2016 03:38 PM

Here is the least crappy I could do in 10min:
http://nsa38.casimages.com/img/2016/...5132721862.jpg

alm001 05-05-2016 03:52 PM

Hey, careful with that last hosting site, I don't know if i clicked something by accident, but its got some security issues.

Ben006 05-05-2016 03:57 PM

casimages.com ?

I've used it for years without issues :/

rick3000 05-05-2016 04:16 PM

Great job! I really like that it is fully reversible, I might do this over the summer. :cheers:

To clarify, basically those male disconnects get plugged into the relay board instead of the relay, then you plug the relays into the added interlocking sockets, with pin 85 wired to the switch to manually override the fans?
It would be great if there was a way to clean up all the male disconnects, but it doesn't look like anyone makes a male relay plug, unless you want to gut a standard relay.

Ben006 05-05-2016 04:22 PM

Quote:

Originally Posted by rick3000 (Post 494767)
It would be great if there was a way to clean up all the male disconnects, but it doesn't look like anyone makes a male relay plug, unless you want to gut a standard relay.

I have spare relays that are waiting to get destroyed for the sake of DIY's ;)

And yes, that's exactly it, you plug the quick disconnect terminal instead of the relays. and the relays into the interlocking sockets.

I have to get a glue gun so I can lock the wires inside the sockets once for all.

rick3000 05-05-2016 04:25 PM

I really love this, my 986 does not like the summer heat, so I will probably do this. Although I may just use fuse taps (a slighter fancy solution than wrapping a wire around the pin), then see if I can wire it to an OEM switch. I still have two button blanks to fill. :cheers:

Ben006 05-06-2016 09:17 AM

I opened a relay today...
I have to test it ! the base with prongs should be reusable ;)

The problem with using the OEM switches is that they are one stable position, not 3 like the one I use, so to have control for high and low speed, you'd have to use to more relay and two switches!

steved0x 07-26-2016 08:12 AM

Quote:

Originally Posted by alm001 (Post 494761)
Hey, careful with that last hosting site, I don't know if i clicked something by accident, but its got some security issues.

I just went to it to view the pic, no issues. I clicked the pic to get a closeup and it opened in a new tab. When I closed it, it took me back to the original tab, which now had a selection of lovely ladies for me to choose from... Luckily they were SFW.

<iframe width="560" height="315" src="https://www.youtube.com/embed/NhJ7pXtViWY" frameborder="0" allowfullscreen></iframe>

Ben006 07-26-2016 10:19 AM

Ahah, did you choose one?

It's weird it always works with me... maybe adblock is blocking the pop-ups efficiently!


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