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Thread: Zionsville Radiator & Electric Fan Install - w/pics!

  1. #1
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    Zionsville Radiator & Electric Fan Install - w/pics!

    I spent about 70 mins tearing the front of my engine apart yesterday afternoon. Today, I was greeted by this. A Zionsville Super Duty Cooling Kit:







    Dog approves:



    Other items that came with the kit. I purchased the two speed fan upgrade:



    Making a mess - as usual:



    OEM water pump:



    Not pictured (from the AWESOME Max @ www.oembimmerparts.com):

    HEPU water pump
    New Continental belts
    New OEM coolant hoses
    New thermostat/housing
    New brake pads

    Went from this:



    To this:









    More to come... I'll finish it up tomorrow evening.

  2. #2
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    That's beautiful. How much did it run you? With all these blow ups I've been hearing about, it sounds like a good idea.

  3. #3
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    Goods nice...but, looks little heavy tho..

  4. #4
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    www.zionsvilleautosport.com

    Check prices for your specific application.

    Suffice to say, it's a lot. However, if you plan to keep your car, I think it's great insurance.

    Purty tig welds FTW!

    Plus, losing the plastic fan and fan clutch is a plus in my book.

    50+ HP at the wheels - no bs. <sarcasm intended>

  5. #5
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    Quote Originally Posted by DJKraft View Post
    Goods nice...but, looks little heavy tho..
    You're right, all of the factory pieces are a whopping 3.5 lbs lighter than the new stuff going in. I just weighed it all. Maybe I should send it back?

  6. #6
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    Nice radiator. I put one in my 7. Love not hearing the clutch fan all the time in traffic.

    FYI. The expansion tank on mine failed. It cracked along a weld. Good news though, it wasn't a catastrophic failure like the plastic tank could have been.
    I called Zionsville to let them know. I sent my tank back to the last Friday. It came back yesterday all nicely rewelded and I was back in business.
    I was a little disappointed in the failure but the customer service from Zionsville was excellent.

    Hope you don't have a problem. Enjoy.
    E38 6spd, 4.6is, VF Engineering Supercharged, Dinan HFM/TB, 3:64Quaife, VAC Motorsport underdrive pulleys, SuperSprint headers/mufflers, Smile factor.
    01 740i, Imola Red, stock.
    98 318ti, beater.
    97 540i, yard art.

  7. #7
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    Quote Originally Posted by bimmerfixr View Post
    Nice radiator. I put one in my 7. Love not hearing the clutch fan all the time in traffic.

    FYI. The expansion tank on mine failed. It cracked along a weld. Good news though, it wasn't a catastrophic failure like the plastic tank could have been.
    I called Zionsville to let them know. I sent my tank back to the last Friday. It came back yesterday all nicely rewelded and I was back in business.
    I was a little disappointed in the failure but the customer service from Zionsville was excellent.

    Hope you don't have a problem. Enjoy.
    Good to know they took care of you. Thanks for the info bimmerfixr.

  8. #8
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    The Zionsville product looks indestructable!








    04/1997 Build Date. 84,000 miles. Mods limited to black BMW roundel front license plate, wheel locks and an M5 rear trunk lip spoiler. 12" Kicker sub and amp in the trunk.

  9. #9
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    This thread should be NWS!!!

    If this is not pronographic, then I don't know what is!

    PS. I found the perfect antifreeze on e-Bay for you.





    "I'd smash that (Jennifer Connelly) like a failed coup in sub-Saharan Africa."
    ~Macktheknife in my epic Jennifer Connelly OT Thread

  10. #10
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    Wow! Is that a Vizsla in the pic?

  11. #11
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    great radiator and great photos.

    how many miles do you have your 540?
    what made you take the plunge towards a Zionsville?
    03' 540iT M-Sport Wag

    "...if sense were common, wouldn't everyone have it ?!?!"

  12. #12
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    OMG it looks great! Let me know how you like it.

  13. #13
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    Quote Originally Posted by dmako View Post
    Wow! Is that a Vizsla in the pic?
    No, she's a Yellow Lab. Her kind is referred to as a Dudley. That's a yellow lab with Chocolate pigmentation. For some reason, it gives them the pink nose and yellow eyes. She's about 18 mo old. Both of her parents were chocolate.



    Here she is with her brother and sister - LOL Boston Terrorists... er Terriers.


