Dell Inspiron 5160 Heat Issue

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There should be no problems with fans running constantly other than battery drain. You only have to worry about fans that use sleeve bearings. My Dells use ball bearing fans. Fortunately the fans are user replaceable and cost much less than $700 cpu.
 
Are you sure your speedstep is working properly? The 5160 uses a P4-M which when at full pelt will get toasty...but steps down to as low as 100mhz I think when it doesn't need it.

Also you might try a program called SpeedswitchXP ....it allows you to manually control the power profiles. I used it and just set the profile for battery optimized to keep it around 1.6ghz....then if I wanted more power for playing a game or something just set it back to normal dynamic switching.

Also make sure your heatsink isn't full of dust. I periodically blew a can of compressed air through to keep it clean.
 
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