Elec cooling fan - MPGs UP!

[Lumpy]

Removed my engine driven cooling fan and replaced with an electric fan, about a month ago. That is the ONLY change I've made. Prior to the fan change, my van got ~14 MPG. Those are uncorrected for tire size. ie I'm really getting maybe 10% better (my speedo is off by just about 10% exactly). After the fan change - Filled up this morning and got 18 MPG. Still uncorrected mileage. Nothing else has changed. Driving pattern has been exactly the same predictable six mile round trip every day or two.

4 MPG increase from elec fan replacement...


Lump

[redfury]

Well, I replaced my fan and didn't see one lick of change in my mileage. What fan did you go with? A JY pull or a kit fan?

[Lumpy]

[which fan]
Dorman new fan, sold as a Ford Taurus replacement.


Lump

[Swong]

sounds great !!! mind posting your steps of diy + pets needed ?

[Corsemoto]

Yeah, not sure about the the 30% mpg increase but would like to see more detailed install info.

[TDMobile]

sounds great !!! mind posting your steps of diy + pets needed ?

Do different animals have different mechanical skills? kidding kidding.

Lump, you still have the original engine, right?

[Swong]

hehehe... i mean parts... too many beers last nite..

[Lumpy]

There really aren't "steps" or anything particular tricky about installing the elec fan. Remove fan shroud, remove old, engine driven fan, install new, elec fan, wire it up per instructions included with the fan controller. In my case, I had to figure out exactly which connection pin was which on the new, Dorman fan. That was the only thing the least bit challenging. In terms of experience/skill level/degree of difficulty, I'd say it's probably slightly more challenging than changing a battery, less physically demanding than rotating tires. No unusual tools required. You have only to be comfortable with wiring in a 12v couple of wires. I chose to remove my radiator and flush it while I was in the neighborhood, but it can certainly be done with the radiator in place. I also added a water temp gauge and fan shutoff toggle on the dash, neither are absolutely required either. If you're not adding a gauge and/or switch, there's no wires to fish through the firewall. All connections should be present within the eng compartment.


Remove headlight shrouds (for that "transformer" look) and grille to access radiator front. You'll need to access the front of the radiator even if you don't pull it, in order to mount the elec fan -




Remove shroud -




Remove eng driven fan (HF Color Coded Ratcheting box end wrenches) -




Remove fan and reveal a space big enough to fit a bowling ball -




Mount new, elec fan to radiator. I used the push through zip lock tie things supplied with the fan -







I also used a couple of 1/4-20 nut and bolt combos where the fan brackets met the radiator frame -




Simple spacer from some scrap aluminum tube -







Now enjoy a fist's worth of space between the elec fan and the water pump pulley -







Lump

[redfury]

I did a write up on installing a 2 speed ford/Lincoln fan in my van using parts not supplied by a kit. It's a little bit more involved, but if you can install a car stereo, you can do this.

[Lumpy]

That's exactly what mine is. Fan made for a Taurus/Linclol etc. Not difficult at all to install. Easier than a stereo, to me. Less tiny, cramped spaces and a lot less wires. But whatever it's compared to, not difficult in the least.


Lump

[sadglad]

Can you tell us more about the fan controller you used?

Even a 1 mpg improvement would pay for itself in no time.

[Corsemoto]

Nice work Lumpy and thanks for the info/pics. How much does that old metal fan/fan clutch assembly weigh? Didn't realize you had a metal cooling fan and not plastic, nice little reduction in reciprocating mass and load on the engine.

[Lumpy]

Can you tell us more about the fan controller you used?

Even a 1 mpg improvement would pay for itself in no time.

It's a CompressorWorks TorqueFlo 733647, about 35 bucks from AutoZone -
http://www.autozone.com/autozone/parts/ ... 61_9583_0_

Comes with everything you need including fuses, mounting hardware, install diagrams and instructions etc.

The fan is a two speed Dorman 620-101, about 100 bucks from RockAuto. I'm using the low speed only. If I find I want to use the high speed, I can simply pull the spade connector off the low speed terminal and reconnect it to the high speed term.

I don't think the push through zip tie things came with the fan. As I recall, those came with my transmission cooler. I didn't use them there, so I had them available to use for this project. You can buy those zippy things anywhere. And some people don't use them at all, they use aluminum or steel fabricated brackets or whatever instead. The fan gets sucked up hard against the back of the radiator. So whatever mounting system you use is only holding the thing in place while the fan is off. The mounting is not under the constant stress of the fan trying to pull it apart or anything, just the opposite.



Lump

[redfury]

that install kit is the bees knees compared to what I did to connect mine electrically. I went after high amp relays, bought a seperate fan thermostatic controller and did all the wiring into the relays ( building the connectors into the relays with the proper terminals )

I have 2 relays, with the high speed set up on a switch on the dash for when I'm towing. It doesn't turn on until the engine is up to temp because the front end of the circuit is designed to not run the fan continuously under Key On power, nor is it designed to keep running as long as the thermostatic switch calls for it. The wiring is pretty straight forward though, no matter which way you go about doing it.

Of course, now that you posted that link to the fan, I'm trying desperately to find a replacement fan for the one I pulled, and I can't seem to find the year/model that fits the fan I pulled from the JY for $15!

[Shad0wXCalibur]

Are you sure your mechanical fan wasn't constantly engaged or something? Not trying to doubt you. It's just that's a huge MPG increase. My 87 with mechanical fan got 21 mpg. Couldn't have imagined it going to 24 or 25 with an e-fan. But hey. Looks like a real good install.

[sadglad]

It's a CompressorWorks TorqueFlo 733647, about 35 bucks from AutoZone......
Lump

Thanks for the tip. I have reward points from AutoZone. Now I know what to use them on. I'll be looking for a fan this weekend on my JY rounds.

[Wagon Master]

that install kit is the bees knees compared to what I did to connect mine electrically. I went after high amp relays, bought a seperate fan thermostatic controller and did all the wiring into the relays ( building the connectors into the relays with the proper terminals )

I have 2 relays, with the high speed set up on a switch on the dash for when I'm towing. It doesn't turn on until the engine is up to temp because the front end of the circuit is designed to not run the fan continuously under Key On power, nor is it designed to keep running as long as the thermostatic switch calls for it. The wiring is pretty straight forward though, no matter which way you go about doing it.

Of course, now that you posted that link to the fan, I'm trying desperately to find a replacement fan for the one I pulled, and I can't seem to find the year/model that fits the fan I pulled from the JY for $15!

If I recall correctly, the Taurus/Sable fan is from a 90-96 3.8, while the motherload fan is from a 91-94 Mark 8. The Mark 8 is larger, stronger, and would fit the radiator better, but they are RARE.

[redfury]

Apparently. The only thing I can find a picture of is the motor. Needless to say, the E fan is a nice upgrade to the van, especially for running A/C.

Here's my write up, if anyone is interested.
viewtopic.php?f=34&t=13238

[Swong]

Thanks fellows!!!! Great write ups!!

[decypher]

Thanks Lumpy
After the clutch fan died for the second time in my1988 S 15 2.8 lt, I decided to try an old Cavalier fan I had hangin around. I am glad to say after 3 years it is still going and I swear it is easier on gas but never really put numbers to it.Warms up quicker in winter which is nice..
Just today it looks the damn "fail safe" thermostat I installed not even a year ago failed today. Thermostat doesn`t come much above 40 after driving 4 hrs. I suspect a reason it recently failed drive clean.
Seeing I have to do go digging again, I will see about installing an electric fan.