Ok, even with the FAQ there is still so much information about where to get parts in there that any installation tips have kind of gotten lost. I decided that I would break in the new forum and post the steps that I took to install ramcharger fans in my TPI Monte.Ramcharger Dual Electric Fan Installation
I have a TPI system, so the wire set up might be slightly different
First things first: You need to locate the fan system. I ordered mine from an Authorized Vendor of this site, SMM Performance (Protouraero) at 219-926-9793 , but you can the set up at a local junk yard or Ebay.
Here is what you are looking for:
If you are getting it from a salvage yard, these are the cars to look for:
Chrysler Concorde 93 - 97
Chrysler LHS 94 - 97
Chrysler New Yorker 94 - 96
Dodge Intrepid 93 - 97
Eagle Vision 93 - 97 ESi or TSi
These all use the same fan set up, so any of these cars should work. Make sure you get enough of the wire system that you are able to splice into a custom wire harness.
1. Wire Strippers/Crimpers
2. 10 Ga. primary wire (I used red and black, but any two colors will work as long as you can distinguish the power and ground)
3. 8 Ga. primary wire - the same two colors as the 10 ga.
4. Two automotive relays - I got mine at radio shack, but most parts stores sell them in the fog light section (make sure they are 30/40 AMP)
5. Heavy Duty zip ties or electric fan mounting kit (which is really just fancy zip ties)
6. 10 Ga. butte connectors
7. 10 Ga. FEMALE spade connectors
8. 8 Ga. FEMALE spade connectors
Optional Supplies (I used all of these, and will be referencing them):
1. Fused power distribution block (You need it to be fused, so I decided to do it this way in case I need to add any other electrical accessories)
2. 4 Ga. Power wire - from a car audio store
3. 2 Automatic temp sensors - there are several different brands and models. I used an Imperial part from Advance Autoparts that cost about 14 bucks, it is an exact copy of the Flexalite adjustable fan control
4. Cutlass radiator top plate - not necessary, but looks a lot nicer, and it is more secure.
5. Heat shrink tubing to waterproof wire connections.
Ok, now that all the supplies are together, you are ready to get started. We will start with mounting the fans because it is the simplest.
Depending on the radiator you have in your car, some trimming/shaving may be necessary to get it to fit. I was lucky, and my fans fit perfectly between the tanks of the radiator. What you need to do is simply test fit it to see if any trimming is needed. This may be easier with two people, because it can be hard to line up the fan and keep it steady because you are bending your arms around all sorts of other stuff in the engine bay.Test fit
1. Slide the fan down behind (in between the radiator and the engine) the radiator
2. If the shroud fits (it will be snug) in between the side tanks of the radiator, you are done. If not, keep reading.
3. Identify what part of the fan is hitting the radiator (usually going to be the 4 original mounting tabs)
4. Pull the fans out and trim - it will be easiest to use a rotary tool like a Dremel, but the plastic is fairly easy to cut with a utility knife (just be careful!).
5. Repeat steps 1 - 4 until the fans fit nice and snug.Mounting
1. Pull the fans back out and lay them on a flat surface.
2. Using a drill bit that is big enough to feed zip ties through the hole, drill 6 holes around the perimeter of the fan shroud. I drilled one hole in each corner, and one on top center, and one on bottom center.
3. If you have push in type temperature sensors, push the sensor into the fins per the directions that come with the unit (near the upper left corner in an SS) and mount them in a location that is convenient for you. I mounted mine right on top of the fan shroud so they are easy to get to should I need to adjust them.
Picture - Temperature sensors mounted to fan shroud:
(The reason why the sensor wire is bundled outside of the shroud is because I previously had a flexalite controller and it crapped out, so I replaced it with the one from Advance after I already had everything mounted.)
4. Now feed a zip tie through each hole and through the fins of the radiator, around the side of the radiator and secure it back.
Picture - Zip tie securing fan to radiator, and zip tie securing A/C line:
5. Find an appropriate location to mount your relays and fuse panel. For me, this was on the inside of the passenger side fender (make sure that you are not getting in the way of the hood hinge). Go ahead and mount them so we will be able to run wires to them next.
Picture - Power Distribution and relays mounted to inside fender:
6. Install radiator top plate to secure radiator to car.
Picture - radiator top plate installed:
This is the most time consuming part of the install, so take your time. It is easier to spend a couple of hours doing it right the first time, then having to go back and do everything over.
I will list the steps that I took to wire everything and then I will post my wire diagram.
1. Locate a good 12V switched power source.
- According my service manual, the Choke Heater circuit in the main fuse panel is not used in V8 cars but still wired in. Look at the main fuse box, it is labeled "C/H".
2. Splice 8 ga. wire into the source you have chosen.
3. Run the wire through the firewall and into the engine bay and to the temp sensors.
4. Split (splice an extra 3 inch piece to form a Y) the wire and put two 8 ga. spade connectors on the ends. Now connect them to the appropriate terminal of the temp sensor.
5. The other terminal of the temp sensors will send the trigger signal to our relays, so connect spade connectors to some more 8 ga. wire and run the wire from the output connector of the temperature sensor to the 85 spade on the relay. (Do this for both temp sensors)
6. Use 10 ga. wire to run from your fuse panel (2 locations) to each relay. Use spade connectors for each end. You will be connecting these wires to the 30 spade of the relay.
7. Locate a suitable ground near the relays, and using 8 ga. wire, connect spade 86 of each relay to this ground.
8. Locate a suitable ground for the fans. Using 10 ga. wire, connect the black wire on the fans to that ground.
9. Connect each of the remaining wires (green and yellow for mine) of the fan to spade 87 on their own relay using 10 ga. wire.
Picture - close up of relays:
10. Use the 4 ga. wire to run from the battery to the fuse block.
Picture - close up of fuse block:
11. Install 30 AMP fuses, and test.
12. In order to set the temperature sensors, turn both of them as high they can go and start your car. Once your car reaches the temperature you wish for them to turn on at, turn the knob of one of the sensors until the fans kick on. Now, shut the hood and let the car heat up, once the temperature rises to where you want high to kick on, turn the knob of the second sensor until the fan kicks on.
OPTIONAL STEP: Connect A/C to fans. Many people think that it is necessary to have your fans on when your A/C is on, so here are the steps of how I connected the A/C to my fans.
1. Locate the green trigger wire for your A/C compressor (one of two wires that actually plugs into the compressor).
2. Splice 8 ga. (the color you used for "hot") wire into that green wire.
3. Run that wire to the sensor that you have set as your "high" temperature turn on. And splice the wire from your A/C into the output wire of the temperature sensor.FINAL STEP
Use wire loom to cover wires and zip ties to secure wires!!! (I ran out of wire loom so in the pics, some of mine are uncovered) Unnecessary, but wire loom makes everything look professional.
Final install pictures: