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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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  #51  
Old 08-20-2011, 07:17 AM
Schitzo Schitzo is online now
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Yes those relay sockets are nifty. I just wish I could get actual terminals that way I dont have to splice wires etc.

After some research I have settled on the following parts for my overhaul.

Stock radiator
Dual low profile cooling fans (sourced from another OEM)
91/99 C dual temp switch to control the fans
E30/Euro E36 coolant reservoir
E30 1.4 bar cap
Stock M54 thermostat
Geba water pump
ECS WP pulley
Stock radiator hoses

I am happy the fans clear all the front accessories. They also cover 95 % of the radiator core.
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  #52  
Old 08-20-2011, 09:22 AM
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16valex 16valex is offline
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Quote:
Originally Posted by *****zo View Post
Yes those relay sockets are nifty. I just wish I could get actual terminals that way I dont have to splice wires etc.

After some research I have settled on the following parts for my overhaul.

Stock radiator
Dual low profile cooling fans (sourced from another OEM)
91/99 C dual temp switch to control the fans
E30/Euro E36 coolant reservoir
E30 1.4 bar cap
Stock M54 thermostat
Geba water pump
ECS WP pulley
Stock radiator hoses

I am happy the fans clear all the front accessories. They also cover 95 % of the radiator core.
Nice research, I like every thing except for the 1.4 Bar cap, that's hefty 30% reduction in pressure, in turns you are going to loose quite a bit of cooling. I'd keep the 2.0 Bar cap and see how it works out. I think it's going to be just fine.

I have a question about the 91/99 dual temp switch. Does this mean you are going to have a two stage electric fan set up?
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  #53  
Old 08-20-2011, 10:18 AM
Schitzo Schitzo is online now
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Quote:
Originally Posted by 16valex View Post
Nice research, I like every thing except for the 1.4 Bar cap, that's hefty 30% reduction in pressure, in turns you are going to loose quite a bit of cooling. I'd keep the 2.0 Bar cap and see how it works out. I think it's going to be just fine.
Alex the issue of pressure caps on E39s has come up several times and there are sound arguments for going with either cap. My choice to go with the 1.4 bar cap is purely based on successful experience using this cap on an engine that has higher compression, higher displacement and sees much more abuse than this M54 will ever see. That said, if I do find that the 1.4 bar cap is less than ideal,I will switch back to the 2.0

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Originally Posted by 16valex View Post
I have a question about the 91/99 dual temp switch. Does this mean you are going to have a two stage electric fan set up?
Yes. This will allow me to have a 2 speed setup without necessarily having a dedicated controller. Below is the wiring schematic I use on the LS1 and is the same I will use on this car. It uses 3 relays and 2 fuses. Below 99C the fans will run at 50% (low speed) and at 100 % (high speed) above 99C.

EDIT: Noted an error in my drawing on relay I. The 12V IGN and 12V constant should be reversed!!


Last edited by Schitzo; 08-20-2011 at 11:56 AM.
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  #54  
Old 08-20-2011, 12:01 PM
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16valex 16valex is offline
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Quote:
Alex the issue of pressure caps on E39s has come up several times and there are sound arguments for going with either cap. My choice to go with the 1.4 bar cap is purely based on successful experience using this cap on an engine that has higher compression, higher displacement and sees much more abuse than this M54 will ever see. That said, if I do find that the 1.4 bar cap is less than ideal,I will switch back to the 2.0
Robert, I guess I missed the whole debate thing, but since it's from your known experience then that is where it counts the most.

Nice two stages fan set up hand draw BTW
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  #55  
Old 08-20-2011, 05:26 PM
Schitzo Schitzo is online now
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Today was a very productive day. Got the fans mounted on the shroud and mounted them in the car. There is plenty room between the accessories and fans. The closest sport is between the A/C compressor and plastic fan guard.

