Ford Windstar E-Fan Wiring Question
 

Hi All,
5.3 w/6l80 in an 86' with Ford Windstar efans. I had one fan run on constant till I had time to clean the wiring up. Well that time came yesterday and I tried to wire the fans off the PCM with the wires I had stubbed out and I let the engine get to 225 degrees and nothing happened. I supposed I had them wired up wrong and am looking for some help. I was looking around and found this drawing, can anyone confirm if this will work?

http://i735.photobucket.com/albums/w...2/untitled.png

Or can anyone help with wiring??

Thanks!!

Re: Ford Windstar E-Fan Wiring Question
 

Hello houston Ben. you wiring diagram shows how to wire up high/low speed electric fans using (3) relays. a friend wired his lsx fans using (2) relays with the same high/low speed feature. His instruction came from lt1swap.com. in the past, i wired my (2) electric fans using (2) relays, with (1) speed. my pcm was programmed to turn on fan (1) at 195F and fan (2) at 215F. this has worked well for me in the past. Houston Ben, you can be the guinea pig. im interested to see the results.

Re: Ford Windstar E-Fan Wiring Question
 

the fan trigger signal from your ls pcm is a ground not a 12v signal.

Re: Ford Windstar E-Fan Wiring Question
 

That wiring diagram looks good. I've wired fans like that in the past and it's the way GM did it on the fourth gen Camaros (and probably others). Both fans will run at half speed for low and both fans will run at full speed for high.

Re: Ford Windstar E-Fan Wiring Question
 

depending on your year of computer, 99-04(i think) didn't have electric fans from the factory but the computer had the capability to supply the ground but you had to have them programmed to do so. So it you have and 04 and down, is yours programmed to turn them on? Like posted above too, the computer supplies ground to the relay. And also make sure you have the correct pin from the computer, I just did mine in an 03 and was off one pin and the fan ran as soon as I hooked it all up. Moved one pin over to the correct location and everything worked as planned. Lt1swap is a great source for info, thats where all of mine comes from. Good luck

Re: Ford Windstar E-Fan Wiring Question
 

Thanks for the replies, sorry I forgot to mention my engine and trans came out of a 2011 1500. I had the harness redone and the two fan wires stubbed out. I guess I will try this and see then.

Re: Ford Windstar E-Fan Wiring Question
 

Using three relays works if you have two fans, low they're run in series and high they're run parallel. Do you have one or two fans?

Re: Ford Windstar E-Fan Wiring Question
 

I have two fans, each fan has one positive (red) and one negative (black) wire.

Re: Ford Windstar E-Fan Wiring Question
 

With two fans the three wire relay is the way to go. Here's the diagram I use.

Re: Ford Windstar E-Fan Wiring Question
 

I have to did up an old thread, I finally got around to getting my third relay and wired them up like so
http://i735.photobucket.com/albums/w...LAYDIAGRAM.jpg

Engine temp got to 231 to turn on fan and turned off at 193. Problem is, I thought they would both turn on but just the small one turned on. Looking at the diagram can anyone tell me why only one turned on??

Thanks for any and all suggestions.

Ben

Re: Ford Windstar E-Fan Wiring Question
 

I guess I could take out the 5 relay one and run both remaining relays like relay 1 and hook both 85's to the PCM fan contrl 1 for the ground on both relay. Then run both fan grounds to a ground..... will that work? I am not an electrician....but I play one on tv...

Re: Ford Windstar E-Fan Wiring Question
 

If relay 1 does not operate (because of bad wiring, missing control signal, faulty relay, etc.):

1) Neither fan will run when you reach the low speed fan temp
2) The fan on the left in the diagram will come on at full speed when you reach your high speed fan temp.

If relay 2 does not operate:

1) Fan 1 and 2 will run at half speed when you reach low speed fan temp
2) The fan on the right in the diagram will run at full speed when you reach high speed fan temp and the fan on the left will be off.

If relay 3 does not operate:

1) Fan 1 and 2 will run at half speed when you reach low speed fan temp.
2) The fan on the left in the diagram will run at full speed when you reach high speed fan temp and the fan on the right will be off.

Since you're not getting both fans on at half speed and then getting just one fan on at 231, it sound like you have wiring/relay problem with relay #1 in the diagram.

Re: Ford Windstar E-Fan Wiring Question
 

Thanks for the reply dayj1!

Question, relay 1 & 2 are 4 pin and 3 is a 5 pin, could that be a problem that I am not using 5 pin for all 3 relays?

