Davies Craig EWP-FAN, EWP 80 Installation Instructions Manual

P/No:8926

EWP®80 & EWP® -FAN DIGITAL CONTROLLER

INSTALLATION INSTRUCTIONS

DAVIES, CRAIG EWP® (ELECTRIC WATER PUMP) AND PUMP CONTROL

Congratulations on your purchase of the Davies, Craig EWP® 80 & EWP® -FAN Digital Controller which is
designed to replace the existing belt driven mechanical water pump of your engine and to switch your
Thermatic® Fan on and off. The Digital controller will vary the speed of your EWP® in response to the engine
temperature and switch the Thermatic® fan at 3°c above the target set point. The EWP® will continue running
after hot engine shut down to prevent damaging heat soak. When your EWP® is used to replace the mechanical
pump, you will notice an increase in engine power and torque, especially at high engine speeds. Automatic
gear changes, both up and down, will be smoother.

PLEASE READ THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE YOU START WORK.

ALSO NOTE THAT THE EWP IS A „CIRCULATION‟ PUMP IDEAL FOR „CLOSED CIRCUIT‟ OPERATION SIMILAR

TO AN AUTOMOTIVE COOLING SYSTEM. IT IS NOT A „SELF-PRIMING‟ PUMP AND THEREFORE WILL NOT

OPERATE WITHOUT A POSITIVE „HEAD‟ IN AN „OPEN‟ SYSTEM.

CONTENTS:

EWP® COMPONENTS:

No. Description Qty.

1. EWP Pump Assembly 1

2. Inline Adaptor 1

3. Digital Controller 1

4. Wiring Harness with 10A fuse 1

5. Angle Adaptor 1

6. Straight adaptor 1

7. O-ring 2

8. Thick Rubber Sleeve 2

9. Thin Rubber sleeve 4

10. Hose Clamp 4

11 .HARDWARE COMPONENTS

No. Description Qty.

11a. Screw Self tap 5
11b. Scotchlock 1
11c. Ring Terminal 1
11d. Ring Term.(Yellow) 1
11e. Sensor Assembly 1
11f. Adaptor M5 Bolt 6
11g. Adaptor M5 Nut 6
11h. Adaptor Washer 18
11i. M5 cap screw long 6

Please contact Davies, Craig for
additional straight or angled adaptors if
required.

ISO 9001

Standards

Lic No 4528

Australia

DAVIES, CRAIG

PROPRIETARY LIMITED

A.B.N. 71 004 918 825 A.C.N. 004 918 825

MELBOURNE AUSTRALIA

77 Taras Avenue
P.O. Box 363
Altona North
Vic 3025 Australia
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.daviescraig.com.au

1 2 3 2 4 9 8 7 6

11 5 10

Page 2 of 8

SECTION ONE: INSTALLING THE EWP®

The EWP® should fit in the lower radiator hose connecting the radiator to the existing mechanical water pump
housing. Check the area for available space and shape of the lower hose. The section of radiator hose
connected to the bottom of the radiator must be connected to the inlet of the electric pump and the section of
radiator hose connected to the original pump/engine block must be connected to the outlet of the electric water
pump. The pump inlet and outlet are marked on the pump. The EWP® should be positioned as low as
possible to maximise the gravity feed from the radiator and prevent air entering the pump.

1. Configure the electric pump so that the motor‟s black rubber drain boot is at 6 o‟clock, that is, pointing

down so that any condensation forming in the motor will drain. If the EWP cannot conveniently be
positioned with the rubber drain boot at 6 o‟clock, the motor can be rotated 180. This in most cases will
allow the rubber drain boot to be positioned in the preferred 6 o‟clock position. To rotate the motor,
follow these instructions:

a. Turn EWP over to gain access to the 2 screws, which fasten the motor to the pump body.
b. Slowly unscrew the first screw halfway, then unscrew the second screw all the way and then finally

unscrew the first screw totally. Be careful not to alter the alignment of the motor shaft when unscrewing
the screws.

c. Carefully ease the motor away from the pump by no more than 1 mm.
d. Rotate motor 180C, keeping the shaft square and making sure no plastic shavings lodge between the

motor and mounting surface.

e. Fasten motor to pump body. Slowly tighten the two screws incrementally until both are home. Do not over

tighten.
If it is impossible to mount the boot at 6 o‟clock, cover the rubber boot with silicon to ensure no water can

enter the motor. Assemble the EWP® plastic adaptors (Item No‟s: 5 & 6) to suit the hose configuration and
space available. Make sure that the adaptors have an o-ring (Item No: 7) between them and the flange
faces on the pump body. The short bolts (Item No: 11f) supplied should be used to connect the adaptor
(Item Nos: 5&6) to the inlet face and the longer bolts (Item No: 11i) to connect the adaptor (Item Nos: 5 &

6) to the outlet face with the nuts (Item No: 11g) provided. The washers (Item No: 11h) provided should
be used between the bolt head and the flange face and between the nut and flange face.

