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

[Chris Almy <chris.almy@xxxxxxxxxxx>]

Duke,
Looking over the wiring and pictures, it looks like the mechanic at least 
did the job correctly (although a bit ugly). Each fan has a relay and fuse, 
so the current setup is safe. However, I wouldn't bother trying to get the 
wiring back to stock. It may not be long enough now and you don't want to 
have a bunch of short jumpers in there. So if I was you, I would cut the 
ends off the fan controller and use butt connectors (or better yet solder) 
and connect it directly to the car's wiring.

Let's start with the connector that has the two fused wires. These two 
wires provide power to the fans. Connect each one to the black/green wires 
(order is not important). The third remaining smaller wire on the connector 
is for the fan fail light. This isn't necessary, but it connects to the 
purple/brown wire if you can find it.

On the other fan controller connector, there are two wires. The green wire 
is the ground. Just connect this to any ground point or ground wire. The 
red wire is the 12V trigger wire. This connects to the black/orange wire. 
But from your diagram, you have a black/brown. Follow this wire and see if 
it connects to a black/orange. If not, test to confirm it's the trigger 
wire. You can do this by checking for 12V when the AC compressor has cycled 
on. And with the compressor cycled off and a cool engine, there should be 0 
volts.

Finally, there is the main power wire for the controller. Just run this 
directly to the battery. The brown/slate wire is no longer necessary. 
Remove them from where they split off the brown wire. Wrap the brown wire 
up in electrical tape or heat shrink tubing to prevent it from shorting.

I hope this helps. Should you want to restore to the factory had it, you 
can still skip the circuit breaker connections, because it's bypassed by 
the fan controller. Page M:18:10 of the workshop manual has the schematic 
for this system, which may be helpful.

Chris
VIN 4099

At 04:42 PM 9/24/2005 -0500, you wrote:
>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)





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