[DML] LONG! Electrical experts: Fan relay wiring help

["Duke" <at88mph@xxxxxxxxxxxxxxxx>]

Welp, its been awhile since I messed around in the relay compartment so when 
I went to install the new fan fail relay update, I found a REAL mess.

This was probably done about 15 years ago (I've had the car for 19 years 
now) by a shop that I used to use before I started working on the car 
myself. (not the current shop I use though)  Anywho, its a HUGE mess.  It 
seems, according to the 'cooling fan circuit' that I'm missing a relay (only 
6 on the long row instead of 7) and it looks like the cooling fan relay and 
the thermal trip braker are missing from the car.  Now, I don't know how its 
been working correctly for so long, but here are some pics of the setup they 
had.  For all I know, the setup I had was a good setup, but I know it isn't 
right and I want to get it back to the correct way.  (Unless anyone thinks 
it would be better to put it back like it was)

Here's a pic of what I'm working with (I left the pics big so that you could 
see everything) :)
http://temp.corvetteforum.net/c5/at88mph//ratsnest1.jpg
(HUGE mess! In the left hand corner are the cooling fan relays.  You can see 
a connector that's missing a wire on the other relay.  I accidently pulled 
out the fuseable linked wire.  It was just like the other one and it went to 
the other green/black fan wire.

Here is a diagram of how they were ran:
http://temp.corvetteforum.net/c5/at88mph//currentrelay.jpg
(**sorry, at the top, I list the wire being 'brown'.  After looking closely 
its actually a brown/slate)

Here is a pic of the relays themselves:
http://temp.corvetteforum.net/c5/at88mph//fanrelays1.jpg
(again, the yellow connector that is missing a wire is the one that had a 30 
amp fuse going to the black/green of the DMC)

Now, this is where I get a little confused.  Here is a pic showing where it 
gets power from (I'm guessing?)
http://temp.corvetteforum.net/c5/at88mph//ratsnest2.jpg
That wire goes from there down to the 6 relays and daisy chains into most of 
them.  (BTW, yes, I know about the RPM relay but that's a story for another 
day :) )


I pulled out the blue relay and it only had one black/brown wire attached to 
it (the center pin I'm guessing goes to the 'fan fail light)  I cut it so I 
could redo the relay.
http://temp.corvetteforum.net/c5/at88mph//originalrelay.jpg
(lovley huh?)

Now here's where it REALLY gets interesting! I tried hooking it back up like 
factory and then I realized I was missing another relay!!!  I took the blue 
relay plug and hooked up the black/green wires (for the fans) to the two 
outside terminals, and hooked the small black/orange wire back up to the 
center terminal (for the light) I noticed that a thick brown/orange was 
originally in the back terminal (shown in pic with a connector on it for God 
only knows whyhttp://temp.corvetteforum.net/c5/at88mph//originalrelay.jpg ) 
, however according to the DMC diagram, its supposed to be a black/slate. 
I'm so confused on what I've got goin on I don't know where to begin!  I 
went ahead and hooked up the black/slate to the rear terminal, but it goes 
somewhere back into the wiring harness and not to a thermal trip (which I'm 
missing)

Basically, what I *THINK* I have is about a 10 guage black/slate wire and a 
12 guage black/orange wire which I'm not sure where it goes. They seem to be 
stock and unmodified b/c they go back into the wiring w/o any cuts.  Also I 
seem to be missing the cooling fan relay (item #5 in the workshop manual sec 
M:18:10) plus the Thermal Trip (item #4 M:18:10).  I'm not sure the thermal 
trip is gone.  Does anyone have a pic showing where its at in the relay 
compartment?

Maybe someone can look at how its hooked up and figure out what they had 
going and if it was a good or a bad thing.  I'm thinkin bad b/c of the power 
straight to the framing like that 
(http://temp.corvetteforum.net/c5/at88mph//ratsnest2.jpg  ) but it did work. 
Maybe I should have just left it alone since it worked, and it has worked 
for the last 15 years...but I was really wanting to install the new fan fix 
and have the fans stagger and also have the 'fan fail light' working.

Thanks for reading all of this and thanks for any help!

Duke
















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