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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 01-24-2017, 07:44 AM
V8Mike V8Mike is offline
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Location: Chicago
 
Join Date: Oct 2015
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Mein Auto: 2003 540i6
Zionsville radiator problem

Hi Folks;
I replaced my radiator, thermostat, cooling lines and fan a few months ago. I used the zionsville kit with the 2 speed electric fan.

So far it's worked great, temps are good and it's tight as a drum with no leaks. Only problem is I get a "Check coolant level" warning on every start. I have it filled roughly half way up the expansion tank, and as far as I can tell I thoroughly and properly bled the system of air. I've checked the levels and feel they're safe so I'm not worried about damage but the message is really annoying. I believe I've installed the coolant level sensor properly, and it seems to be connected properly but I really don't know if it's working. It's also hard to know how much coolant to add as there is no floaty level checker thingy.

I contacted zionsville but the customer service has been less than stellar as I can't get anyone to reply to my messages. Any suggestions from anyone who has this system?
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  #2  
Old 01-24-2017, 12:11 PM
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matt540 matt540 is offline
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Mein Auto: 2000 DINAN 540, 1983 745
Add a little more, mine has to be about 3/4ths full for the check coolant level not to show in the dash.

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2000 Dinan 540 Dinan F&R strut tower brace, M5 F&R sway bars, Koni Sports, Eibach springs, Powerflex polyurethane bushings, Dinan stage 2 engine software, Stage 1 trans software, Zionsville cooling kit, resonator delete, Dinan exhaust, Dinan TB, AFE cai, 18" style 5's, 235/40/18 275/35/18, Ultimate cup holders, rear cup holder delete/coin holder, Hella taillights, clear sides, Depo AE, M5 spoiler
1983 745 turbo, style 138 wheels
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  #3  
Old 01-24-2017, 01:02 PM
V8Mike V8Mike is offline
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I'll give it a try thanks. If it's that simple I'm going to feel really dumb.
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Bury me in my e39.
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  #4  
Old 01-24-2017, 01:57 PM
540nj 540nj is offline
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Quote:
Originally Posted by V8Mike View Post
I'll give it a try thanks. If it's that simple I'm going to feel really dumb.

Not sure about the zville set-up, but I've got a check coolant light on for a while. Original sensor from new, 140K miles. Bought a replacement, but haven't gotten around to installing yet.

Coolant level hasn't changed in a year.

Dave
03 540i6
95 993
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  #5  
Old 01-24-2017, 02:04 PM
edjack edjack is offline
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Mein Auto: '97 540i 6 speed
Is there a float in the tank?

BTW, these guys are gearheads; they're probably not schooled in the art of customer service.
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Last edited by edjack; 01-24-2017 at 02:05 PM.
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  #6  
Old 01-24-2017, 07:03 PM
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matt540 matt540 is offline
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Mein Auto: 2000 DINAN 540, 1983 745
What happened?

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2000 Dinan 540 Dinan F&R strut tower brace, M5 F&R sway bars, Koni Sports, Eibach springs, Powerflex polyurethane bushings, Dinan stage 2 engine software, Stage 1 trans software, Zionsville cooling kit, resonator delete, Dinan exhaust, Dinan TB, AFE cai, 18" style 5's, 235/40/18 275/35/18, Ultimate cup holders, rear cup holder delete/coin holder, Hella taillights, clear sides, Depo AE, M5 spoiler
1983 745 turbo, style 138 wheels
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  #7  
Old 01-25-2017, 08:16 AM
V8Mike V8Mike is offline
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Location: Chicago
 
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Mein Auto: 2003 540i6
There is not a float in the tank. Just a level sensor in the bottom.

As for "what happened" - nothing, it's all good. The kit seems great so far after about 3 months use with the exception of the low coolant warning. I just haven't been able to get a response to any of their customer service emails. Haven't bothered trying to call yet.
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Bury me in my e39.
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  #8  
Old 01-25-2017, 08:47 AM
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matt540 matt540 is offline
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Mein Auto: 2000 DINAN 540, 1983 745
Did adding more coolant fix the problem?

Sent from the moon
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2000 Dinan 540 Dinan F&R strut tower brace, M5 F&R sway bars, Koni Sports, Eibach springs, Powerflex polyurethane bushings, Dinan stage 2 engine software, Stage 1 trans software, Zionsville cooling kit, resonator delete, Dinan exhaust, Dinan TB, AFE cai, 18" style 5's, 235/40/18 275/35/18, Ultimate cup holders, rear cup holder delete/coin holder, Hella taillights, clear sides, Depo AE, M5 spoiler
1983 745 turbo, style 138 wheels
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  #9  
Old 01-25-2017, 10:14 AM
V8Mike V8Mike is offline
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Location: Chicago
 
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No unfortunately. I will try just a tad more.
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Bury me in my e39.
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  #10  
Old 01-25-2017, 10:38 AM
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matt540 matt540 is offline
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Location: Michigan
 
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Mein Auto: 2000 DINAN 540, 1983 745
It could be the coolant level sensor

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2000 Dinan 540 Dinan F&R strut tower brace, M5 F&R sway bars, Koni Sports, Eibach springs, Powerflex polyurethane bushings, Dinan stage 2 engine software, Stage 1 trans software, Zionsville cooling kit, resonator delete, Dinan exhaust, Dinan TB, AFE cai, 18" style 5's, 235/40/18 275/35/18, Ultimate cup holders, rear cup holder delete/coin holder, Hella taillights, clear sides, Depo AE, M5 spoiler
1983 745 turbo, style 138 wheels
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  #11  
Old 01-26-2017, 02:14 PM
waters17 waters17 is offline
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Location: Lapeer, Michigan
 
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Mein Auto: 2003 540i/6
I have the same issue with my zionsville radiator. It randomly started last year, but the message is now on all the time. Coolant level is perfect. I looked into it briefly, and IIRC, the coolant level sensor in the Zionsville is a different BMW part number than the stock level sensor. -not sure though. It also looks like it's a pain to replace since the bracket for the air quality sensor is located directly under the coolant level sensor.
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