Zionsville shroud on stock 540i radiator, what am i missing?

[joekitch]

So, i'm in the middle of installing the zions fan shroud onto the stock radiator. My radiator seemed fine and $700 for their radiator isn't a price i am willing to pay at the moment.
However once i slid the thing in i realized....i don't really have any way to mount this thing. It seems to rest on the stock plastic mounting feet on the bottom alright but there's nothing to attach it on top?



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There's holes on the radiator but the shroud's edge is totally blank?

And to make matters worse, how are you supposed to mount the aux air quality sensor? That little shelf it's sitting on is blank aluminum...



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So do i absolutely have to bust out a drill and a drill bit for drilling aluminum and start poking holes in this thing?

[computiNATEor]

Pretty much. I would recommend using rivets or riv-nuts. Harbor Freight's got you there.

- - - Updated - - -

Time to start drilling. I would recommend the $500 RK Autowerks radiator (it's primarily designed for the M5, but it's a drop-in replacement) way before choosing one of Zionsville's units, which have arrived slowly, warped, and with unnecessary fittings (just ask Stück/Jordan). Give RKA a call to verify fitment.

As for the air quality sensor, you could mount it with Velcro or similar. I don't remember what I did, TBH.

[geargrinder]

Huh. I wouldnt rivet, you want to be able to pull the shroud. Just some screws or bolts should be ok.

The rad attachement isn't huge surprise since you're only getting half their "system" but the flat AUC shelf is kinda boge. Couldn't spec a couple quick cuts in that piece so the sensor mounts like factory!? Weak.

[nauqneyugn]

For the aux air quality sensor, maybe drill some holes in the shelf to run zip ties through?

[TxDarth]

Huh. I wouldnt rivet, you want to be able to pull the shroud. Just some screws or bolts should be ok.

The rad attachement isn't huge surprise since you're only getting half their "system" but the flat AUC shelf is kinda boge. Couldn't spec a couple quick cuts in that piece so the sensor mounts like factory!? Weak.

I agree completely = 6 years ago or so when I was installing mine I looked at the OEM install and duplicated the mounting with several carefully drilled holes. I also decided that just below that area would be a good place to locate the wiring for the electrics for the 2 sped fan... more carefully placed drilled holes and the rest is history...

[geargrinder]

Nice Darth. But what's "Lou" speed?

[TxDarth]

Nice Darth. But what's "Lou" speed?

Flash distorted the LOW on the right !

[computiNATEor]

Huh. I wouldnt rivet, you want to be able to pull the shroud. Just some screws or bolts should be ok.

The rad attachement isn't huge surprise since you're only getting half their "system" but the flat AUC shelf is kinda boge. Couldn't spec a couple quick cuts in that piece so the sensor mounts like factory!? Weak.

Riv-nuts are removable. https://www.amazon.com/Astro-1427-Ha.../dp/B004KLVJAA

[joekitch]

got the thing in and its running great, i'll put some pictures together of my setup at some point soon to serve as documentation for others

[joekitch]

just to confirm, "P0128 BMW - Thermostat Low Coolant Temperature" is the code i should expect to get without the resistor on the thermostat electrical plug right? I haven't actually soldered that plug together yet so i was waiting for some code to appear, and that one did this morning

[JimLev]

Possibly, that code is for low coolant temp, not sure the resistor will do anything for that code.
What does Test 7 say your KTMP is?

I'm running 88-92C with a 105C t-stat, a PWM circuit connected to the t-stat heater, and a resistor. No codes.

[Mach540]

The code you get with no resistor is
P1622 - Map Cooling Thermostat Control Circuit Electrical

My 88C thermo seems to be getting wonky, so my car is running 82C-85C. A little better than the 78-80C earlier this spring. Got another on order from ECS, but it looks like they're out till July.

Anyways, I'm running way cooler than normal, and no codes related to that.

[joekitch]

update on this particular adventure, i'm now getting a constant coolant level low warning even though the tank is at the proper level (filled about an inch above the chamber the float fits into)
turns out these e36 coolant level sensors are crappy and like to die a lot, drat :|

[Mach540]

I soldered my level switch to short it out.......... No more "Check Coolant Level" warnings.....

[joekitch]

i'd rather have a working sensor to be honest
although i did use an URO float which isn't oem, but it sounds like even the oem or oe sensors constantly break as well. bummer