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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 01-03-2011, 04:41 PM
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16valex 16valex is offline
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E39 Electric Fan OEM Style!

Here are the parts that needed for the mod. I ordered them though Summit Racing.

1- SUM-G4904 - Electric Fan, Single, 16 in. Diameter, Reversible, 2,010 cfm, Black, Plastic, Each $84.95
- I went with this because it's a curved fan which will lower the noise level, and I'm very please with the outcome, also it is reversible for puller or pusher type of use.

2- DER-16749 - Fan Control, Thermostatic, Adjustable, 150 to 240 Degrees, Kit $39.95
- I picked this because temperature setting to activate the fan is adjustable.

3- ATM-2283 - Radiator Hose Adapter, Aluminum, 1.5 in. to 1.5 in., Kit $37.95
- Aluminum and they are the only place that I can find to carry 3/8 NPT port.

I also bough a new fan shroud, so I can take my time working without hurrying.

I went to work at it, to begin I cut the top porting of the shroud to make it even. Here are some pix.
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  #2  
Old 01-03-2011, 05:16 PM
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16valex 16valex is offline
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Then I went to work on the fan itself

Remember, the fan is shipped as a pusher, there will be instruction for you to turn it to a puller.
While you're at it, look at picture #3 remove the motor, rotate the motor about 60 degree to find the higher mounting points using the same screws, this helps reduce the profile of the fan, the more profile the better.

Here is a picture of the fan itself has to be cut in order to accommodate the shroud. I had to cut about half an inch from the top center.
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Last edited by 16valex; 01-03-2011 at 06:10 PM.
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  #3  
Old 01-03-2011, 05:26 PM
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16valex 16valex is offline
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Now it's time to fasten the fan to the shroud I chose.

Need 5 M6 by 30 mm long. Need 5
Need 15 M6 nuts.
And 10 lock washers.

I had to grind the head of the bolts down a little to fit inside the fan slots. Take a look at the pix.
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  #4  
Old 01-03-2011, 05:45 PM
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16valex 16valex is offline
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Time to drill holes and install the fan inside the shroud.
I put the fan on top of the shroud and then eye ball for even gap all around.
With magic marker, I marked the 5 positions where I will be drilling and about 1-1/4 inch depth.
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  #5  
Old 01-03-2011, 06:00 PM
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16valex 16valex is offline
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I thought it would better to give it some re-enforce strength so I went and bought some 1x1x1/16 thick aluminum angle bracket and some JB Welder from Home Depot.

I also went wild on the JB welder. Hey no such thing is over engineer!
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  #6  
Old 01-03-2011, 06:24 PM
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16valex 16valex is offline
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Now for the thermo sensor switch adapter in the lower radiator hose.
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  #7  
Old 01-03-2011, 06:35 PM
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16valex 16valex is offline
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Hooking up electrical. Almost there!

For always on 12 V battery power is blue color tap connector RED wire.
For ignition switch ON power to activate the relay circuit its the GRN/WHT wire.
And lastly for the Override toggle switch I also tapped into this GRN/WHT wire.
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  #8  
Old 01-03-2011, 06:49 PM
gjvah gjvah is offline
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Wow, nice write up. Would the same parts be used for a 540? Or does the bigger engine need a different fan? I've wanted to do this for as long as I remember myself.
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  #9  
Old 01-03-2011, 06:49 PM
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16valex 16valex is offline
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Start the car up make sure you top off cooling water and bleed the system. Take her out and give it a nice spirited drive to bring up the temperature, you know when your car is up to operating temperature is when your lower radiator hose is nice and warm.

Now let the car idle, unlock your OBD and monitor your engine temp.
I adjusted mine to come on at 96 degree Cesius but this will change when the Summer is here.

