Kenlowe Cooling Fan Conversion Kit 75 ZT (an Updated How To)

[Jules]

KENLOWE COOLING RADIATOR FAN CONVERSION KIT 75 ZT

After fitting many of these kits, I thought it time to write an updated HOW TO.
As time goes by better ideas, improvements, suggestions & feedback from other owner's evolve.............and the result is I hope you'll agree the Ultimate non OEM modification to the Cooling System.

The price is the same whether you buy the kit from us or Kenlowe.......bought from ourselves all the "Tailoring" to the duct cowling is already done, saving you approx 2 hours.

In operation, the Fan is quieter than OEM & motor windings are more efficient so 35% less energy is used to power them. (more MPG)

A big plus here is that because it's a true 2 SPEED motor (2 separate winding circuits), there is of course no big power wasting RESISTOR to go wrong.
Additionally, the kit still employs the original Rover Fan Control Box so all the ECU control intelligence for when the Fan should rotate (and at what speed) is maintained.


The wiring is different & simpler than Keith's original thread, so to is the way we now anchor the Fan ducting with many hours now trimmed off the job, it takes no longer to fit than the OEM design cooling fan
ie approx 3 -5 hours depending on your competence!
My Thanks still go to Keith for giving me the idea in the first place, and to other members who fed back further improvements

Tools list:
8mm,10mm, 13mm sockets
Pozidrive screw driver No2
Side snips
Dremel not mandatory
No 25 Torx key bit
Crimper or Soldering iron or both



Remove Fuse no 4 (80 amp) near battery
Remove bumper (plenty of links to follow)
Remove slam panel as a whole assembly. http://www.the75andztclub.co.uk/foru...ead.php?t=9653
leave headlamps, bonnet catches & crash beam in place






TO AVOID HAVING TO DEGAS AIRCON SYSTEM:
Scribe a line with sharp Stanley knife & then nibble away cowling.








Top AC pipe entry.Cut out within red area
Bottom pipe:
Make a similar cut for the lower AC pipe.




Remove old Rover motor from cowling
(No 25 Torx Qty 3 bolts)
These will be rusted in on older cars and will have to be drilled/ground out.
Remove complete motor assy Control box & cable loom through the front of the Seimens Cowling
An Extra hard Cobalt drill bit is required due to the hardness of the bolts



Once Rover cowling is removed, mount Kenlowe centrally , with KENLOWE LABEL at TOP.
Use Qty 6 good quality cable ties. (min 7.00mm width supplied)
Make sure tie ends do not fowl the fan blades.
Nuts & Bolts could be used Radially, on the outer edge of ducting if preferred. (pics at the end)
Kenlowe's official fixing universal kit uses much smaller plastic ties so these are well up to the job !





Fit the connectors onto the 3 wires.
Squeeze the tabs onto the copper strands to secure prior to soldering. (ideal method)
If you cannot solder , crimp the terminals (bullet or spade type)




How the terminals should look after soldering.Either use both male & female terminals (if you want to unplug motor at later date)
Or just use the female connectors as butt connections as shown which facilitates the soldering.



Colour code for 4 WIRE SYSTEM Diesel, Petrol 2.0 2.5 KV6 & V8 :
RED - GREY BLACK - BLACK GREY- BROWN
(PURPLE NOT USED. And as long as black goes to black it doesn't matter which way other 2 wires go, the polarity will be correct)

COLOUR CODE for 1.8 Petrol K series 3 wire:
BLACK - BLACK BROWN - RED GREY- PURPLE



Petrol 3 speed control box. NO PCB
LEAVE ALL WIRING AS IT IS.
Cut Purple wire half way down the loom & tape up.
Test fan BEFORE refitting slam panel
If NO motor rotation when Aircon selected, the large relay may have failed (new one supplied)
If motor rotating permanently, again suspect same relay.



Diesel 3 speed control box. WITH PCB
LEAVE ALL WIRING AS IT IS.
Cut Purple wire off & tape up.
Test fan BEFORE refitting slam panel
If NO motor rotation when Aircon selected, the large relay may have failed (new one supplied)
If motor rotating permanently, again suspect same relay.
If removing the PCB to replace suspect relays, unplug Red & Grey wires, then GENTLY UNCLIP PCB & swing out to the side to access relays.









Kenlowe Fan fitting snugly into Siemens cowling
At this stage we suggest you test the Fan (see testing procedure below




Don't shorten any cables if you require the control box to be repositioned near the battery.
We recommend to relocate control box.
Easy access if relays ever fail in future (or PCB in diesels)
Recommend making a blanking plate out of Aluminium or Plastic to fit in the hole where control box was as 20% of the airflow will escape here.



Position of Waterproof connections
(below expansion tank)



KV6 2.0 & 2.5 Petrol Variants
If decision has been made to reposition the Control box,
Extra holes can be added for a long Cable Tie to secure Control Box



KV6
Suggested fan loom routing for repositioned Control Box



KV6
Fan Control Box in it's new more accessible location



DIESEL VARIANT RE-POSTIONED CONTROL BOX
An FBH is shown here (Webasto Fuel burning heater), even more room here if an FBH is not fitted.

Your installation is complete. Feedback always welcome.
If the Fan does not rotate or rotates permanently even when it should not, replace the large relay (supplied) in the control box



DIESEL VARIANT
CAUTION IF FBH FITTED, MAKE SURE CABLE LOOM IS ROUTED AWAY FROM FBH EXHAUST.
It is highly recommended to move the Fan Control Box. The wires are long enough to re position it next to the battery or fuse box.
Easier access if a problem occurs with relays at a later date, avoiding the need to dismantle front end again !



ALTERNATIVE MOUNTING METHOD.
Kenlowe Ducting integrated into Siemens Cowling
A proper engineering approach using Nuts & Bolts



Qty 4 to 6 Bolts with 15mm spacers will suffice



Testing procedure. (hint...carry this out BEFORE re-fitting slam panel)
Replace Fuse 4
Start the engine (no real need for Diesel variant!)
Press Demist this should activate SLOW cooling Fan.
Test high speed from the Trinary here: http://www.the75andztclub.co.uk/foru...ad.php?t=35577
Good luck

[Dragrad]

Post copied to How To forum. Thereby allowing this thread to be commented upon. As it is in the Technical Help forum, it would be appreciated that any posts would be constructive to the OP's post

If there are any amendments to the OP's post I would be grateful for a head's up so that I can update to the How-to forum

This post has been re-opened to allow the OP to update.

(Jules you have a PM)

[t5tart]

shame this has lost all the photos ... would have been very useful to me right now

[Jules]

Really annoying this
Google have changed the URL codes .
I wonder how many of my 100's of photos have been affected ?

It may take some time to get this sorted so please bear with me.
very busy workshop to run at present and many back orders to deal with.

[Jules]

I've restored a few important photos for now.

[t5tart]

Originally Posted by Jules

I've restored a few important photos for now.

Thanks Jules

any chance of the kv6 wiring ones ???? and the repositioning ones

thanks for your time again

why I host my pics on my own domain server for my website

[Jules]

It's all in hand to be on my own domain.
But it's time I ain't got at the moment.

KV6 water pump & belts job has to be out of here by the morning then I have a car to prepare for NEC classic car show.

[Jules]

Originally Posted by t5tart

Thanks Jules

any chance of the kv6 wiring ones ???? and the repositioning ones

thanks for your time again

why I host my pics on my own domain server for my website

If you read the text all the colour combinations are there.

Basically the Kenlowe requires it's black to earth.
The Kenlowe brown and Kenlowe grey must have positive feeds from the fan control box relays
DO NOT connect them to ground as the motor will burn out in 5 seconds flat.


Are you converting from a 4 wire motor?

[t5tart]

Originally Posted by Jules

If you read the text all the colour combinations are there.

Basically the Kenlowe requires it's black to earth.
The Kenlowe brown and Kenlowe grey must have positive feeds from the fan control box relays
DO NOT connect them to ground as the motor will burn out in 5 seconds flat.


Are you converting from a 4 wire motor?

I believe its a 4 wire 02 plate mg zt I havent had the bumper off to have good look but no resistor visible odds on its a 3 speed tho

[t5tart]

oh and what is the point of re routing the control box ???