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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Thu, Jul-28-2016, 09:59:02 PM   #31
jared212
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

Would be just like the original diagram you posted. Grey Spal relay wire spliced to brown fan motor wire. My original thought was that if the spal relay(A2) directly spliced into the brown wire is not kicking in until about 50% it should be possible to tweak the signal to only energize the relay at 100% to make a true aux fan function.
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Old Thu, Jul-28-2016, 10:49:40 PM   #32
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

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Would be just like the original diagram you posted. Grey Spal relay wire spliced to brown fan motor wire. My original thought was that if the spal relay(A2) directly spliced into the brown wire is not kicking in until about 50% it should be possible to tweak the signal to only energize the relay at 100% to make a true aux fan function.
Ah, so you're just putting a cap on the relay input to make sure it flicks on at 100% - that makes more sense, I just got confused when you were referring to the PWM signal.

I'll see if I can get you a frequency either tomorrow or during the weekend- curious to see how it works!
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Old Sun, Jul-31-2016, 02:53:47 PM   #33
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

104 Hz according to my DMM
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Old Tue, Aug-02-2016, 03:54:45 PM   #34
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

Damn! I thought it would be in the 15kHz range. I am going to try this current sensing relay on the pos side of the fan motor instead Functional Devices RIBXKTF I really appreciate the intel!
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Old Tue, Aug-02-2016, 06:55:32 PM   #35
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

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Damn! I thought it would be in the 15kHz range. I am going to try this current sensing relay on the pos side of the fan motor instead Functional Devices RIBXKTF I really appreciate the intel!
Cool - good luck! Just keep in mind the area you're working in is pretty vibratory and exposed to the elements - no screw terminals for the final setup, I hope
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Old Fri, Feb-24-2017, 11:15:32 PM   #36
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

Hey guys does anyone know the difference between the Spal 30102049 and the Spal 30102120 fan as far as sound difference? How much louder is the 2120 straight vs the 2049 curved?
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Old Sat, Feb-25-2017, 04:20:08 AM   #37
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

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(Goes without saying, but I'm not responsible for any damage to your car. Do NOT do electrical work without disconnecting the battery)
Update:
Here's the basic wiring diagram - be sure to make sure that your wiring looks pretty close to mine, as I have no idea as to whether or not BMW changed their design at some point (my car is a 2003.5)


Here's the wire from the Aux fan you need to splice into:
I wasn't able to heat-shrink this guy without the wire shrinking it, so I had to resort to electrical tape


If everything is working, you can test by hitting the AC- which should be enough to engage the SPAL fan relay.

Although they're in ideal proximity for the fan's ground lug, I do *not* recommend the following for grounding:
- Any of the coolant reservoir bolts (they go to plastic studs)
- The front bolts by the headlights (they get hot with the fan's current)
- Vanos bolts, as there's not enough thread with the lug there and you might strip it

I'd highly recommend that you solder the wires together rather than using butt-splices, but if you aren't comfortable soldering, I at least recommend the heat-shrink splices.

If you're cool with soldering, definitely grab:
-Heatshrink (adhesive-lined, if possible)
-Un-insulated, single core wire
-Electrical tape, since splicing the Aux fan is a pain.

To splice the heavy (12ga) wires, push them together, squeeze the strands back together, tightly wind the un-insulated wire around, then solder, then heatshrink. You should go from this:

To this:


Even if you're not comfortable soldering, I highly recommend using the heat-shrink as a strain-relief like so:


[OP]
After getting my stuff from Bimmerworld, I got a little handout of instructions that was a little less than helpful.. in fact it's pretty much wrong in every way.

Talking with Bimmerworld the first time this didn't work made it sound like you could just splice into the PWM signal from the ECU to power the coil in the relay... nope. Let the car idle and *neither* came on.

Interesting note, the signal is actually an inverse (5v) duty cycle, meaning that the ECU actually widens the LOW portion of the signal when it wants the fan to kick on... even if the ECU *could* power the relay, it wouldn't work properly.

Then, I assumed they meant you want to power the relay based on the power (grey) wire going directly to the Aux fan motor, and must've just switched the colors (since the instructions show a splice to a blue wire)... also wrong. The fan controller has a constant 12V on, not even switched, so doing this means your fan will run until the battery dies. However, it *does* switch ground (brown wire).

The trick is actually to wire the relay (hot) trigger to 12V, then wire the ground of the trigger to the negative wire going to the Aux fan's motor.

Took some pictures which I'll post later, but hopefully that helps a few people looking for advice!

Thanks for the diagram. To clarify the way it's wired up, the Spal fan turns on only when the AUX fan turns on? Or is it constantly on when the engine is on?
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Old Sat, Feb-25-2017, 05:06:35 PM   #38
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

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Thanks for the diagram. To clarify the way it's wired up, the Spal fan turns on only when the AUX fan turns on? Or is it constantly on when the engine is on?
It will only be on when the aux fan is on. So you the SPAL fan is controlled by the temp sender in the lower rad hose.
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Old Sat, Feb-25-2017, 11:04:28 PM   #39
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

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It will only be on when the aux fan is on. So you the SPAL fan is controlled by the temp sender in the lower rad hose.
Interesting. At what temp does the AUX fan come on? It also comes on when ever you turn the AC on correct?
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Old Sun, Jun-18-2017, 04:46:31 PM   #40
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Default Re: How to (actually) wire up a SPAL fan to the aux controller

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Interesting. At what temp does the AUX fan come on? It also comes on when ever you turn the AC on correct?
It's not necessarily temperature, it's whenever the DME commands ~50% duty cycle. In other words, the engine could be cold at ~120*, but engaging the AC will make it come on to cool the AC system
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Discussing How to (actually) wire up a SPAL fan to the aux controller in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)