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Thread: *DIY Volvo Electric Fan Conversion

  1. #1
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    *DIY Volvo Electric Fan Conversion

    I've been asked a bunch of times to make this DIY and i finally got around to doing it. Just to make it known, I AM NOT RESPONSIBLE IN ANY SHAPE OR FORM IF YOU FORK YOUR INSTALL UP AND OVERHEAT YOUR ENGINE. That out of the way, here we go.

    This is installed on my v8 car, a '94 touring with the b40/6spd swap. I first installed it on the stock radiator 540i/6 rad with minor trimming to the volvo shroud, and it is now installed on the mishimoto e36 m3 rad (see morozo's PSA thread) as you see here. Just some more trimming involved. Ive heard about this install being done on i6 cars, so it can be done.

    specs:
    -fan is two speed, high and low
    -fan rumored to be ~3000 cfm, so its a beast
    -fan module is ground switched, just as the stock radiator sensor wiring is
    -fan module takes care of the transition from low to high speed

    step one: gather necessary parts. You need the fan and the wiring (its already attached to the fan), the fan relay module (and the other two plug/pigtails that plug into the module), some sort of fuse and wiring bits. I believe the fan i got came from a mid-90s 850 sedan. These fans were used in a slew of volvos from the 90's (and possibly newer), so look around the junkyard, youll find one. ive also been told that there are possibly two versions. both interchangeable, one with more curved blades. the more curved blades are quieter. get the shroud too obviously.

    step two: remove your current clutch fan and shroud. if your clutch is seized like the two i had, they get thrown in the trash.

    step three: trim the fan to fit and mount it. this is up to you. the top is easy since there is a part of the shroud that "hooks" over the top. i drilled two small holes in the radiator upper metal piece and installed two speednut like things on it. drilled two corresponding holes in the shroud and used two screws. top is done. the bottom i just zip tied on the original radiator. with the mishimoto, i used the hook thats OEM to e36's to mount the drivers side bottom. Zip ties on the pass side. again, this is up to you how to mount it. it fits almost perfect on the stock radiator with almost no trimming. it slides into a grove on the drivers side (look at how it comes off the volvo and youll see what i mean), then zip tie the pass side. super easy. the distance to the waterpump pulley was close, so keep an eye on that. i also had to trim a little bit from the fan itself to clear the intake tube.

    step four: wire up the module. Pick a spot where you want the module to go and mount it in a way that it is removable. keep in mind that the fan wiring is only so long, so use it as a guide, or extend the wiring. There are three plugs on the module, one for the fan plug, one for the power, and one for the wires that trip low and high speeds.

    The first part of this involves the main power wiring. This wire is pretty big (10 or 12gauge). i powered mine directly from the jump terminal in the engine bay. its got power all the time. yes, if my radiator sensor somehow dies and shorts one of the speeds to ground, it will kill my battery. I should relay this to an ignition powered wire, but i didnt. oh well. On this wire i used a pretty unique fuse. Its a self reseting fuse that can handle high current draw. i got it at autozone for like 6 bucks. i used a 25A/30A, dont remember exactly (see: http://www.amazon.com/COOPER-BUSSMAN.../dp/B001PT7X8W). these things are cool. if you get a short, they stay open till you fix it. last fuse you will ever buy for this job. Once this is ran, leave it unplugged until the end for safety.

    second, cut the wiring behind the radiator cooling fan sensor (this: http://www.ecstuning.com/BMW-E34-525..._All/ES166575/) and leave a couple inches. you can leave the brown wire attached if you choose, i chose to make my own (theres a convenient ground post right behind the headlight on the pass side). tape individually and tuck the stock wiring away. be sure not to short anything out here. The purple wire on the OEM plug is for the low speed trip, the black for the high speed. One the module side, the center plug is for these trip wires. pin 1 is for low speed, attach this to the purple wire from the OEM harness. pin 2 is for high speed, attach this to the black wire from the OEM harness.

    The last thing to do is to plug in all the wiring to the module and make sure the ground wire from the fan harness is grounded. to test, jump from the purple wire to ground and make sure low speed kicks on, and the same for the black wire for high speed. Now as long as your radiator sensor is good, everything should work fine! One thing to note is that this is now a totally independant system from the engine and A/C. the front a/c condenser fan will no longer kick on under an overheating situation, as it did stock. This is fine since theres no reason to be redundant IMO. This volvo fan is a beast and does its job well. The front condenser fan still kicks on when the a/c tells it to, just as OEM, so thats no problem.

    now for pictures.
    module, left is fan plug, center is trip plug, and right is main power



    how it looks



    upper mounting screws



    lower mounting, drivers side


    close to the waterpump pulley



    module placement, fuse, and wiring




    let me know if i missed something or if anyone has any questions.
    Last edited by AHenry014; 08-28-2012 at 07:51 PM.
    -Alex

  2. #2
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    Thanks..
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  3. #3
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    Nice write up, I need this. Twice.

  4. #4
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    A very oem looking install. I might have to do this myself!
    E34 525it/5 S52
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  5. #5
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    Where is he relay located on the vulva?

  6. #6
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  7. #7
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    This fan setup is awesome!


    I put mine in just before bimmerfest and it worked flawlessly through far too many hours of traffic!

  8. #8
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    The relay I believe is on the radiator support. Just follow the wires for the fan up and you'll find it. Can't miss it really.
    -Alex

  9. #9
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    Cheers!