Some more pix and enjoy.
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  #10  
Old 01-03-2011, 06:53 PM
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Quote:
Originally Posted by gjvah View Post
Wow, nice write up. Would the same parts be used for a 540? Or does the bigger engine need a different fan? I've wanted to do this for as long as I remember myself.
I'm pretty sure it would be fine. I think the V8 has more access than the I6, so this will probably a plus for the V8 guys.
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  #11  
Old 01-03-2011, 07:30 PM
cn90 cn90 is offline
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Quote:
Originally Posted by gjvah View Post
Wow, nice write up. Would the same parts be used for a 540? Or does the bigger engine need a different fan? I've wanted to do this for as long as I remember myself.
gjvah,

The V8 thingy is here:
http://bimmer.roadfly.com/bmw/forums/e39/7743176-1.html
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  #12  
Old 01-03-2011, 08:10 PM
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CoreyMNK CoreyMNK is offline
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Awesome write up! I need to change my fan ASAP! The bearing has gone bad and my fan wobbles pretty bad. When ever I go over a speed bump you can hear the fan hit the shroud, or when I hit the brakes. Sometimes when I'm sitting at a stop light you hear a god awful grinding noise because the fan is wobbling and hitting the shroud. On top of the bearing being bad one of the blades is cracked, to the point where I feel it may fly off if something were to hit it when it's spinning. Once Spring rolls around I'm going to be using your write up!
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  #13  
Old 01-03-2011, 08:16 PM
cn90 cn90 is offline
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Quote:
Originally Posted by CoreyMNK View Post
Awesome write up! I need to change my fan ASAP! The bearing has gone bad and my fan wobbles pretty bad. When ever I go over a speed bump you can hear the fan hit the shroud, or when I hit the brakes. Sometimes when I'm sitting at a stop light you hear a god awful grinding noise because the fan is wobbling and hitting the shroud. On top of the bearing being bad one of the blades is cracked, to the point where I feel it may fly off if something were to hit it when it's spinning. Once Spring rolls around I'm going to be using your write up!
Don't delay this any further unless you want to pay $2K for the hood repair! Replace the Fan Clutch (use Sachs) and Fan Blade (BMW only) now, then cooling overhaul later.

Your Water Pump bearing may be going soon.

Best is to do a complete cooling overhaul NOW! It is not that hard, just gather the parts and spend a Saturday doing it.

Last edited by cn90; 01-03-2011 at 08:24 PM.
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  #14  
Old 01-03-2011, 08:18 PM
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16valex 16valex is offline
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Quote:
Originally Posted by CoreyMNK View Post
Awesome write up! I need to change my fan ASAP! The bearing has gone bad and my fan wobbles pretty bad. When ever I go over a speed bump you can hear the fan hit the shroud, or when I hit the brakes. Sometimes when I'm sitting at a stop light you hear a god awful grinding noise because the fan is wobbling and hitting the shroud. On top of the bearing being bad one of the blades is cracked, to the point where I feel it may fly off if something were to hit it when it's spinning. Once Spring rolls around I'm going to be using your write up!
Man, what are you waiting for? The fan hit the ceiling? JK! But seriously, you should have your issue addressed right about now.

Thanks for the praise, and PM me if you have any question.
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  #15  
Old 01-03-2011, 08:46 PM
pleiades pleiades is offline
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Wow 16valex, you took this a step or two further than I anticipated. Looks great, can't wait to read your first in-depth report on all the noticed benefits.
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  #16  
Old 01-04-2011, 05:39 AM
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Originally Posted by pleiades View Post
can't wait to read your first in-depth report on all the noticed benefits.
To put the pressure on you ... ...

I just added this to the bestlinks thread as the first link to go to for an E39 clutch fan to electrical fan conversion DIY.
- Mechanical fan delete DIY fan clutch to electrical fan (1) (2) (3) (4) (5) (6) (7)

What I did was search in that thread (only) for the electrical fan conversions already listed by others as best links - and then organized them into a single line as shown above.

Of course, if you know of better links, just add them to the bestlinks thread.

