Hello, the first few parts needed for
Project Setrab Oil Cooler plus SPAL Radiator Fan just arrived today:

This is Earl's 501 ERL, a Billet Thermostat with built in 3 1/8"NPT sensor thread:



This is the SPAL Fan (Made in Italy) that I am going to install as a PUSHER in front of the A/C condenser, because our cooling fan only turn on at temperature over 90Celcius... or if we turn on A/C,
which make our car run cooler if we turn on A/C... but
sometimes, when I really want to "ahem" push the car to the limit,
I want the A/C off to free the horsepower, but since the fan won't turn on early, it cause the temperature to shoot up before the fan kick in...
so this SPAL fan will run independent of the factory fans,
this way I can have this SPAL fan run early without turning on A/C...
I will connect this SPAL fun with the Setrab oil cooler fan switch which mean it will start at around 80 degree celsius just like the fan on the Setrab Fan Pack Oil Cooler (on the way)...




on this picture you notice I install the SPAL bracket to test fit. I bought 4 pieces of this SPAL bracket,
and they are PERFECT!!!... all you have to do is slide the plastic shoe into the mounting at the fan,
then you have the steel bracket ready to be connected to you car body. I am glad I bought this 4 original SPAL bracket,
and they are cheap too... now I need to buy the SPAL wiring so I don't have to cut the socket...





Back to Earl's thermostat again,
just want to show the 3 holes 1/8npt ready for Defi Gauge Oil Pressure, Oil Temperature and Setrab Fan Switch.






This is the inlet outlet holes which I am going to have adapter for -10 AN hose. I plan to use all Goodridge 811 Fitting plus Goodridge 910 Kevlar Braided Lightweight hose (instead of regular Stainless Steel braided one).

 

Setrab Oil Cooler with FanPack model FP119M22I just arrived half an hour ago

I also bought the Setrab Mounting Bracket and Setrab 180degree Thermostat Switch:



The protective packaging is awesome:



It's very small in size which I prefer for this application because I want as small pressure drop as possible since our engine is small engine,
plus the smaller size will make it easier to mount it in front of the A/C condenser/Radiator without blocking any incoming air.
I know the right location for this right behind the front reinforcement bar where it is already blocking the air anyway, and because oil cooler had fan, it won't need to be feed fresh air all the time.
I was looking at behind the foglight, but the space there is so tight plus it don't allow much hot air to be vent out...
I compare it to the size of my glasses
this actually about the same size as large PC CPU Air Cooler







The Build Quality though is very very very good...
no wonder Setrab is used by World Class Racing Team...
take a look at the mounting bracket... it have rubber dampener everywhere, even on the center part...







I test fit the bracket:



Tomorrow Earl's Oil Cooler Sandwich Plate Adapter suppose to arrive,
so I can start measuring the hose and fitting angle required and order them

 

Setrab recommend using Medium Thread Locker (Loctite) for the bracket bolts:







Tightened in to snug, make sure you don't deform the rubber dampener:



The Thermostat Switch with AN10 Adaptor:







I am separating the switch from the AN10 adaptor and screw the switch directly to the inlet from engine sensor port at Earl's Themorstat,
fit perfectly... but in the end, I am thinking of using back the AN10 adapter for the thermostat and will use the oil inlet from engine sensor port for Mugen Oil Temperature Gauge later in the future...:

 

Yesterday, the Earl's Billet Oil Cooler Sandwich Adapter arrive and I test fit with Honda Fit OEM oil filter, Perfect Fit









This one is Earl's 1/8" NPT to 1/8" BSPT (PT) Adapter for future Mugen (by Defi) PT Thread Oil Temperature and Pressure Sensor. I also need it for future Defi PT Thread Fuel Pressure Sensor.



I then jump to installing the SPAL Radiator Pusher Fan first because otherwise it will be difficult to install the Setrab Oil Cooler (due to tight space), First I install a bracket at the bottom bolted to the body:



Then I install SPAL mounting bracket to the fan and then bent the plate and bolted it to the other bracket above.
Please note that the SPAL push fit plastic bracket is very tight so it is best to spray silicone lubricant first to make it easier to push and lock in:



Ok, to be continued below ...

 

Then install the Upper Left Bracket (lot of bending the mounting plate required):




Now the right side bracket:



(both left and right bracket) ready



Now time to install the Setrab,
first enlarge the holes on the Setrab mounting bracket to fit the bolt spacing on the ready to use holes at the back side of bumper reinforcement bar:



Test Fit, and it fit well



Tightened all the bolts, notice I add a layer of thick rubber to further dampened the vibration (Oil Cooler last longer if not exposed to vibration),
I also add extra plate behind the rubber:







I had one more SPAL mounting bracket so I decided to further reinforce by connecting the right SPAL lower mounting bracket to Setrab lower mounting point (I utilize the rubber dampening plate that came with Setrab mounting bracket). I also order 1 more SPAL mounting bracket, when it arrive, I will use it for the left lower side.

