Page 1 of 5 12345 LastLast
Results 1 to 25 of 102

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

  1. #1
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech

    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
    Join Date
    Nov 2002
    Location
    San Pedro, California
    Posts
    1,152
    My Cars
    88M3-89M3-91MTech-98528i
    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
    Join Date
    Nov 2006
    Location
    Paramus, NJ
    Posts
    464
    My Cars
    98 540Ia
    Goods nice...but, looks little heavy tho..

  4. #4
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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
    Join Date
    Sep 2006
    Location
    Southeastern, Pa
    Posts
    1,580
    My Cars
    00 740i 6spd, 01 740i
    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
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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
    Join Date
    Oct 2004
    Location
    Flower Mound, TX
    Posts
    1,140
    My Cars
    '97 540i, '10 Vette GS
    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
    Join Date
    Sep 2006
    Location
    New York
    Posts
    5,563
    My Cars
    2003 525i

    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
    Join Date
    Jul 2006
    Location
    CT
    Posts
    199
    My Cars
    1999 BMW 528i
    Wow! Is that a Vizsla in the pic?

  11. #11
    Join Date
    Mar 2007
    Location
    Nor Cal
    Posts
    45
    My Cars
    03' 540iT Sport Wag
    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
    Join Date
    Mar 2002
    Location
    seattle
    Posts
    4,341
    My Cars
    540it,E36 & E30 Touring
    OMG it looks great! Let me know how you like it.

  13. #13
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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
    Join Date
    Mar 2007
    Location
    Vancouver, BC, Canada
    Posts
    602
    My Cars
    2000 M5, 2012 X5 35d
    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.
    2000 M5
    2012 X5 35d

  16. #16
    Join Date
    Mar 2007
    Location
    NY
    Posts
    266
    My Cars
    02 bmw 540i
    awesome man...
    ///M
    2002 540iA sport sterling grey, umnitza predator ice, yellow fog

  17. #17
    Join Date
    Jul 2006
    Location
    Westchester county, NY
    Posts
    2,567
    My Cars
    Jeep, merc wag
    nice job, those welds are a thing of beauty...

  18. #18
    Join Date
    Jun 2004
    Location
    Knoxville, TN
    Posts
    4,097
    My Cars
    2001 BMW 530i
    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
    Join Date
    Sep 2006
    Location
    Southeastern, Pa
    Posts
    1,580
    My Cars
    00 740i 6spd, 01 740i
    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
    Join Date
    May 2007
    Location
    NYC/NJ
    Posts
    670
    My Cars
    540it, Z3
    congrats on the upgrade. looking forward to pix of it installed

  21. #21
    Join Date
    Mar 2007
    Location
    Surprise,Arizona
    Posts
    823
    My Cars
    1987 BMW Mustang GT 5-speed
    IT's.....beautiful.

  22. #22
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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
    Join Date
    Mar 2007
    Location
    Nor Cal
    Posts
    45
    My Cars
    03' 540iT Sport Wag
    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
    Join Date
    Feb 2006
    Location
    Bay Area, Ca
    Posts
    792
    My Cars
    1997 528i
    nice investment

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

    Pictures:
    http://forums.bimmerforums.com/forum...d.php?t=851604

  25. #25
    Join Date
    Sep 2006
    Location
    Lone Star State
    Posts
    4,417
    My Cars
    2003 BMW 540i M-Tech
    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!

Page 1 of 5 12345 LastLast

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •