Table of Contents

Page 1 - Background, current happenings.
Page 2 - Current and future modifications.
Page 3 - My previous truck
Page 4 - Modification - electric fans
Page 5 - Modification - Tahoe mirrors w/heat and puddle lamps
Page 6 - Modification - LED lights

Flex-a-Lite Electric Fan Installation

This page is all about the installation of my Flex-a-lite (FAL) #292 electric fans. You can install these fans or, like a lot of other people do, install fans from a late model Camaro, Firebird or Corvette. I went with the FAL (although the more expensive route) because they gave the best look for a stock-like appearance. (Although you can now go with the 2005 factory fans, which require the large radiator.)

I have to say the engine compartment is so much more quiet. Other than the FIPK sucking air I wouldn't know it was running. That stock fan clutch is really noisy.

I didn't use any of the FAL wiring or the included variable speed controller (VSC). I installed using the PCM (to trigger fan1) and A/C clutch compressor circuit (to trigger fan2) as the controlling circuits for the fans. I thought about getting the Nelson harness, and although a nice piece, it didn't satisfy my "limited-exposure" wiring that I wanted to do. I had some Metri-pak 280 series terminals, connectors and relays so I did a custom wiring install myself. I wired up using the two-relay method (the third relay in the picture is for some future use). Here are the schematics for both types of relay hookups: 2-relay and a 3-relay . When using the PCM as a trigger (pin 42 of the blue connector), you must have the PCM reprogrammed to actually recognize fan control and then set your on/off temperatures accordingly. I used LS1Edit to do this.

I found a nice hiding spot under the fuse box cover to place the relays and fuse holder and made all my power and ground connections within the fuse box area. No factory wires were spliced in this wiring installation - which is how I like to keep things. All you see is one clean wire loom running from the fuse box cover down to the fan connectors. I think it turned out real well.

Here is a picture of the new wire loom:

Here is the picture of the fans installed. Notice the connectors installed at the bottom of the fans; this allows for easy removal of the fans, if need be, and gives a more stock appearance:

Here are the front and rear shots of the weatherpack connectors:

Here are the before and after pics of the fuse box:

Steps for the installation:
1) Remove upper fan shroud
2) Remove fan/fan clutch assembly. I used an adjustable wrench and a soft face hammer to persuade getting the nut loose. About 3 hits and all was good.
3) Remove lower fan shroud.
4) Lower FAL fan assembly into place and bolt up. Start all bolts, then adjust as needed while tightening all bolts.
5) Install wiring. I tapped all my wiring from the fuse box area. 12V power came from the right hand side power post (as seen in the picture). Relay1 trigger was from the ignition circuit (ground side is the PCM, pin 42 on the blue connector). Relay2 trigger was from the A/C clutch compressor circuit (hooked in from underneath the fuse box). All grounds (other than the PCM one) were connected to a bolt on the fenderwell by the fuse box - visible in the picture above. I bought a PCM terminal connector from the dealership in order to connect up the PCM ground trigger. This was a little troublesome trying to poke it down into the connector as the wire was only 18AWG and not strong enough to keep from bending. There is some yellow "weatherstripping", for lack of a better term, that seals the connector pins. You must poke a hole in this in order to insert the terminal connector. Use something large enough so that there won't be too much trouble getting it through. But, don't poke too big a hole because you still want it to seal and keep out any foreign matter.
6) I used LS1Edit (other software programmers are available) to set the PCM to recognize the use of electric fans and then set the ON/OFF temps for the fan.