    Quote Originally Posted by ShapeShifter View Post
    Where is he relay located on the vulva?
    Quote Originally Posted by NJe34Crew View Post
    looks like its by the MAF


    Nice try, wrong car...
    Last edited by ShapeShifter; 08-28-2012 at 09:19 PM.

  10. #10
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    Bahahha.
    -Alex

  11. #11
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    The Volvo relay is mounted at different locations. I got mine out of a 740 and the relay was under the passenger side headlight.

    Nice write up Henry.... Though I wish you had told me the shroud was useable. I left it in Atlanta.

    *edit*

    Just to add for those who do not know. This is the Volvo version of the famous Ford Taurus fan. If you search online you will see why as its one of the most powerful OEM cooling fan out there. I got mine at a pick and pull in Ga for $21 including the relay.

    Just to drive home the point......there were MANY 90s Taurus' in that yard 99% of them already had the fans picked!
    Last edited by eightynine535; 08-28-2012 at 11:50 PM.

  12. #12
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    Quote Originally Posted by ShapeShifter View Post
    Nice write up, I need this. Twice.
    X3.

    Great write up... looks so simple nearly anyone can do it. I planned on using one of those Mark VIII fans... they're 4300CFM however they're so deep theres not enough room. Shame too... those fans will push themselves off of the ground with a 12v source... use an 18v source and they become lethal weapons lol

    I'll do some investigating at the yards and see if i can pin the fan down to a specific range of cars. Shouldn't be hard as theres a yard that specializes in that swedish junk around here

    2 E34s. 1 E36. 3 Mx-6, 2 626, 06 Trailblazer SS, '73 Vette, 5VZ 4runner, and one insanely screwed up property tax bill each year.

  13. #13
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    Quote Originally Posted by mikeday1036 View Post
    This fan setup is awesome!


    I put mine in just before bimmerfest and it worked flawlessly through far too many hours of traffic!
    pics?

  14. #14
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    variation on a theme
    i didnt try the stock volvo shroud (as i didnt have it lol)

    also, i fitted a lower temp sensor in the rad, think it was from a 4 pot 3 series, its an 80/88, and my fan is wired in place of the aux fan, using all stock bmw wiring, simply because my ac was long gone...
    Long time E34 owner
    Now E39 530D touring Sport Auto

  15. #15
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    Quote Originally Posted by eightynine535 View Post
    pics?
    I'll see if i can grab some later. Mines not too much different than ahenz though

  16. #16
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    Another avenue you might want to consider when wiring it up instead of using the Volvo relay is to use Flex-a-lite's variable temperature control relay.

    I installed a Flex-a-lite in my E32 M60 and being able to adjust the switch on temperature is a really nice feature:

    https://dl.dropbox.com/u/1549180/740_pics/flexalite.jpg

    You can see the relay/rheostat in front of the brake booster.

    Great write-up. I'll have to hit the local yard and grab a fan.

  17. #17
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    Just out of curiosity, what should I look to pay for the fan? My local wrecker wants $100 for it...


    2000 530i Cosmosshwarz
    1990 M5 Alpineweiss

    1988 735iL Burgundrot Metallic
    1982 323i Polaris Silver
    1989 535i Cirrusblau Metallic
    1982 323i Helrot
    1992 520i Sterling Silver
    2004 330i Mystic Blue
    1990 535i Alpineweiss
    1988 535i Delphingrau
    1989 535i Royalblau

  18. #18
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    i paid £20-£30 delivered from ebay
    you local breaker is takeing the p*** out of you
    Long time E34 owner
    Now E39 530D touring Sport Auto

  19. #19
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    Quote Originally Posted by trive2
    Just out of curiosity, what should I look to pay for the fan? My local wrecker wants $100 for it...
    Paid $21 for fan and the controller at a pick and pull in Ga.

  20. #20
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    yea thats way too much. find another junker. i payed 30ish i believe for two relays and the fan/shroud
    -Alex

  21. #21
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    I bought my Volvo fan today, let's see how she mounts up on a 535i!


    2000 530i Cosmosshwarz
    1990 M5 Alpineweiss

    1988 735iL Burgundrot Metallic
    1982 323i Polaris Silver
    1989 535i Cirrusblau Metallic
    1982 323i Helrot
    1992 520i Sterling Silver
    2004 330i Mystic Blue
    1990 535i Alpineweiss
    1988 535i Delphingrau
    1989 535i Royalblau

  22. #22
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    Quote Originally Posted by trive2
    I bought my Volvo fan today, let's see how she mounts up on a 535i!
    How much and which model/year did it come from?

  23. #23
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    Messaging some guys to see if they wanna hock off the fan and controller cheap... let's hope there's no big market for these in NZL...

  24. #24
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    Quote Originally Posted by trive2 View Post
    I bought my Volvo fan today, let's see how she mounts up on a 535i!
    Which wrecker did you get a fan from, and how much did they charge you for it? I think I might try to get a hold of one & put it in when I do my water pump this month!

  25. #25
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    I have absolutely no clue. It was a non-turbo blue/green Volvo 850. I got it from a dodgy Portugese panel shop in Slacks Creek as it was being carried away on the truck. Paid $60 for the fan and wiring.


    2000 530i Cosmosshwarz
    1990 M5 Alpineweiss

    1988 735iL Burgundrot Metallic
    1982 323i Polaris Silver
    1989 535i Cirrusblau Metallic
    1982 323i Helrot
    1992 520i Sterling Silver
    2004 330i Mystic Blue
    1990 535i Alpineweiss
    1988 535i Delphingrau
    1989 535i Royalblau

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