Writeup: Installing 5.9l efan into 4.0l ZJ - JeepForum.com
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post #1 of 11 Old 08-08-2020, 05:11 PM Thread Starter
Marcos
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Writeup: Installing 5.9l efan into 4.0l ZJ

Finally got around to installing the efan in my Jeep. My big concern all along was clearance to the front of the engine. After some trial and error, it turns out using the XJ water pump gives enough room, after which the closest point is the back of the fan motor to the edge of the crank pully at just over 1/4in. A little close for my liking, but it'll do for now. You can get some more clearance by trimming the shroud or finding a way to move the bottom of the radiator forward. Also, the connector and harness are a little close to the pulleys and belt so must be secured well.

After changing out the water pump, installation was fairly straightforward. I removed the fan shroud brackets so I could use the stock efan brackets, and also make it easier to slip the fan in and out. My Jeep is a 93 with the slot mount fan shroud, so I had to improvise some clips to hold the bottom of the fan in place.

I went with the Delta Current Control variable speed controller, wired to the high speed of the fan. I added a hi amp relay on the feed side to make sure the fan wouldn't run with the ignition off. It's actually triggered by the ASD relay so it won't run when the engine isn't running. The DCC controller comes with a radiator fin probe for temperature sensing, so I cut a notch in the fan housing to allow the wires to pass through without getting crushed.

Benefits I am hoping to achieve:
-no more drag accelerating from stoplights in warm weather
-better AC cooling at idle
-easier access to service under the hood

So far I've only driven it a little bit but the drag is definitely gone. Time will tell on the AC and how well the fan keeps cool on hotter days. I'll add pics later.

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post #2 of 11 Old 08-08-2020, 05:29 PM Thread Starter
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Here's a before an after, and a closeup giving you an idea of how close thing are. Despite this, the fan slips in and out pretty easily.
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post #3 of 11 Old 08-08-2020, 05:39 PM Thread Starter
Marcos
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Here's a comparison of the 2 water pumps, and a look at the front of the engine all buttoned up.
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post #4 of 11 Old 08-08-2020, 05:41 PM Thread Starter
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Here are the lower fan clips I had to improvise. I didn't have time to paint them so I'll have to keep an eye on them to see if they rust quickly.
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post #5 of 11 Old 08-08-2020, 05:49 PM Thread Starter
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Here is the DCC controller and the relay tucked beside the battery tray. The fan motor wiring and the temp sensor wiring run under the tray. The radiator fin probe is mounted near the outlet to sense the temperature of the coolant returning to the engine, to determine how much additional cooling is required by the fan. There's also the slot I cut in the fan, which was the only modification I did to the fan assembly itself (other than running the replacement motor and Ford connector).


As for wiring, I had to tap into the ASD circuit and the AC relay circuit (runs the fan at 50%) so for now I have the wire end inserted into the relay terminals of the PDC. not a fan of doing it this way but it was the least intrusive method for now.
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post #6 of 11 Old 08-08-2020, 06:40 PM
kg6mov
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Good work yo!


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post #7 of 11 Old 08-09-2020, 01:31 AM
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Nice solution to use an XJ water pump!

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post #8 of 11 Old 08-09-2020, 07:40 AM
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Curious, what temp must the probe see to turn the fan on?

Ive always read that the probe goes right at the inlet.

1994 ZJ-I6 w/270,000 mi
1998 ZJ 5.9 w/66,000 mi Slate Black
2004 KJ w/108,000 mi
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post #9 of 11 Old 08-09-2020, 07:44 AM Thread Starter
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It's adjustable via a screw on the controller. I'm still fine tuning it as I'd like it to come on a little sooner.

The unit is designed around sensing the return temperature. Sensing at the inlet won't account for how much cooling is already taking place under current conditions (eg, airflow from cruising at highway speed, or cooler ambient temperatures)
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post #10 of 11 Old 08-09-2020, 10:46 AM
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Interesting. Im just thinking about the stock 5.9 cooling. It has a switch in the upper hose that turns on low speed and a switch in the lower hose that turns on high. By the time the lower hose gets warm enough to turn on high, the engine is already pretty hot. Do you have a way to see the actual temp of the engine? Im wondering if the temps will be all over the place. On a cool day under a heavy load, the engine could be (just making these temps up) 220 but the cool air would be removing enough air to not call for the fan. On a hot day, the radiator alone wont be removing as much heat so the fan would be running all of the time so the temp would be lower, say 195F. If the probe is near the inlet, it will be the actual temp of the engine and should maintain a steady temp. Maybe Im overthinking this.

Do you have original heater hoses on that thing?

Where did you get the heat shield and wrap for the fuel rail?

1994 ZJ-I6 w/270,000 mi
1998 ZJ 5.9 w/66,000 mi Slate Black
2004 KJ w/108,000 mi
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post #11 of 11 Old 08-09-2020, 01:24 PM Thread Starter
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The 5.9 uses fan switches that close at a preset temp, and runs the fan at 1 of 2 set speeds. This controller uses a temperature sensor and it can vary not only the temperature when the fan first comes on, but also the speed. You could set it to come on at a relatively low outlet temp. Sensing at the inlet might allow you to turn on the fan sooner, but you would need the outlet reading to determine the airflow demand for cooling needs. It's basically a feedback signal.

I have a DRB2 so I can see what temperature the PCM sees, but I just haven't done it yet. I also have an IR thermometer but I find it's hard to get a good reading.

Those are the original heater hoses that came with the Jeep when I got it in '03. Haven't leaked yet. I have replacements that I'm waiting to put on when I do the heater core, since these are pretty much fused to the current heater core tubes.

Those heat shields and wraps are part of a kit from DEI. Totally solved the hot start/vapor lock problem for me. You can get it from multiple vendors and on Amazon. https://www.amazon.com/dp/B015NOKWQY..._HZemFb46HD2SJ
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