How to convert from belt-driven clutch fan to dual electrical fans...

I really want to create a ram-air setup for my camaro using the TPI dual filter setup. To make this work however, I need to switch from the clutch fan to electric fans, so that I have room above the radiator shroud for the air " snorkel". I came across a great deal on the fans, so off I went...

Parts Needed:
  • Upper radiator shroud

  • Lower fan mount - GM PART # 10055083 - I ordered this new from a GM dealer - about $9.50

  • 2 Electric fans

  • Fan electrical connectors (2) or a dual fan harness. I obtained the connectors from 2 V6 junkyard cars.

  • 2 conductor wire to run from the fan connector to relays

  • Fuse kit - I used a 30 amp inline fuse

  • Battery connection - I used a side terminal adaptor with accessory mount

  • 1 or 2 relays depending on your control mechanism - see below for more commentary.

  • Your favorite electrical connection accessories - electrical tape or solder or crimp connectors, etc

  • Split tube loom - I used some 1/2" for the fan wiring.

  • Split tube loom holders - I used (2) 1/2" holders attached to the fans.

  • Body U-Mounts and bolts - see the diagram for details

  • Fan Control - there are many theories on how to control the dual fans. I will start with simplicity - both fan relays will be energized by the ignition circuit. If this proves to be too much load on the alternator, I will rethink the plan. In the summer, I don't see much of an issue with this setup. Eventually, I will have one fan controlled by engine temp, and the other triggered by use of the air conditioning. I will likely also have a manual override switch to run both fans on demand.

    Click on bordered images for full size...
    This is a diagram of the dual fan setup

    This is a mock-up of the fans & brackets.

    Instructions (as I remember them, your mileage may vary!)

    1) Remove clutch fan nuts

    2) Remove clutch fan

    Pic of old shroud & clutch fan...

    3) Replace clutch fan nuts

    4) Remove bolts that join upper & lower radiator shroud

    5) Remove upper radiator shroud bolts and a/c hose bracket (on one of the shroud bolts)

    6) Remove upper shroud (I pulled mine up - be careful with the A/C hoses - mine leaked quite a bit during this operation)

    7) Remove lower shroud bolts

    8) Remove lower shroud (I pulled mine up)

    9) Clean between radiator and condensor

    Lots of crud between radiator & consendor...

    This is the crud in my shopvac...Yuck...

    10) Mount upper shroud, make sure it has radiator rubber mounts and the u-bolts for the fans

    The upper bracket from the donor car was missing a rubber mount, so I moved it off the old shroud...

    11) Move u-bolt from old shroud mounting location (passenger side) to the location closer to center

    12) Mount lower fan bracket, make sure it has the 4 u-bolts for the fans

    13) Mount fans

    Pic of one of the new fans after mounting...
    Gotta love the special coolant absorbing pink towel...

    14) Check alignment - I shimmed one fan (with washers on the lower mount) that appears to have a slightly twisted bracket

    15) Attach fan electrical connectors and carefully power up each fan to check for movement or obstruction. I used a 12v battery charger for a quick test

    16) Extend fan electrical connector wiring using 12 gauge wire (same as connector)

    17) Wire fans to relay(s) depending on your fan control method

    Relay Wiring pic #1...

    Relay Wiring pic #2...

    18) Wire fans to ground (I used a body ground by the battery (see the relay mounting pic)

    19) Wire relay to fuse, then extend fuse lead to battery (I added a side battery terminal extender, and used a 30 amp inline fuse with cap)

    20) Wire relay to control and ground (I used a new ignition lead run through the firewall, along the driver's side, then over to the fan wire loom)

    21) Mount relay using u-bolt (Mine is between the battery and the passenger headlight - see pic)

    Wire looming pic #1...

    22) Wire loom everything & use wire loom holders (there are holes in the fan brackets for them)
    Look at the nice wire looming job :>)

    Wire looming pic #2...

    Questions? Comments? Know a better way? Let me know!
    Email me at: icole at technovelocity dot com