hey NAM,

I'm in the middle of swapping the cooling fan in my gf's r53 with a dorman fan. I got everything hooked up, but the connector pins on the smaller connector are too thick to fully insert into the stock plug. I am assuming that the smaller connector is for the low speed fan, as it is still not working with the new fan.

My question: Is there any way around this problem. Should I just push as hard as i can until it slides in? Could I cut the connector off of the stock fan and wire it into the dorman harness?

 

I would NOT cut the car side wiring...
If you decide to "fix" the issue, chop the connector off the old fan....
That way the car side wiring stays intact.

 

PS
Since the plugs are pretty standardized, i would look closely before giving up, and making the wiring into chopsuey....if you do this step, be sure to solder the wires, or vibration and corossion WILL be an issue quickly. Simply put, you should not have to chop wires to get an aftermarket part in that is made specfically for the mini (not so for "will fit universsl parts though where some faberication, etc is needed).

 

Thanks. I gave them a thorough look. The pins on the dorman fan are about double the thickness of the pins on the stock fan connector. Don't know why. The high speed fan connector is a perfect fit, but the low speed connector just doesn't fit. I can't understand why is wouldn't. I was expecting someone to chime in with a similar experience. The wires on both harnesses are the same color. I am fairly confident that if I cut off the old connector and wire it in, it will work. I was thinking of just using a couple wire taps and taping it up. Is it necessary to solder?

 

Moisture and a bit of salt+copper....
Also taps are good for just a bit of voltage/ampage...not the full amount. If you are not going to do a full splice with solder, and then a shrinkwrap, the wires will 100% be an issue...and you will have to do it again if the car does not catch fire from the wiring or crack a head from ovetheating, etc.
is it possible they sent you the fan gor the wrong year range??

 

+1 on Zippy's comments. Taps are fine for light current, but you're looking to power the fan. Corrosion may not be an issue depending where you live, but I'd say it's well worth getting a soldering iron, some solder, and shrink tubing to make sure everything is watertight. Inside the car is a different animal, but the engine compartment will get hot, wet, and everything in between.

edit:
Oh, and don't forget a serious tongue lashing for the supplier, along with pictures so they understand the problem. If you're lucky, they'll reimburse enough to pay for the iron, etc. that you needed to make it right.

edit #2:
Another reason to check all connectors before removing anything! Just had my rear window replaced, and the connectors were wrong. Much swearing after the window had already been glued into place.

 

thanks for the advice. I'm just very surprised that there is even an issue with the connectors. I purchased the dorman fan from rockauto which many have recommended on several threads.

 

I had the same issue with the dorman fan from rockauto. I cut off the low speed fan connector from the old fan and soldered it on to the new fan.