2. Add the appropriate thickness rubber sleeves (Item No‟s: 8 & 9) to the adaptors (Item No‟s: 5 & 6), if

required, to suit your particular hose diameter.

3. Cut out the required section of the lower radiator hose. Connect the pump inlet and outlet to the

appropriate hoses ensuring that the pump is oriented in the CORRECT ORIENTATION as shown in Fig
9, page 9 “BLEEDING THE EWP®”. Ensure hose clamps are tight.

Do not bleed EWP® until you installs the digital controller and disables the mechanical pump.

SECTION TWO:

INSTALLING THE EWP® & FAN DIGITAL CONTROLLER (Refer Figure 2 below)
Do not begin the installation of the Digital Controller prior to the EWP® being installed.

1. The controller must be fitted inside the passenger compartment. Locate a hole in the firewall (approx.

20mm in diameter) where the harness wiring (including the sensor & pump “T-connector”) will be able to
pass through. If a spot of adequate size cannot be located, then wires may be cut then re-joined as a last
resort.

2. Pass the “T-connector” of the wiring harness though the firewall into the engine bay and connect to pump.

3. Pass the black sensor connector through the firewall and out to the thermostat housing/ Inline adaptor

(Refer page number 3 to 5 on installing digital controller sensor)

Page 3 of 8

4. Connect the wiring harness to the controller and mount the controller (using 2 of the screws provided) in

an appropriate position such as near the fuse box so that there is access to the temperature adjustment
button --- avoid mounting the controller where it may be exposed to direct sunlight. Ensure a good earth
connection using the self-tapping screw provided. NOTE: The earth lead must be connected to a metal
part of the body.

5. An additional screw is provided for mounting controller fuse holder where necessary.

6. Connect the red wire from the wiring harness to the battery positive using the ring terminal provided.

Connect the green wire from the wiring harness to an ignition source – the wires may be spliced then
soldered if necessary. Ensure no wire is exposed, by insulating the join with electrical tape.
Connect the green wire to the Fan relay if you wish to control the Thermatic® fan 3ºC
above the set point (refer to page 7, setting the Digital Controller)

7. Mount „Remote Test Light‟ in a location, which will be visible. The „Test Light‟ may be fitted by

inserting it through a 4.6mm dia. drilled hole in a plastic area of the interior/dashboard or simply with

adhesive tape. The „Remote Test Light„ has pin connections to assist installation. Heat shrink or insulation

tape can be applied to these pin connections once the test light is mounted. This will ensure the connection
points are insulated and secure.

NOTE: In carrying out the wiring procedure, please bear in mind that it is advantageous to minimise
voltage drop and this can be achieved by keeping the wiring as short as possible.

Figure 2: Digital Controller Wiring Diagram.

REMOTE

TEST

LIGHT

+VE IGNITION

SOURCE

PASSENGER

COMPARTMENT

FIREWALL

ENGINE BAY

Fan Relay

SENSOR – TO BE INSTALLED IN
THERMOSTAT HOUSING OR IN-

LINE ADAPTOR

“T” CONNECTOR

EWP®

DIGITAL
CONTROLLER

TEMP.

ADJUSTMENT

BUTTON

EARTH (Ground)

BATTERY

FUSE

HOLDER

EWP

Page 4 of 8

Remove the engine thermostat from the thermostat housing and install the sensor using method A or B as
shown below. Re-fit the thermostat housing without the thermostat and ensuring that there is no damage to the
thermostat-housing gasket.

DIGITAL CONTROLLER SENSOR INSTALLATION

There are two installation methods available:

A) IN THERMOSTAT HOUSING METHOD

Please ensure these instructions are read in their entirety before proceeding with installation.

 It is recommended that the Sensor assembly be installed in the thermostat housing (not supplied).

However, please check wall thickness of thermostat housing as it is recommended that the Sensor
assembly be installed only if there is a wall thickness of at least 3.0mm. If the thickness is less than 3mm,
please proceed with installation method „B‟

 We suggest removal of the thermostat housing before beginning the installation process so that metal

shavings do not enter the cooling system.

STEP 2: Drill an 11.0mm (7/16”) hole

through the marked area. For your safety and
to avoid drilling on an angle, please ensure
thermostat housing is well secured before
beginning the drilling process.

STEP 1: Mark location on thermostat
housing where sensor assembly is to be
fitted – “top of dome is recommended”.

¼” BSPT TAP

(not supplied)

TAPPING
WRENCH

STEP 3: Using a ¼” BSPT tap, tap the hole to allow the sensor
assembly to “just” protrude the thickness of the thermostat housing

(refer to diagram). It is recommended that the fitment of the sensor
assembly be checked regularly to achieve the condition in the
diagram.

Figure3: Sensor Installation Method A