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|While I was a at DE in eastern Washington, my front fender mounted oil cooler fan died. The car runs too hot at the track without this fan, but will run cool enough on the street/highway, so I was able to drive the car home.
This photo shows the fog light removed and the horns partially removed (needed the photo so I could remember where the wires went!)
|I ended up removing the front turn signal lights, the bumper bellows, and this real weird large piece of metal that appears to be part of the bumper. There is a sequence to this: Foglight first, the horns, then the large piece of metal, the bellows, then the turn signal lights.
In this photo you can see the bottom half of the cooler, and the nasty rusted lower bracket.
|Since I removed the bellows, I was able to see into the side of the cooler. It also allowed me to get my hands in to remove some of the bracket attaching bolts.
This photo shows the upper bracket, which doesn't look all that bad. I had removed the attaching machine screws before I took this photo.
|The original fan, finally out of the car. Weird thing was, this fan worked when I bench tested it. Possibly a piece of junk was lodged in there? Who knows, but I decided since I was already in this far, I'd replace the fan..|
|This is what the cooler looks like with the fan removed. You can see the mounting points for the fan.|
|Another shot of the cooler without the fan on it. As you can see the upper right mounting point is WAAAAYYY up there and there is the horn bracket a bit in the way. Once you get the cooler in there, it is pretty tough to get the machine screw started, especially with big old hands like mine.|
|This is the replacement fan, which is a 7.5" diameter SPAL fan. I decided on this fan based on feedback from a number of Rennlisters who had done this replacement before. When I called to order the fan, SPAL-USA didn't have it in stock, the order they had coming in wouldn't even take care of their backorders and the next shipment was due in 2 months. So, I ordered it from Racer Parts Wholesale, who had it in stock, and shipped Fed Ex next day.|
|The new fan on the left and the original fan on the right. They are almost exactly the same diameter, but the mounting positions are a little different. An orginal fan from Porsche is $275, and this fan was $75. One hopes that it will work as well, but even if I have to replace it again the future, I have all the parts necessary to mount another fan.|
|Since the mounting points were a little different on the new fan, I made some mounting brackets from some thin aluminum sheet stock I had. I set the two fans back to back with the original brackets on the original fan, then used the mounting holes as a template to measure out the new brackets. Not things of beauty, but all I have to work with is a 3/8" drill, bench grinder, and a MotoTool. A little paint and they don't look too bad.|
|This is the fan with mounting brackets attached. I attached them with some small metric machine bolts with nylock nuts, so I don't think they will come loose. They aren't adjusted yet, that took about 1/2 hour of fiddling once it was back in the fender.|
|This is the fan installed on the oil cooler. I was able to use the stock mounting holes on the cooler, just move the attaching brackets a bit to make them fit. I used new machine screws to mount the new fan to the cooler.|
|One last photo of the fan installed before I started putting all the lights and horn back on. This does show a little better how the fan is mounted to the cooler.|
|This is the switch that I installed to override the thermo switch on the oil cooler itself, as the opening temp of that thermo switch is known to be quite high. The switch is a lighted one, so that when the fan is operating, it will glow red. Not real high tech and I did get it from Radio Shack.|
|The wiring for the oil cooler fan is in two different sets of wiring, although they are both in the same bundle. The power to the fan is in the larger brown and black wires with the large black connector. This comes from the relay and supplies the power to the fan. The connections I made for my switch are the smaller blue/white and brown wires that control the relay and go to the thermo switch. I merely tapped into them with some connectors (I used green wire for the power connected to the blue/white and black connected to the brown for ground). I then ran those wires inside the corregated wire loom up the side of the trunk, in though a bulkhead hole with some other wires (utilizing its rubber grommet), under the dash to the location of the swtich. Pretty simple design, just not easy for a 6'5" guy to get under the dash to do the wiring!|