Next up will be making the mounting tabs to mount the shroud on the radiator. I will use the similar tabs as on the stock shroud.



plenty of space

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  #56  
Old 08-20-2011, 11:11 PM
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bluebee bluebee is offline
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Originally Posted by 16valex View Post
Robert, I guess I missed the whole debate thing
From the bestlinks ...
- Modifying the cooling system pressure cap (1)
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  #57  
Old 08-21-2011, 07:12 AM
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Quote:
Originally Posted by *****zo View Post
Today was a very productive day. Got the fans mounted on the shroud and mounted them in the car. There is plenty room between the accessories and fans. The closest sport is between the A/C compressor and plastic fan guard.

Next up will be making the mounting tabs to mount the shroud on the radiator. I will use the similar tabs as on the stock shroud.



plenty of space

That looks hot! I like

Cut off the water pump tread will give you some more room to maneuver had you you not thought of it .
Keep us updated, very nice so far.

Quote:
From the bestlinks ...
- Modifying the cooling system pressure cap (1)
Thanks BB
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  #58  
Old 08-21-2011, 07:17 AM
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*****-zo, I forgot to ask where did you get the aluminum shroud? Or did it come with the dual fans as an ass'y?
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  #59  
Old 08-21-2011, 08:13 AM
bimmerteck bimmerteck is offline
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Quote:
Originally Posted by *****zo View Post
Yes those relay sockets are nifty. I just wish I could get actual terminals that way I dont have to splice wires etc.
The pins are available separately either with or without a lead wire. I'll get the part #s you'll need for the relays and post them up here. Here are 3 or 4 different ones that are selected by the gauge of the wire used on that particular pin. I posted an example pic of the round OE "repair pins" I use to add extra circuits to the motor harnesses I install for customers using vacant pin locations in the stock connector housings.





The dealerships should have almost all of the pins used in the more recent vehicles in the in their factory electrical repair box. (looks like an overgrown tackle box) The part numbers you need will be either stuck on the actual mini bin where the pins are stored, or if it's a much newer kit they will be on large laminated cards that store with the box itself. Unfortunately most dealers aren't really cool with random people walking back into their service bays and helping themselves to the factory tool cabinets. . . so you'll most likely need a frendly dealership tech to do the digging for you.


PS, your hand drawn wiring diagram looks great, I wish the guys whose cars I work on would be kind enough to document that well when they attempt to modify their cars, it would save me a lot of time, and them a lot of money.

Last edited by bimmerteck; 08-21-2011 at 08:15 AM.
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  #60  
Old 08-21-2011, 05:11 PM
Schitzo Schitzo is online now
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Originally Posted by 16valex View Post
*****-zo, I forgot to ask where did you get the aluminum shroud? Or did it come with the dual fans as an ass'y?
I had the shroud made locally last year while helping a friend install an electric fan in his 540i. I had an extra one made just in case I would need it and I am glad I did because it has come in handy for this project

The fans are out of an early 2000s 3.4 pontiac grand am. They come as a pair with a one low profile fan and one high profile. So I had to buy two sets of fans and just used the two low profile fans. The 4 fans cost a whooping $40 at the local salvage place.

Quote:
Originally Posted by bimmerteck View Post
The pins are available separately either with or without a lead wire.
I have always had a hard time finding BMW terminals hence I have always gone with delphi terminals and connectors. If you do have the part numbers I be more than happy to take them to the local dealer and see what I can find.
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  #61  
Old 08-21-2011, 07:45 PM
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Quote:
Originally Posted by *****zo View Post
EDIT: Noted an error in my drawing on relay I. The 12V IGN and 12V constant should be reversed!!

Fixed.
- How to post, shrink, modify, edit, annotate, merge, & upload pictures for posting here (1)

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Last edited by bluebee; 08-21-2011 at 07:47 PM.
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  #62  
Old 08-21-2011, 10:07 PM
Schitzo Schitzo is online now
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Quote:
Originally Posted by bluebee View Post
Fixed.
- How to post, shrink, modify, edit, annotate, merge, & upload pictures for posting here (1)
Thank BB but that link does not show what to do if you are too lazy to correct the mistake.

Anyway, the error only applied to "relay I" and not the others. Below is the correct schematic for any one interested.