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  #17  
Old 01-04-2011, 08:01 AM
cn90 cn90 is offline
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16valex,

I admire people who do fan clutch delete, but I want to add my 2 pennies:

- I saw a similar fan on ebay for $15 + $16 shipping = $31.
http://motors******.ebay.com/ky.moto...=p3911.c0.m283

- Dyno before vs after? In different forums that I have seen, this mod provides no noticeable gain in HP, may be 0.001 HP gain LOL.

- I don't understand the fuss about this mod: is it HP gain or reducing noise? My car runs on a brand-new Sachs Fan Clutch and is dead quiet!
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  #18  
Old 01-04-2011, 08:52 AM
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16valex 16valex is offline
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Quote:
Originally Posted by cn90 View Post
16valex,

I admire people who do fan clutch delete, but I want to add my 2 pennies:

- I saw a similar fan on ebay for $15 + $16 shipping = $31.
http://motors******.ebay.com/ky.moto...=p3911.c0.m283

- Dyno before vs after? In different forums that I have seen, this mod provides no noticeable gain in HP, may be 0.001 HP gain LOL.

- I don't understand the fuss about this mod: is it HP gain or reducing noise? My car runs on a brand-new Sachs Fan Clutch and is dead quiet!
Cn90,

Any gain in HP is a bonus for me because that is not my intentions for the conversion.

Too many horrific stories about clutch fan explosion.

In case your aux fan take a dump, and now your engine cooling depends on the clutch fan to save it from over heat ( this is where I don't trust it)

Extending the WP's life

More room for easy access to belts and roller w/o having to deal with the clutch fan is priceless .

And BTW, if Ebay looks too good to be true then it is. The labor is too great and precious to waste with garbage parts.
I paid 84 dollars for the fan from Summit Racing that said made in USA, this alone worth a lot to me.
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  #19  
Old 01-04-2011, 09:15 AM
cn90 cn90 is offline
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Of interest is the E30 people installed a Volvo Fan + Volvo 2-stage relay, it fits very nicely too:

http://forums.bimmerforums.com/forum...php?p=20599479





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  #20  
Old 01-04-2011, 09:31 AM
edjack edjack is offline
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cn90, I believe we'll find that 16valex is an engineer, or a rabid tinkerer, and that goes a long way towards explaining this mod.

Nice sanitary installation, though. Only hope the engine doesn't leap forward!
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  #21  
Old 01-04-2011, 09:38 AM
cn90 cn90 is offline
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Haha...edjack is right,

My 2-cent: the fan clutch only explodes if you neglect it for too long like 100-140K miles, and the problem is worse with V8 engine.

So for my I6 engine, I simply replace the Sachs Fan Clutch/Fan Blade every 80K, and I sleep well like a baby.
I think 16valex has too much time on his hands haha...
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  #22  
Old 01-04-2011, 09:43 AM
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doru doru is offline
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This is a good write-up.
Question: for this setup, if you need to change the electrical motor, can you do it (you said you applied JB weld) - remove the fan and access the motor without breaking anything?
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  #23  
Old 01-04-2011, 11:05 AM
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16valex 16valex is offline
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Originally Posted by doru View Post
This is a good write-up.
Question: for this setup, if you need to change the electrical motor, can you do it (you said you applied JB weld) - remove the fan and access the motor without breaking anything?
I think it will last the life of the car but if you have to replace the motor just slide the shroud out to replace the motor.
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  #24  
Old 01-04-2011, 11:25 AM
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16valex 16valex is offline
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Originally Posted by edjack View Post
cn90, I believe we'll find that 16valex is an engineer, or a rabid tinkerer, and that goes a long way towards explaining this mod.

Nice sanitary installation, though. Only hope the engine doesn't leap forward!
I'll take either one above, I've considered it's a compliment.
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  #25  
Old 01-04-2011, 11:28 AM
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16valex 16valex is offline
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Quote:
So for my I6 engine, I simply replace the Sachs Fan Clutch/Fan Blade every 80K, and I sleep well like a baby.
That until one day your engine will over heat or the fan will explode on you
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