I have an 1992 Camaro RS with a 305. It has a single electric fan. The fan does not work, whatsoever. I found that by replacing the fan relay the fan would once again work, however within a day or two the new fan relay would burn out. I am done dealing with replacing relays and dealing with overheating.

I would like to bypass the relay and wire my electric fan directly to a switch inside of the car.

Despite several searches I could not come up with a good description of how to do such a project. I red about wiring a switch to the green wire off the relay to a ground. Will this by pass the relay completely as I would like?

Also what options are available for adding an mechanical fan to the Camaro, that way I would have both a mechanical fan and a electric fan.

Thank you for any assistance that can be provided!

 

Whats burning up on the relay?

The relay is there to take the current of the fan, you dont want all that current running thru a switch on the dash.

 

Replace the fan motor

 

Is there a quick and easy way to test whether fan motor works or not?

 

Sounds like there is to much resistance in the fan motor and it's overloading the relay.... Like what was said before, even if you choose to run a switch instead of the automatic operation you still need to run a relay, you just don't want that much current running thru just a switch.

Mark.

 

In this photo you can see that the top right hand pin and the bottom center pin have some burn marks.

 

A simple test, physically spin the fan, if it tight and stops quick, the motor bushing are shot.
If the fan spins freely, similar to a ceiling fan, the motor may still be fine.

Granted, a physical spin test doesn't take into account a burnt winding or worn out brushes.

If there is a problem enough to burn a relay and/or the wiring, how will replacing it (the relay, a switch) with a switch solve the problem ?

Considering you have a turd TBI (had one, so don't boo-hoo me on calling it a turd), the fan will only come on at 238°F or, with the HVAC controls set to the A/C. So, for practical daily driving, with the A/C off, a TBI fan will almost never run.

 

Sure... look at the relay connector, and if the pins that go to the contacts (the 2 big ones... the 2 little ones are the relay coil) are hot and/or burnt looking, your motor is smoked.

All a relay is, is an electrically operated switch. It takes a small amount of power to operate it, and controls a MUCH larger amount of power. There's no reason to "bypass" anything in that system. Just repair it. If the connector is too badly damaged to re-use, just go to the boneyard and cut one off of some other car; and splice it NEATLY and CAREFULLY onto your car's wiring. Don't do a crappy hack job, otherwise the places where the new wires meet the old wires at the splice, will burn up just like your connector. Keep in mind that any switch you put in there would have to be heavy-duty enough to handle ALL THAT power, and would have to be wired with HUGE wire, as well. Not a smart idea at all.

 

Would there be a benefit to switching to a dual fan system rather than the single fan?

 

If the system is bypassed, would it/ could it affect the A/C System and prevent the compressor from running? IF so, what would you need to do to prevent this issue?

Mine was already bypassed in this manner by the previous owner. I probably won't have time in the next few weeks as I have been and will be travelling, but if you're still working on this in April send me a PM to remind me to check it out for you.

 

No

 

I think so... You would have to do a little wiring to make it happen too.

I changed out to the dual fan set-up. Wired the second fan switch into the first relay circuit. So both fans come on with the ecm/switch on head/ or manually with my re-wired driving light switch.

 

I think you meant to say, No. On a stock Lo3, there is no benefit.
They barely have enough power to overheat with no fan, if the cooling system is in proper order.

Even GM saw no reason to use the ECM to control the fan to turn it on at 220°F and just opted to use the 238°F fan switch only.