Spal electric fan conversion (fan clutch delete)

[bmw540san]

Let me start by saying that this is IMO and I've had this upgrade perform flawlessly on both of my E39's for well over a year now. Some may disagree with some aspects of this upgrade but 2 things are clear:

1. fan clutch is sort of obsolete system by now and while it performs fairly well on BMW engines, it does create potential issue by literally disintegrating and creating quite a bit of damage. There are different opinions on why but the fact is that it does happen on V8.

2. While DME controlled thermostat does have some advantages it is set to 105 C + which is simply to close to dangerous temps. BMW did this in order to decrease emissions and improve fuel economy but one thing is clear: More heat = more pressure which puts stress on plastic cooling components.

Also, these are original 11 year old parts with 96k miles on them, so it's not like I'm trashing brand new parts. Another thing I like about the this upgrade is the extra room in engine compartment.

So here we go: (items in the first picture)

High performance ultra quiet Spal fan

195F Spal sensor with wiring and relay:

Sensor will be placed in Auto Meter radiator hose adapter right after the lower radiator hose OEM coolant sensor. The sensor will activate the Spal fan if the coolant coming out of radiator is 195 F (90 C) and the fan will stop when the coolant cools down to 175 F (80 C). As I said, having this on both E39's, the Spal fan will come on at certain situations but never more than 30 sec.

Upper radiator hose for non Vanos M62 engine:

This hose will be connected to M62 95 C conventional thermostat (not pictured) which will replace the original OEM DME controlled 105 C thermostat. 95 C thermostat is direct fit to the WP opening. The disconnected DME wiring will have proper resistor in order to keep DME from throwing a code.
It's worth mentioning that 95 C thermostat is found on early 1996-97 840ci and in my 540 is keeping the temp around 95-97 C which is hot enough to properly burn all contaminants in combustion chamber and yet there is extra 10 C of buffer compared to OEM 105 C.

24" x 24" 0.080 6061 aluminum sheet:

As in both of my e39's, I prefer to keep OEM shroud which I modify to receive aluminum plate with the cutout for Spal fan. This way, the OEM look is retained and everything is sealed in order for Spal fan to properly pull heat from radiator (sort of vacuum function)




Contens of 195F Spal relay kit: Everything is high quality and it was very easy to wire the system on my E39's






Fitting the 195 F Spal sensor into Auto Meter radiator hose adapter. I've used this Permatex sealant on E39's and it's designed for coolant purposes and it doesn't interfere with the ground function of adapter body.




Continued here:

http://www.xoutpost.com/bmw-sav-foru...-part-2-a.html