Cooling System Overhaul My way

[Schitzo]

Are you going to speak on whether or not you'd consider producing these for sale? I know it'll take a while to figure out how you need to be compensated... material cost, time, shipping etc.. but if you'd consider it, how about a ballpark #$?

Even if I wanted, I just wouldn't have time to make this into a kit.

Spent sometime today making the mount for the AUC sensor. BMW typically mounts it with the intake on the sensor perpendicular to the air flow. I did the same.




sensor air intake


Clears the top hose with plenty of room to spare

[16valex]

Schitzo, You sure are handy with aluminum fabrication

[Jason5driver]

Schitzo, You sure are handy with aluminum fabrication

+1.
Looks stock.
Amazing...!

[cswrc]

I will be using a reservoir out of a E30. It is self bleeding and has a much better build than the regular E39 units. It will mount on the wheel well by the ABS module.
http://www.realoem.com/bmw/showparts...=17&fg=05&hl=8

I haven't done the wiring yet but as of now I am planning on using the schematic below with a E36 dual temp switch. Otherwise I may use a dedicated controller if I can find one I trust.

Are you using the E36 dual temp switch in place of the E39 one or in tandem? If in tandem are you using a hose adapter?

[Schitzo]

Are you using the E36 dual temp switch in place of the E39 one or in tandem? If in tandem are you using a hose adapter?

I'll be using a hose splice on the lower radiator hose. The E30/E36 switch will have nothing to do with the stock E39 temp sensor.

[cswrc]

I'll be using a hose splice on the lower radiator hose. The E30/E36 switch will have nothing to do with the stock E39 temp sensor.

Cool. I'm finishing mine up but will using the Volvo 2 speed fan relay.

[Schitzo]

The volvo relays are another good choice for fan control. Definitely post up when you can.

[Schitzo]

I have been really busy and haven't touched the car since completing the AUC sensor mount. However I did find the ideal radiator hose splice into which the temp sensor will mount. It is made out of Al and has 1 5/16 ends with a M14 x 1.5 threaded hole for the sensor. I bought it from a member on here who sells several different size splices such as this one. For any one doing an electric fan swap and will be using the BMW sensor with the M14 threads, you can purchase the splice from the link below. Enter 1-5/16 x 14 mm x 1.5 p under the "specify size" tab
http://www.jagsthatrun.com/Pages/Par...rass-Tees.html

[Jason5driver]

I have been really busy and haven't touched the car since completing the AUC sensor mount. However I did find the ideal radiator hose splice into which the temp sensor will mount. It is made out of Al and has 1 5/16 ends with a M14 x 1.5 threaded hole for the sensor. I bought it from a member on here who sells several different size splices such as this one. For any one doing an electric fan swap and will be using the BMW sensor with the M14 threads, you can purchase the splice from the link below. Enter 1-5/16 x 14 mm x 1.5 p under the "specify size" tab
http://www.jagsthatrun.com/Pages/Par...rass-Tees.html

Excellent!
This is exactly what I need!
Thank you!

Jason

[cnn]

I have been a little lazy. Didnt get much done over the weekend. However, I received the expansion tank and painted it the wrong color. I need more of a flat black to match the rest of the engine bay.

The tank will be positioned as seen in the pic below. It will be the highest point on the cooling system circuit.

Schitzo,

I think you are doing a great job.
Your proposed reservoir location is in fact used by Volvo 850, S70, V70 over the years. It sits near the suspension tower, at the highest point.

I am attaching a Volvo pic so you can see:

[tonytone4143]

rob!! you always seem to amaze me with you talent!!! keep up the good work brother

[Schitzo]

Schitzo,

I think you are doing a great job.
Your proposed reservoir location is in fact used by Volvo 850, S70, V70 over the years. It sits near the suspension tower, at the highest point.

I am attaching a Volvo pic so you can see:

Thanks for the pic Cam. That location is ideal in that it places the reservoir vent line easily at the highest spot on the cooling system. When done I believe it will look as though it came that way from "zee Germans" .

rob!! you always seem to amaze me with you talent!!! keep up the good work brother

Thanks Tony. This is how I take a break from my work. Its fun for me.
Hope the touring is coming along well. You know how to get a hold of me if you need any help.

[Schitzo]

Test fitted the hose splice, received the parts I need to start on the wiring. Also starting routing the main power wire. I will have it bolt onto the positive "Jump start" lead. This should provide clean battery power without necessarily affecting other circuits.
Next up will be wiring the relays.

[Schitzo]

90% of the wiring is done. Unfortunately I ordered the wrong terminal for the fan motor connector so I have to wait till the right parts comes in from Texas. Once done the wires will be wrapped with cloth tape similar to what BMW uses. It should blend in nicely with the stock wiring harness.
The relays will sit in a Radioshack project box once done.


Completed relay stack (I usually use Tefzel M22759 wire but was out of the 12 gauge size so I went with TXL instead.)


Fuse Box fit nicely in e-Box (actual fuses will be 20A)

[jamesdc4]

Amazing work! Can't wait to see the final results.

[Schitzo]

Finished wrapping the harness but still awaiting the connectors to arrive tomorrow.Prior to wrapping I tested the harness and everything works as should. Hopefully the car will be back running before the white stuff drops.

[Jason5driver]

Sorted out the aux water pump today. I'm not sure why BMW chose to add this pump to the E39s after 9/98. It essentially pumps the water from the coolant reservoir back to the engine. When I did the LS1 swap, I deleted the aux pump from my system and had no heating issues over the winter. However since I don't have a reason to delete it from this car I will be keeping it. I will mount it on the bottom left corner of the shroud.

proposed mounting position

Are you still using the Auxiliary water pump?
It doesn't look connected..
I think mine is toast...
When at idle, the fan will kick on, and, it takes a we bit to get the heat going in the car...

[Schitzo]

Are you still using the Auxiliary water pump?

Yes I will be using it.
Its just not connected in that picture.

[Schitzo]

I completed the cooling harness yesterday and tested the fans in the car. All I can say is HOLY OVERKILL BATMAN!! The fans move an immense amount of air at low speed and at high speed they are just ridiculous. I doubt they will need to switch to high speed much.
Time to start putting everything back together.

Completed harness

[540Indy]

but Zionsville makes me drool

Zionsville it only 1hr and $1800 away from me

[larinah]

Can You post part numbers for the parts You used. This definitely looks to be in my future

[Schitzo]

Can You post part numbers for the parts You used. This definitely looks to be in my future

I will put something together.


Today I had a chance to fab up the coolant reservoir tank support bracket.It clears the hood nicely.Just have to paint it semi gloss black.

[Jason5driver]

Yes I will be using it.
Its just not connected in that picture.

My aux. water pump...

[Schitzo]

That doesn't look good. What happened?

[Jason5driver]

That doesn't look good. What happened?

I do not know.
It looked like the cap had been pulled off...
However, I am not sure how, since the belly pan was on when I found it that way...
Needless to say, I am pretty sure my aux. water pump is toast, because there is no heat from the car until I drive the car for a wee-bit long, and driving on the highway for a while...