Re: Ford Windstar E-Fan Wiring Question
 

It's OK to use 4 pin relays for 1 and 2. Just double check your wiring on relay 1 and verify that it matches the diagram that you posted. The way that you're trying to set them up is the best way, IMO. Your fans will last longer since they'll only be running at 1/2 speed most of the time.

Re: Ford Windstar E-Fan Wiring Question
 

Cool, thanks for the help. Also, what temp is the low speed supposed to turn on at? I have not changed the stock temps.

Re: Ford Windstar E-Fan Wiring Question
 

The temps probably vary by year and application, but the following values are what I had in my notes.

Low On: 226
Low Off: 219

High On: 235
High Off: 227

Re: Ford Windstar E-Fan Wiring Question
 

here's what I got from my mail order tuner, and it works fantastic.

"Your fan controls are programmed for 201 on, and 197 off for the blue 42,
and 204 on, 201 off for red 33 control. The PCM will supply GROUND to
activate the fan relay, and will only command the relay on when engine is
running and coolant temp reached. It is better sometime to verify temp the
computer is reading from the coolant temp sensor with a scan tool. Also, do
not share the coolant temp sensor with anything else, the PCM should be the
only thing hooked to it."

Re: Ford Windstar E-Fan Wiring Question
 

Don't mean to hijack the thread. With the relay diagram above you can make a hi and low speed on a 1 speed fan motor? Fan with only 2 wires to wire it?

Re: Ford Windstar E-Fan Wiring Question
 

Yes you can, on a DC motor the speed is based on voltage applied, by running 2 motors in series you basically cut the voltage in half. 6 volts to each motor hence 2 speeds, 1/2 speed(6V) and full speed (12V). Your older heater fan works the same way, on the fan speed switch it has resistors on the rear which cut the voltage to the motor 12V, 9V, 6V hence 3 speeds.
Hope it helps.
Rob

Re: Ford Windstar E-Fan Wiring Question
 

Ok thanks rob. I will have to get another relay and re wire with the above schematic.
Thanks
Scott

Re: Ford Windstar E-Fan Wiring Question
 

Dayj1, so will my engine be fine running it that hoe or should I leave one fan on at all time cooling it at about 198?

Re: Ford Windstar E-Fan Wiring Question
 

231 isn't that bad. The factory high speed fan setting was 235, after all. With that said, I wouldn't want it to run that hot permenenty, but I don't think it will hurt it while you're testing out your fan wiring.

Did you get a chance to look at the wiring again? Just to be clear with what I was trying to say earlier, both fans should initially come on at half speed when you hit your low speed temp. Then both should come on at full speed if the engine continues to get hotter and reaches the high fan temp.

I had relays on the brain last night, but another thing that could cause the symptoms you're having is if one of the two fans in your Windstar setup is bad. I know you said the smaller fan comes on, but have you tested the larger one to know for sure that it works?

Re: Ford Windstar E-Fan Wiring Question
 

Thanks for the reply, I haven't had a chance to check the wiring yet but will this week, but Both fans do work. I didn't think the temps would be bad due to being factory settings but just wanted some singer maroon on my thoughts.

Thanks again!

Re: Ford Windstar E-Fan Wiring Question
 

Thanks for the reply, I haven't had a chance to check the wiring yet but will this week, but Both fans do work. I didn't think the temps would be bad due to being factory settings but just wanted some confirmation on my thoughts.

Thanks again!

Re: Ford Windstar E-Fan Wiring Question
 

Got a question is the wire from the PCM for fan 1 relay 1 above?
And I an guessing "A" is ground and "B" is the 12 volt wire? Normally?

Re: Ford Windstar E-Fan Wiring Question
 

I guess you could connect it to which ever can you wanted

Re: Ford Windstar E-Fan Wiring Question
 

Yes, you are correct on all that.

Re: Ford Windstar E-Fan Wiring Question
 

Great thanks

Re: Ford Windstar E-Fan Wiring Question
 

Ok, spent a few hours trying to figure out why both fans won't turn on when needed.

http://i735.photobucket.com/albums/w...LAYDIAGRAM.jpg

So I found both 1 and 2 relay work, but I don't know how to test #3 which is a 5 pin relay. If I have #3 hooked up correctly 87a should have 12 volts to it correct?? I have tried this but get no voltage out of 87a. Am I doing something wrong?

Re: Ford Windstar E-Fan Wiring Question
 

87a on 3 will only have power when 1 is energized,, and the fan is on. If the fan is missing or unplugged, it won't.

Re: Ford Windstar E-Fan Wiring Question
 

Just looked at it again, I am getting 3V out of 87a, could #3 relay be bad??

