Electric Cooling Fan Conversion
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Monk
- CHC Trail SuperGuide
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- Location: Ontario
Re: Electric Cooling Fan Conversion
Great posts, love the pics
96 HMC4
Optimizer N/A
Super Swamper IROKS 39.5x13.5x 16.5
Optimizer N/A
Super Swamper IROKS 39.5x13.5x 16.5
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whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
So the new water pump is installed. I torqued the pump bolts in a criss-cross pattern in multiple passes. The first pass was at 15N-M and then the final pass was at 30N-M. I did probably 8 total passes until no bolt moved. I used thread sealer just to be sure there would be no leaks!
As well, before I installed the new water pump I retorqued all the front cover bolts...good thing to since I could do up to 1/2 a turn on most of them.
Before installin the new pump I completely flushed all the coolant line and passages with the Evans Prep Fluid to make sure that it would be water free! I even made my front tires completely flat and jacked the rear over 2 ft up to help drain the engine block completely!
So with all the new hoses and thermostat in place, I filled the system with new Evans WaterLess Coolant and did some tests before I installed the new Electric Fan.
So now that my H2 has been converted...I am Saying Why the Heck didn't I do this YEARS ago!!!
I even did an interesting test. Since I am converting from my mechanical fan over to electric fans, I ran the engine with no fan at all with only the Evans Coolant to keep it cool. Well, after running for about an hour and even a short drive, the coolant never once went over 100C!!! That is Amazing! I had no fan at all not mechincal or electric!!! Talk about efficient!
Next test I did was open the rad cap as fast as I could....Absolutely NO Pressure!!! Awesome! Not even a Pssst!
Last test I did was take a sample of coolant from the radiator drain and test the BRIX index with a refractometer. PURE Evans Waterless Coolant is 55.7 or 0% water content. I managed to get mine to 55.1 which is 1%. We are allowed up to 5% for gas engines and 3% for diesels!
So Overall, I am Super Impressed!
Evans Waterless Coolant is definitely the way to go!!!
As well, before I installed the new water pump I retorqued all the front cover bolts...good thing to since I could do up to 1/2 a turn on most of them.
Before installin the new pump I completely flushed all the coolant line and passages with the Evans Prep Fluid to make sure that it would be water free! I even made my front tires completely flat and jacked the rear over 2 ft up to help drain the engine block completely!
So with all the new hoses and thermostat in place, I filled the system with new Evans WaterLess Coolant and did some tests before I installed the new Electric Fan.
So now that my H2 has been converted...I am Saying Why the Heck didn't I do this YEARS ago!!!
I even did an interesting test. Since I am converting from my mechanical fan over to electric fans, I ran the engine with no fan at all with only the Evans Coolant to keep it cool. Well, after running for about an hour and even a short drive, the coolant never once went over 100C!!! That is Amazing! I had no fan at all not mechincal or electric!!! Talk about efficient!
Next test I did was open the rad cap as fast as I could....Absolutely NO Pressure!!! Awesome! Not even a Pssst!
Last test I did was take a sample of coolant from the radiator drain and test the BRIX index with a refractometer. PURE Evans Waterless Coolant is 55.7 or 0% water content. I managed to get mine to 55.1 which is 1%. We are allowed up to 5% for gas engines and 3% for diesels!
So Overall, I am Super Impressed!
Evans Waterless Coolant is definitely the way to go!!!
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Last edited by whitehumh2 on Thu Mar 19, 2015 11:05 pm, edited 1 time in total.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
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whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
This weekend I will finish the fan install. I am noticing that I will need to reshape both the Engine oïl cooler lines and the transmission oïl cooler lines. Just too close to allow the Electric Fan assembly to fall into place! Oh well, it is not like I didn't expect some challenges.
On a side note the wiring harness that i received for PMC of NC http://www.pcmofnc.com/ Is Stellar!!! I am super impressed with the quality of workmanship and the sealed connectors. The included instructions are excellent...gonna make the final steps of the install very easy!
Here is what I got!
Almost Done, So stay tuned for the final stages!!!
On a side note the wiring harness that i received for PMC of NC http://www.pcmofnc.com/ Is Stellar!!! I am super impressed with the quality of workmanship and the sealed connectors. The included instructions are excellent...gonna make the final steps of the install very easy!
Here is what I got!
Almost Done, So stay tuned for the final stages!!!
You do not have the required permissions to view the files attached to this post.
Last edited by whitehumh2 on Fri Mar 20, 2015 6:15 am, edited 1 time in total.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
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whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
So today I finished it all off and IT IS AWESOME!!! I am Super Pleased! I still have to reflash my ECM to activate the fan control and do some final checks but overall done!!
So here are the final steps;
So I had to start by getting to the ECM. Can you see where it is hiding?
Yep, right Under that black cover!
Once the cover is off you can finally see it!
Once you release the spring clip retainer, you need to rotate the ECM to get access to the main connectors.
So here are the final steps;
So I had to start by getting to the ECM. Can you see where it is hiding?
Yep, right Under that black cover!
Once the cover is off you can finally see it!
Once you release the spring clip retainer, you need to rotate the ECM to get access to the main connectors.