  14. #14
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    Quote Originally Posted by dumale View Post
    great radiator and great photos.

    how many miles do you have your 540?
    what made you take the plunge towards a Zionsville?
    40k miles.

    Well, I went with the Zionsville after getting spooked by all of the failure rates of a flawed OEM design (whether it be Behr or Nissens - you can argue for either of them). I don't want to do anything but flush coolant for the next 6 yrs.

  15. #15
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    That thing is sweet. I would have done it if I did not also do my new diff,... and lights... and ... arg, spending too much money.

    I did my entire cooling system for half the cost of that kit, but that kit is probably worth it... next time I may at least to the rad.
    '90 325ix 5 Speed

  16. #16
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    awesome man...
    ///M
    2002 540iA sport sterling grey, umnitza predator ice, yellow fog

  17. #17
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    nice job, those welds are a thing of beauty...

  18. #18
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    Great looking radiator. You can see why it's so expensive.
    Steve
    2001 530i/5 S+P CDV delete/Akebono ceramic pads/M5 SSK/RedLine MTL/M5 rear sway bar
    BMWCCA Member #337964

  19. #19
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    Sidebar. The instructions tell you to wire the relays to ignition(term 15) power. I wired mine to B+(term 30). That way when the engine gets shut off and engine temp is high, the fan will keep running and hopefully lower cooling system pressure. Was worried about battery voltage and restart, 8 months and never a problem. Just a thought. Maybe more 540/740 owners should get this and get the price down. too late for me but, what the hell?
    E38 6spd, 4.6is, VF Engineering Supercharged, Dinan HFM/TB, 3:64Quaife, VAC Motorsport underdrive pulleys, SuperSprint headers/mufflers, Smile factor.
    01 740i, Imola Red, stock.
    98 318ti, beater.
    97 540i, yard art.

  20. #20
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    congrats on the upgrade. looking forward to pix of it installed

  21. #21
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    IT's.....beautiful.

  22. #22
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    Quote Originally Posted by bimmerfixr View Post
    Sidebar. The instructions tell you to wire the relays to ignition(term 15) power. I wired mine to B+(term 30). That way when the engine gets shut off and engine temp is high, the fan will keep running and hopefully lower cooling system pressure. Was worried about battery voltage and restart, 8 months and never a problem. Just a thought. Maybe more 540/740 owners should get this and get the price down. too late for me but, what the hell?
    Funny you should mention that. The instructions I received are just a wiring diagram that tells you what wires connect to what and to give it a switched 12v power. No mention of where to get that power.

    So, with that said, I like your idea. Are you referring to the power under the passenger side microfilter housing?

    Thanks.

  23. #23
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    Quote Originally Posted by BlackSapphire View Post
    40k miles.

    Well, I went with the Zionsville after getting spooked by all of the failure rates of a flawed OEM design (whether it be Behr or Nissens - you can argue for either of them). I don't want to do anything but flush coolant for the next 6 yrs.
    I'm not allowed to do much mods because we accepted the extended 100K warranty for our wag.

    Believe or not in two of three routine visits, for a basic oil change, it was requested that my radiator be changed for a new one. That's two radiators in less than 10 months!

    Are the Behr or Nissens that problematic or are we lacking sufficient BMW techs that can do an install correctly ?! Regardless of the issue, the Zionsville is hot - figuratively speaking!

    -D
    03' 540iT M-Sport Wag

    "...if sense were common, wouldn't everyone have it ?!?!"

  24. #24
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    nice investment

    Shakin Dem Dreads, and Goin 18.. Im Shinin'

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  25. #25
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    Quote Originally Posted by dumale View Post
    I'm not allowed to do much mods because we accepted the extended 100K warranty for our wag.

    Believe or not in two of three routine visits, for a basic oil change, it was requested that my radiator be changed for a new one. That's two radiators in less than 10 months!

    Are the Behr or Nissens that problematic or are we lacking sufficient BMW techs that can do an install correctly ?! Regardless of the issue, the Zionsville is hot - figuratively speaking!

    -D
    I'm not sure what the deal is but that's just crazy. Unfortunately, your story is not the only one I've heard like this.

    So, I got it all wired up today. It took awhile because I was meticulous about it. I transferred all of the sensors over and realized I was short a couple of hose clamps. So, off to the auto parts store tomorrow to get a few. I also managed to fold my gasket in half so I'll be visiting the dealership parts counter tomorrow too. I hate when stuff like that happens. Oh well, it could be worse!

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