i hoping to perfect this thread then make it a sticky. so everyone feel free to PM me or leave a message on here if i left something out or if you want more detail and ill fix it up.
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Thermo Fan Setup

items you will need

thermo fans (i used EL - 2 power plugs, EF use 1 plug)
3 relays, 1 per fan and one for aircon
3 relay holders (optional)
a roll of 30amp automotive wire
14 female spade terminals
heat shrink/electrical tape

also as an option 2 plugs for joining loom to thermos (use if you cant get the loom side of the plugs)

tools you will need

wire cutters
wire crimpers



step one - making the loom


first up i removed 3 relays and relay holders from an EA wreck i have. i also kept as much wire off them as possible along with the plugs which run from the altinator to the +'ve on the battery terminal (one black and one red)

i then made up a diagram and searched the forums to make sure it was correct.

i wired the loom up to the following diagram - make sure you attach the 30 amp fuses to EACH constant power wire.


once that was done i cut the plug off the EL thermo's as i didnt have the loom side of the plugs.

i then attached one side of the EA altinator plugs to the thermo loom



and i repeated this process with both fans and the loom i made up.


so now you should have the loom made up and pluged into the thermos. now is a good time to test the relays with a battery charger or car battery. connect the constant and negatives to the battery, then press the switched wire on the + side and the fans should turn on.





step 2 - installing thermos


anyone who has removed a clutch fan will tell you that this is the hardest part of the process.

the way i done it was get a shifter and put it over the clutch fan bolt and a screwdriver through the bolts on the water pump and undone it that way. (refere to car manual)

once the clutch fan is undone you can undo the 2 screws for the fan shroud and remove the 2 items at the same time

now you should be left with a large gap infront of the motor.

unplug your loom from the thermos so it doesnt get damaged and drop the thermos in making sure the bottom of the thermos sit in the clips at the bottom of the radiator and put in the 2 bolts at the top of the radiator to secure it in place (note most EA-ED radiators should have the nuts already there unless they were removed by someone)




step 3 - hardwiring the loom

ok so now we are left with the loom and we also need to run a wire from a switched point to the thermo switch.

find a spot for the relays to be secured to and attach the relays. making sure the plugs for the thermos can reach.

there are 2 ways of running a power wire to the relays.
1. run an 8g wire from the battery terminal then split it into the 3 constant wires (with fuses)
2. run 3 seperate wires to the battery terminal.

once you have the constant wires sorted find a spot for the negative wires to ground to. (im currently using the bolt from the headlight bracing but will be moved to a better spot. if your using a set of thermo fans which have the plugs on the right hand side you can connect straight to the battery.



now you will be left with 1 switched wire. which runs to the thermo switch. the thermo switch has 2 terminals, 1 input and one output. on the output side this goes to 2 of the relays (left and right)

the thermo switch sensor simply slips inside your radiator hose and is usually suplied with some tape to seal it off. once you have the sensor in find a spot for the relay switch to be attached to. then attach the output wires.




on the imput side i ran a long wire from the input of the switch to the cigarette positive wire inside the car (can also use stereo switched wire) using one of these wires will turn the thermos off when the car is off. if you use a constant power your fans will drain the batteries power before you get up in the morning.




with the relay left over you run a wire from the switched down to the blue wire on the air con pump. splice into that and when the aircon is turned on the left fan should turn on.


so now you have your thermos setup. turn the car on (making sure the thermo switch is turned right up) take the car for a drive and get it to the temp you want it to switch on at, pull over pop the bonnet and turn the switch down untill it clicks on and the thermos turn on. allow to cool down and turn off then test it by driving it and keeping an eye on the temperature

its not 100% perfect but i will come back and edit things so it sounds clearer. and get more pics of needed.

hi mate.job well done.huggie.start selling the loom mate.i will send the relay holders to you on wensday mate
stef

g'day.

it looks like the pics have been removed.

any chance i can get a set of pics?

or even the full doco?

hi am also interested in the photos as i only have a write up but done to a v8 Eb.



subscribing as i am doing this hopefully next week end

hey mate can i also get the whole load of pictures as im doin this soon as i know how!!!! sent to email watt-pr@bigpond.com.au thanks

There IS a Technical document for this available @ documents.php?d=97