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   Radiator fan plugs and relay base

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Topic: Radiator fan plugs and relay base (Read 1233 times)

Tompion
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1997 2.3 Ultima estate.

Posts: 2918

Radiator fan plugs and relay base
« on: Sep 4^th, 2018, 3:04am »

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As mentioned elsewhere I’ve recently rewired the engine bay loom on my 2.3. At some stage I’ll probably post details of the terminals & plugs I managed to buy but I thought I’d list the radiator fan plugs separately.

You may find the radiator fan wiring a strange mix of 4.0mm2 & 2.5mm2 wires.
I’m guessing LH drive cars with the auxiliary fuse box on the same side as the fan relay may just be 2.5mm2 & RH drive cars with the fuse box on the other side have the extended section of cable in 4.0mm2 due to voltage drop.
I moved my relay to the other side of the radiator which probably halved the cable run & only used 2.5mm2, I measured the voltage drop as 2.5%.
The earth wires for the relay disappear into the loom to splice with the earth of sensors etc then doubles back to the earth point alongside the relay. I’ve kept the earth short & separate using the earth point under the other headlight alongside the relay in its new position.

You can buy plugs for the fans on Ebay for under a tenner, they’ll be headed something like “Ford 2 Pin Radiator Fan Switch Connector Sierra, Focus, Escort, Zetec”. You can get them for crimping or with tails ready crimped with a splicing kit although the listing I looked at didn’t say what wire size the tails were.
Alternatively you can get 10 from China for less than 2 from somewhere like:
https://www.autoparts-factory.net/_p2502.html

They looked the same to me. As ever it’s down to you whether you exceed the limit for import duty charges.

----------------

The relay base, terminals & seals can be bought from:
https://www.mouser.co.uk/

Paste the Mfr. No from the following into the search box at mouser & you’ll find some data sheets etc:

Mouser No: 829-10740372
Mfr. No: 10740372
Desc.: Automotive Connectors Automotive Connectors APEX 150 MALE 20-22GA UNSLD SN
£9.14 each

Mouser No: 829-60070251-L
Mfr. No: 60070251-L
Desc.: Automotive Connectors Automotive Connectors 9.5DCS-1 F 2.5-4.0MM2 SN SWS
£2.04 each

Mouser No: 649-60040041-L
Mfr. No: 60040041-L
Desc.: Automotive Connectors Automotive Connectors FEMALE 6.3MM TERM 3.0MM INSUL DIA TIN
£1.06 each

Mouser No: 649-60012841
Mfr. No: 60012841
Desc.: Automotive Connectors Automotive Connectors FEMALE 2.8MM TERM 3.0MM INSUL DIA TIN
£0.806 each

Mouser No: 829-15327788
Mfr. No: 15327788
Desc.: Automotive Connectors Automotive Connectors SEAL DCS1 9.5 (2.5-6.0MM2)BLK
£1.35 each

Mouser No: 694-60992604-B
Mfr. No: 60992604-B
Desc.: Automotive Connectors Automotive Connectors SNGLE WRE SEAL 4.8MM 1-2.5 SQMM WIRE SIZE
£0.302 each

Mouser No: 649-60993403
Mfr. No: 60993403
Desc.: Automotive Connectors Automotive Connectors 2.8MM SNGL WIRE SEAL RED .35-.75MM2
£0.69 each

Here's the relay in it's new home under the inlet trunking.

I ran the wires back to the footwell in their own loom. I imagine you could pass it through one of the blank holes in the big bulkhead grommet the main loom goes through.
If you're drilling out the rivets of the PCM cage I suggest you first drill 2 holes between the top 3 rivets & fit 2 self tapping screws. Do the same for the bottom 3 rivets.
Now drill out the rivets, unscrew the self taps, remove the front panel & open the 4 holes for clearance.
This gives you a temporary way to hold it together or permanent if you're not bothered about the added "security" of riveting it back together.

Mike (Simmo) sent me this picture of the PCM cage with 4 new screws fitted ready to drill out the rivets. If you just want access to the large PCM plug you could just drill out the other 3 rivets visible to release the shroud over the connector.