You do not have the required permissions to view the files attached to this post.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
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whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
Once I pulled the connectors out I notice the start of some corrosion trying to get a start. The seal was slightly out of position, so I will clean the ECM and reseal it before reassembly.
Now to get to the ECM connections.
You need to put the Green wire in Terminal 42 of the BLUE Connector.
The connector is numbered so it is very easy to find and insert the terminal
Now to get to the ECM connections.
You need to put the Green wire in Terminal 42 of the BLUE Connector.
The connector is numbered so it is very easy to find and insert the terminal
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Last edited by whitehumh2 on Fri Apr 03, 2015 6:43 am, edited 1 time in total.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
-
whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
Next you need to insert the Blue Wire in Terminal 33 of the GREEN Connector.
You do not have the required permissions to view the files attached to this post.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
-
whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
Now that the wires have been inserted in their respective locations it is time to reassemble!
I started by making sure the ECM was clean and corrosion free!
Next you put the covers back on the connectors. I also put a helping amount of dielectric grease on the terminals prior to reassembling the connectors into the ECM
Next you can see the ECM signal tap you just installed.
I like to shield wires so I added some loom to make sure no wire chaffing!
I started by making sure the ECM was clean and corrosion free!
Next you put the covers back on the connectors. I also put a helping amount of dielectric grease on the terminals prior to reassembling the connectors into the ECM
Next you can see the ECM signal tap you just installed.
I like to shield wires so I added some loom to make sure no wire chaffing!
You do not have the required permissions to view the files attached to this post.
Last edited by whitehumh2 on Fri Apr 03, 2015 7:16 am, edited 1 time in total.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
-
whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
Now we get to the Dual Fan Assembly.
I decided to install some Rive-Nuts into the fan housing to allow me a secure place to mount the triple relays and to secure the fan connections.
I choose to mount the relays at the top center to keep them easily accessible and out of the majority of the water they might have to deal with!
And yes all hardware is stainless steel!
I decided to install some Rive-Nuts into the fan housing to allow me a secure place to mount the triple relays and to secure the fan connections.
I choose to mount the relays at the top center to keep them easily accessible and out of the majority of the water they might have to deal with!
And yes all hardware is stainless steel!
You do not have the required permissions to view the files attached to this post.
Last edited by whitehumh2 on Sat Mar 21, 2015 9:58 pm, edited 1 time in total.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
-
whitehumh2
- CHC Trail SuperGuide
- Posts: 4529
- Joined: Tue Jul 04, 2006 11:47 pm
- Location: Lachine, Quebec
Re: Electric Cooling Fan Conversion
Now that the fan has been assembled with the harness. I did some test fits and found that I needed to add some foam tape to the upper edge to get a good seal to make sure all the air goes thru the fans.
I also had to trim the lower fan assembly lip by about 1/4" to avoid contact of the shroud to the radaitor fins.
Once that was done, I had to remove the engine oïl cooler lines to allow me enough space to drop the fan assembly easily into place.
I had to customize the oïl cooler lines and I think they turned out better than OEM! Plus they now clear the Dual Electric Fans!
The last step was to connect the fan wiring to power and ground and I temporarily connected the manual fan control switch that will be mounted in the upper map light panel above the rear view Mirror...but that will be next week!
I tested the fans and Man do they ever SUCK...Air that IS!!! I highly doubt that the OEM unit could pull that much air thru the rad!
So once I get my flash done and get some roadtesting done I will post an update and as well I will add the pics of the manual control switch.
So, YES it was tons of work...between 25 to 30hours to do everything...But Well Worth every minute!
Overall, I could not be happier!
Looking forward to having an even better H2!
Later,
Kev
I also had to trim the lower fan assembly lip by about 1/4" to avoid contact of the shroud to the radaitor fins.
Once that was done, I had to remove the engine oïl cooler lines to allow me enough space to drop the fan assembly easily into place.
I had to customize the oïl cooler lines and I think they turned out better than OEM! Plus they now clear the Dual Electric Fans!
The last step was to connect the fan wiring to power and ground and I temporarily connected the manual fan control switch that will be mounted in the upper map light panel above the rear view Mirror...but that will be next week!
I tested the fans and Man do they ever SUCK...Air that IS!!! I highly doubt that the OEM unit could pull that much air thru the rad!
So once I get my flash done and get some roadtesting done I will post an update and as well I will add the pics of the manual control switch.
So, YES it was tons of work...between 25 to 30hours to do everything...But Well Worth every minute!
Overall, I could not be happier!
Looking forward to having an even better H2!
Later,
Kev
You do not have the required permissions to view the files attached to this post.
<p class="bbc_center">1 - There is a time for everything,
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
and a season for every activity under the heavens:
3b - a time to tear down and a time to build,
5 - a time to scatter stones and a time to gather them,
Ecclesiastes 3:1,3b&5a
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duncanpa
- CHC Trail SuperGuide
- Posts: 1373
- Joined: Tue Dec 29, 2009 7:39 pm
- Location: McDougall, Ontario
Re: Electric Cooling Fan Conversion
Is it possible to get an even better H2 than yours Kevin??? I think it's called an H1
2005 Black on Black Beautiful BEAST
The Only Way To Get Over It Is To Drive A Hummer
The Only Way To Get Over It Is To Drive A Hummer