 

Here is the view from lower grill:







I just order the rest of the parts (Goodridge 910 Aramid Fiber (Kevlar) reinforced 10an and 6an hose, Goodridge 811 Forged Fitting, and miscellaneous Earl's, Setrab,SPAL, Goodridge fitting, bracket and wiring adapter)... hopefully I can have a working oil cooler and extra radiator fan in about 2 weeks from now

 

More parts for the oil cooler arrived today:
Goodridge 910 Aramid (Kevlar) Braided lightweight hose with Goodridge 811 Fitting (both 10AN size) arrives today:

 

Few days ago, the final parts to have an operating Setrab oil cooler arrives:






So I for the past 5 days, I am doing the rest of the install needed:

I install the relays needed in conjunction with an on off switch on the dashboard to turn off the Setrab oil cooler fan and SPAL fan.

The on off switch were modified Honda CR-V Seat Heater switch.
I relabeled the switch so it show a glowing/backlighted light sign
and oil cooler sign, plus I painted it to give some spice to the interior
I also modified a VSA switch from Honda CR-V, the VSA switch in Honda CR-V have cruise control on off button which I modified for MAP B on the AEM F/IC-6.




and this is the wiring harness I assemble for this switches:






This require 3 relays, 2 under the dashboard for VSA switch (since the
Honda Fit VSA switch is Normally Closed), and another one for DRL trigger activation. The third relay is near the setrab itself.
I also install fuse holder because the trigger line out of the relay for DRL under the dashboard and a trigger line for Setrab Oil Cooler fan/SPAL fan is a long wire from under dashboard to engine bay...
don't want any short... use a mini fuse with 5amp...









I will continue later after I had dinner

 

Setrab need an AN Adapter for it's inlet/outlet,
I decide to use AN10 hose/fitting:



That adapter above will goes in here:


Use Setrab Oil/Lubricant for the adapter thread:




Mounted:









I use Stainless Steel as bracket for the Earl's Thermostat,
and it will be mounted on the reinforcement bar right beside the Setrab Oil Cooler:



Install Setrab Oil Temperature/Thermostat adapter, but I will plug the holes for the thermostat because I will use the location on the Earl's thermostat to feed the Setrab thermostat (180 degree F).
This Setrab adapter will be use in the future for Defi Oil Temp sensor probe:



Install the Earl's thermostat right beside Setrab Oil Cooler behind the reinforcement bar:






Test Fit the orientation of the Goodridge 811 AN10 fitting on the Earl's thermostat:



to be continued very soon:

 

Assembling the hose following Goodridge guidance,
Always apply oil on the fitting thread before assembly:







Well... first hose was too long and I manage to make it kink
So throw away that hose and rebuild another one:






Test fit, and it's perfect (for now), turn out later, this one also too long by 5mm and kink again, so I make another one




Install the AN adapter on the Earl's sandwich adapter and test fit with Honda Oil Filter... Perfect, plenty of space:








Route the hose behind the driver side fog light:



I also buy Setrab billet hose separator (I buy 4 but end up using only 3),
I also buy Setrab hose bracket (but I eventually do not use this
because it's bolt hole is way too small for most Honda M6 bolts, and
I decide to use tie lock):

Setrab billet hose separator installed:





That to further protect the hose against heat and sharp metal edges,
I use wire loom:





This is how the hose connection looks like from above:




Fill with new oil, now need 5 quart instead of 3.8 quart since
the oil cooler and all those hose line need extra oil:



then I turn on the engine check if there is any leak,...
no leak... I run the engine for 20 minutes, but the fan were never
activated..., I have not have time to drive the car hard so I never had both SPAL fan and Setrab fan activated...
I also need to save money to buy Mugen Oil Pressure/Temperature (Made by Defi) gauge so I can monitor those 2 parameters...
anyway, I am very happy with the result,...
especially considering this is the second most complicated (due to lot of fabrication) install of all time
after Sprintex...

So Project Setrab Oil Cooler COMPLETED

 

Project Setrab reopen just to add GREEN LED light indicator on the dashboard,
this way I know when the SPAL cooling fan on both the Setrab oil cooler and Radiator working

 

👍🏽 another quality install and write up thank you

 

Finally able to install Defi Oil Pressure and Temperature Oil Sensor at the Earl's Thermostat Box, plus put NEW Setrab Temperature Switch and move it to a new location for better heat reading,
also install Defi Fuel Pressure sensor.

Hopefully I can install the Defi Advance RS Gauges below my head unit soon, so this sensor will work
and I can monitor all vital function on my engine !!!

 

Update, I moved the Defi Oil Temperature sensor from reading at Earl's thermostat to outside of it (using Setrab AN to NPT adaptor), now my Defi RS gauge read the oil temperature accurately (no delay).

 

as always BMW, another awesome and insanely detailed write up. nicely done!

 

Thank You