15th July 2012, 23:05
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#197
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Company Representative for RK Autowerks
Join Date: Sep 2010
Location: Seattle
Garage:
2003 E39 M5 TiAg
Thanks: 224
Thanked 376 Times in 257 Posts
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Fan Install Instruction Edits
Stock assembly removal
1) Drain radiator
a. Drain plug is located on the bottom left of the radiator
b. Turn the plug counterclockwise and then pull down to release fluid
2) Remove upper radiator hose
a. With a flat head screwdriver, flip up the retaining clip and remove the hose
b. Remove the engine side of the hose by undoing the hose clamp
c. Remove hose
3) Remove stock engine fan
a. These threads are reverse threads
i. Clockwise rotation = removal
b. Will need BMW retaining tool to hold the fan clutch
4) Remove reservoir tank hose
a. Use a flat head screwdriver to remove the hose clamp, pull off hose
5) Begin removal of fan shroud
a. Remove 2 10mm bolts on each corner of the radiator
b. Pry off heads on the 3 plastic rivets
c. Undo both hoses connected to the reservoir
d. Remove shroud and reservoir
i. Save the reservoir as it will be reused
ii. Remove the “black box” on the bottom right of the shroud, this will be reused
6) Remove lower radiator hose
a. With a flat head screwdriver, flip up the retaining clip and remove the hose
b. Unplug the temperature sensor
c. Remove the engine side of the hose by undoing the hose clamp
d. Remove hose
7) Remove radiator
a. By now the radiator should be loose, gradually pull up on it and it will come out.
i. Be careful not to ruin the fins on the radiator during this process
ii. Also note the 2 rubber bases on each side of the radiator, these sometimes fall off
Radiator and shroud installation
1) Drilling mounting holes on shroud
a. Notice the 4 5/16ths holes on the radiator, 2 on the top 2 on the bottom.
b. Lay the shroud ontop of the radiator and mark these holes on the shroud.
c. Use a 5/16 drill and drill 4 holes in the shroud
2) Shroud assembly
a. After holes have been drilled, insert the 4 push rivets supplied to secure the shroud to the radiator
b. Install the black box using zip ties in the same location and orientation as it was on the stock shroud
c. Install the fan using 4 M6 button head bolts with 1 locking washer on each bolt
3) Radiator/shroud installation
a. Install the assembly as you had removed it
i. Make sure the 2 rubber bases are on the radiator and sit in the notches on the car side
b. Secure the radiator at the top using the 2 securing brackets and 2 10mm bolts
4) Lower radiator Temp sensor installation
a. Cut a 1” section in the center of the lower radiator hose and install the aluminum fitting
b. Install the temperature sensor into the fitting, do not use teflon tape
c. Clamp the fitting using the supplied hose clamps
d. Install the hose onto the engine and radiator
e. Install upper radiator hose at this time as well
5) Reservoir installation
a. Secure reservoir in the stock location
i. Secure it using 2 m6 button head bolts
b. Plug in the level sensor on the bottom of the reservoir
Wiring installation
1) Locate Spal instructions in the spal box
a. Mount the spal relay in desired location. Mounting location is not critical, it Is recommended it be in a safe location away from moving parts and any disturbance.
b. Route the Yellow wire from the relay to the driver side cylinder head where the power terminal is located
i. Utilize the fuse setup supplied by spal and the yellow terminal
ii. The wiring orientation should be
1. Yellow terminal -> fuse relay with 30 amp fuse -> butt connector -> yellow wiring
2. The yellow terminal should be plugged into the battery terminal
3. It may be necessary to shorten the wiring
a. Assure you have enough slack in the wiring
c. Routing the red wire to the fan shroud
i. Route the wire as desired to the electric fan
ii. Source the fan plug from the spal wiring box
1. Lengthen the red wiring as desired and connect it to the fan harness using the butt connector
iii. Ground the electric fan harness to the engine ground under the passenger side frame rail.
1. View image for exact location
d. Routing orange wire
i. This wire is for ignition
1. Route this wire to the ECU box
2. The ecu box is located underneath the passenger interior intake
3. You will need to remove the ecu cover
ii. Once you are in the ecu box, tap into the red and white wire on the backside of the ecu box. This is a +12 ignition wire. double check this with your multimeter.
1. Image attached
e. Routing grey wire
i. This wire is for the thermostat to trigger the fan
1. Route the wire to the thermostat in the radiator hose
a. After you have shortened the wire to the desired length, connect the blue connector to it and secure it to the thermostat.
2. Utilize the extra wire provided and ground the thermostat body or the hose adapter (slip the a stripped portion of the wire in between the housing body and rubber hose under a hose clamp) to an available engine ground. (there are a few, pick one that is convenient, I used the engine ground strap on the lower passenger side frame rail). Don't connect the grey wire directly to the ground wire as this will make the fan run all the time. The thermostat works by grounding the circuit when it reaches the desired temperature, so the body of the thermostat or the thermostat adapter must be grounded.
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