Re: Ford Windstar E-Fan Wiring Question
 

Relays are a switch, either on or off, so you shouldn't get 3 volts out of it. Could be because its going through the fan. Have you switched the relays around to see if it changes anything? Are you absolutley sure you have it wired right? Sounds like a wiring issue to me.

Re: Ford Windstar E-Fan Wiring Question
 

I just finished up the fan wiring and wired as above and started the engine for the first time (well woth coolant). Fans worked great. Low speed and than high speed. So the diagrams definitely works
Thanks guys

Re: Ford Windstar E-Fan Wiring Question
 

It depends on when you measure it. With all relays off (i.e. engine temp below the low speed fan temp) pin 87a should be at 0V with respect to ground. With Relay 1 on (i.e. temp above low speed fan temp but below the high speed temp) 87a should read about 6V. If both fans have the same motor it should be really close to 6V but it could vary by a couple of volts if they're not the same motor. With all 3 relays on (i.e. temp above high speed fan temp) 87a should read 12V.

If you can disconnect the control wires from the PCM, turn the ignition on with the engine off. If you ground the green wire in the diagram (fan control 1) both fans should run at half speed. If you ground both the green wire and the blue wire at the same time, both fans should run at high speed.

If the fans work as described above when disconnected from the PCM, then your problem is with the PCM programming or control wiring. If you get any other behavior, the problem is with the relay or fan wiring.

Re: Ford Windstar E-Fan Wiring Question
 

Thanks for everyone's help. I double and triple checked the wiring and all is just as diagramed. I turn the ignition on engine off and can only get the first fan to turn on. This only turns on if I touch #85 from both relay 1 & 3 to a ground. I can't get the second fan to turn on at all even if I ground all 3 85's?? Yes, both fans work.

I'm thinking #3 5 pin relay is broken. It clicks but won't put out voltage.

Re: Ford Windstar E-Fan Wiring Question
 

Which fan turns on in reference to the diagram that you posted? I know it's physically the smaller fan, but is it the one on the left or the right in the schematic?

Re: Ford Windstar E-Fan Wiring Question
 

My guess it's going to be the fan on the right that's coming on.

So if you ground just 85 of relay 1 nothing happens? Try swapping relay 2 and 3, and ground 85 of relay 1, if they both come on low, then replace the 3 relay. Pin 87a on 3 may not be working.

Edit- The more I look at it, this probably isn't going to help. Are you sure the fan on the left is plugged in and works? It seems like the open in the circuit is there.

Re: Ford Windstar E-Fan Wiring Question
 

I'm am positive both fans work, I have switched ray 1 & 2 and then only the left fan will turn on. Only thing I can think of is 87a is dead.

Re: Ford Windstar E-Fan Wiring Question
 

Ben,

In post #35, you said that only one fan comes on when you ground the control line (pin 85) of relays 1 and 3. In post 38, you said the fan that comes on is the one on the left in the diagram.

I'm making one assumption (so tell me if it's wrong). The assumption is that relay 2 and 3 still have their control lines (85) wired together. So when you ground the control for 3, you're also turning on relay 2.

If that's the case, then the problem is either:

1) The fan on the right in the diagram is bad.
2) Relay 1 is bad
3) The normally closed contact on relay 3 is bad
4) The wiring from pin a of the fan on the right to pin 30 of relay 3 is open
5) The wiring from pin b of the fan on the right to pin 87 of relay 1 is open
6) The wiring from pin b of the fan on the left to pin 87a of relay 3 is open

You've assured us that "1" and "2" above are covered.

To test number 3, pull the 5 pin relay (3) out of the circuit. Plug a jumper wire into the relay 3 socket to short pin 30 to pin 87a. Turn the ignition on and ground the control line (pin 5) of relay 1 only. If both fans come on, the problem is relay 3.

If both fans still don't come on with the above test, leave the jumper in place in the relay 3 socket. Ignition on, engine off, ground the control line (85) for relay 1 only. Measure the voltage between a good ground and all the following connections.

1) pin 30 of relay 1
2) pin 87 of relay 1
3) pin B of the fan on the right
4) pin A of the fan on the right
5) pin 30 of relay 3 (even though there is a jumper still in the socket)
6) pin 87a of relay 3
7) pin B of the fan on the left

Then post what all those voltages readings are.

Re: Ford Windstar E-Fan Wiring Question
 

Thanks dayj1, will do, just won't be home for a while. You are correct, post 35 the relays are connected just like the diagram and only the fan on the right of the diagram will turn on.

Post 38, I switched wiring between relay 1 & 2 which then turned the fan on the left on.

You are correct that relay 2&3 #85s are wired together and I will test 3 as suggested and repot findings.

Thanks again for all your help!!