The way it works is between 91 and 99 C the temp sensor will ground Relay I which will send 12V through both Fan 1 and Fan II. As such each fun will only have 6V and hence run at 50% of the speed they are capable off. When the temp goes above 99C, the sensor will ground relay II in addition to relay I which will now send 12V through each fan thus each fan will run at 100%. Its a simple setup but works very well. The fans will hardly ever need to run at 100%


Last edited by Schitzo; 08-21-2011 at 10:15 PM.
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  #63  
Old 09-01-2011, 06:00 PM
Schitzo Schitzo is online now
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Been busy so I havent had much time to work on the car. However I did get a few things done.

Got the ECS aluminum WP pulley. Quite a solid piece and it will clear the fans nicely. Also got around to fabricating 4 of the 6 fan shroud mounting tabs. Should have the remaining 2 done soon.





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  #64  
Old 09-02-2011, 05:33 AM
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*****zo! Nice work, Love the aluminum look, I think you should patten it.
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  #65  
Old 10-24-2011, 03:03 PM
Schitzo Schitzo is online now
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Updating this for those who don't cross the pond. The fans are mounted, AUC support is done and 90% of the wiring is done. I have a few busy weeks coming up but hope to have it done soon.


E30 reservoir


AUC sensor bracket


Radiator hose splice


Cooling fan fuse box in the e-Box

Initial routing of the cooling harness
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  #66  
Old 10-24-2011, 05:57 PM
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*****zo, man! You've got this down to perfection! I can't believe how diligence you are down to the wires. Awesome job!
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  #67  
Old 10-24-2011, 06:15 PM
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Beautiful workmanship.

Very nicely done!
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  #68  
Old 10-24-2011, 07:13 PM
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Last edited by bluebee; 10-25-2011 at 03:18 PM.
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  #69  
Old 10-24-2011, 08:04 PM
Schitzo Schitzo is online now
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Quote:
Originally Posted by bluebee View Post
BTW, to help identify those four fuses in the passenger ebox, ........
Bluebee those fuses are not part of BMW rather they are part of the cooling harness I built. You will not find them in your car. The wires you see on the top right of the picture terminate in the fuse box as seen below.



Quote:
Originally Posted by 16valex View Post
*****zo, man! You've got this down to perfection! I can't believe how diligence you are down to the wires. Awesome job!
Quote:
Originally Posted by AnotherGeezer View Post
Beautiful workmanship.

Very nicely done!
Thanks fellas, its part hobby part OCD
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  #70  
Old 10-25-2011, 06:37 AM
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they are part of the cooling harness I built. You will not find them in your car
Ah. I see. Thanks.

Last edited by bluebee; 10-25-2011 at 03:06 PM.
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  #71  
Old 10-25-2011, 07:15 AM
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Nline6 Nline6 is offline
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On my old 325i I did the FDM (fan delete mod) after the water pump failed, causing the fan to attach everything in the area causing mucho damage. I never had any issues of over heating even on 98* days with the AC on in traffic. I wanted to remove the fan from my 540i, but i am concerned that it might cause problems with over heating, so i havent bothered.
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  #72  
Old 10-25-2011, 12:58 PM
Schitzo Schitzo is online now
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Quote:
Originally Posted by bluebee View Post
....... fuses...
Lets not clutter this one in the name of fuse forensics.
Between the Bentley manual and BMW WDS there is no reason why you should not be able to identify all the fuses in your car or any E39 for that matter.
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  #73  
Old 10-26-2011, 08:55 PM
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Originally Posted by *****zo View Post
you should be able to identify all the fuses in your car or any E39 for that matter.
Done. In this thread I've identified all 88 fuses (F1 to F5, F1 to F114) and their sizes, purpose, and location:
- Need help with location of the fuse boxs and overview of fuse positions

Back on topic, I was wondering how you made that gorgeous radiator hose. I see from this thread how now:
- Cooling System Overhaul My way

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  #74  
Old 11-04-2011, 07:14 PM
Schitzo Schitzo is online now
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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
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  #75  
Old 11-12-2011, 01:59 PM
Schitzo Schitzo is online now
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It was nice out today so I spent sometime in the garage fabbing the coolant reservor support bracket. Just need to paint and route the hoses and this thing will be back on the road.

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