Important disclaimer:
If you decide to do this mod it is at your own risk I cannot and will not be held responsible for any damage that occurs after doing this mod. You do this at your own peril fully understanding there might be consequences to the cars performance.
That's why it is important before you start, to make sure that the cooling system on your car is in perfect condition. Do not use this method if you have an ongoing cooling problem.
Principle of operation:
We are going to use a capillary thermostat to sense the coolant temperature, the thermostat can be set to the desired value with a adjustable knob. This temperature setpoint, when it is reached will make/break a contact and enable the ac fans.
Most thermostats come with a datasheet, 2522212 - 8J is the reference for the thermostat I used from conrad. Below the operation is explained, make sure to read the manual of your own device.
This mod has no effect on the aircon, it does not use the dual pressure switch, the stat is in parallel with it so either can enable the fans.
The stat should be mounted in a splash proof plastic box. Suitable ones can be obtained from Conrad Electronics. I choose this one because its black and it does not stand out in the engine bay. Reference: 1590501 - 8J
When installed in the box it looks like this:
Of course you'll have to drill the hole to accept the thermostat knob yourself. Also you'll have to connect 2 wires to the thermostat before you close the box, so leave the cabling a bit longer until you know how long they should be.
You should be able to find a good grounding point (chassis) in the engine bay, I used the one which is a bit hidden behind the airbox. It is just a matter of undoing the nut adding a good size lug on the cable and you are set. For good comprehension, that would be the cable which is connected to the "C" tag on the thermostat. The second wire will come later.
The thermostat sensor bulb should be cable tied on the top surface of the top hose (side of the RAD closest to the EAS box on the Diesel). It should be covered with foam pipe lagging (28mm does the job) also cable tied in place.
So it looks like this:
I also put some tape over the foam lagging.
As for the second cable, you'll have to gain access one way or another to the dual pressure switch. It might work by just removing the fog light grill under the bumper near side in front of the diesel auto gearbox oil cooler or by removing the bumper entirely.
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Of course you'll have to drill the hole to accept the thermostat knob yourself. Also you'll have to connect 2 wires to the thermostat before you close the box, so leave the cabling a bit longer until you know how long they should be.
You should be able to find a good grounding point (chassis) in the engine bay, I used the one which is a bit hidden behind the airbox. It is just a matter of undoing the nut adding a good size lug on the cable and you are set. For good comprehension, that would be the cable which is connected to the "C" tag on the thermostat. The second wire will come later.
The thermostat sensor bulb should be cable tied on the top surface of the top hose (side of the RAD closest to the EAS box on the Diesel). It should be covered with foam pipe lagging (28mm does the job) also cable tied in place.
So it looks like this:
I also put some tape over the foam lagging.
As for the second cable, you'll have to gain access one way or another to the dual pressure switch. It might work by just removing the fog light grill under the bumper near side in front of the diesel auto gearbox oil cooler or by removing the bumper entirely.
Locate the Blue/black wire on the receiver/dryer dual pressure switch (red circle in picture for location) , join the wire from tag 2 on the stat to this wire by either soldering or with a crimp connector. Re-fit grill or bumper.
Setting up the thermostat:
Run the engine until it reaches normal operating temperature or if you have a Nanocom 98C is what you look for, adjust the stat until the fans switch on then back it off carefully until the fans just switch off. With this setting the fans will only switch on if the temperature starts to rise above normal.
I implemented this on my own DSE and I can tell you it works absolutely fine. However I just use this as a backup solution and do not run it as stand-alone without the viscous fan.
Any question?---> leave a comment or send an email.
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