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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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  #76  
Old 11-14-2011, 07:20 AM
Melrose Melrose is offline
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I have an interesting story to tell about fragile fan blades. While trying to install the Vanos solenoid seal I removed the splash shield and fan and it accidentally dropped only a foot to my shop's comcrete floor. It shattered like glass and lost two blades. It was the original on my '99 540i, so I would say be extremely careful when you remove it.
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  #77  
Old 02-08-2012, 10:17 AM
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bluebee bluebee is offline
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For the cross-linked record, here's another exploding fan today:
- E39 (1997 - 2003) > Broken fan blades

Quote:
Why did the fan disintegrate?
  1. Did the water pump fail?
  2. Or did the viscous fan clutch seize?
  3. Or, was the plastic fan itself developing cracks?
  4. Or, are the rubber motor or tranny mounts bad?
The solution for the first three is the same: COMPLETE COOLING SYSTEM OVERHAUL.
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  #78  
Old 03-12-2012, 08:11 PM
Schitzo Schitzo is offline
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This is due for an update.
I made a few changes to the way the fans will be controlled. Instead of the BMW dual temp switch, I changed to a dedicated fan control module. It will allow me to select what temperatures I want the fans to come one and when to go off. I also can be set to run the fan when the engine is off and the coolant temperature is beyond a specified point. Tomorrow I will get coolant from the dealer and hopefully fire her up on Wednesday.

Controller


Wired and installed
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  #79  
Old 03-13-2012, 06:52 AM
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16valex 16valex is online now
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I like the Dakota controller's features, the high and low fan options is rare. Awesome research Robert!

What the cost for just the Dakota controller Robert?
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  #80  
Old 03-13-2012, 07:14 AM
Schitzo Schitzo is offline
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It's $119 plus $16 for the sender.
You can read more about it in the link below.
http://www.dakotadigital.com/pdf/pac-2700.pdf
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  #81  
Old 03-13-2012, 08:54 AM
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16valex 16valex is online now
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Quote:
Originally Posted by *****zo View Post
It's $119 plus $16 for the sender.
You can read more about it in the link below.
http://www.dakotadigital.com/pdf/pac-2700.pdf
Thanks Robert, very high tech little gadget all digital settings you've got. I sure will use this for my M5 if I ever found a good deal.
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  #82  
Old 03-13-2012, 09:49 AM
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1995i540 1995i540 is offline
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This has nothing to do with faulty parts but lack of basic maintenance and vehicle inspection.

Your WP pulley is torn from one side. This does not happen instantly.

  1. You had a missing fan blade causing vibrations (or bolt securing fan to pulley)
  2. Your hydralic clutch started sticking and you kept driving it
  3. Your water pump pulley was too brittle and cracked
  4. Your water pump bearing was so worn out it seized
'

All four are easily preventable and show signs of problems before hand. I would advise to review maintenance schedule for your vehicle and follow it.

Furthermore, running electrical fan is an invitation to a fire. I hope you carry a fire extinguisher on you at all times.
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Last edited by 1995i540; 03-13-2012 at 09:50 AM.
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  #83  
Old 03-13-2012, 11:30 AM
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16valex 16valex is online now
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Quote:
Originally Posted by 1995i540 View Post
This has nothing to do with faulty parts but lack of basic maintenance and vehicle inspection.

Your WP pulley is torn from one side. This does not happen instantly.

  1. You had a missing fan blade causing vibrations (or bolt securing fan to pulley)
  2. Your hydralic clutch started sticking and you kept driving it
  3. Your water pump pulley was too brittle and cracked
  4. Your water pump bearing was so worn out it seized
'

All four are easily preventable and show signs of problems before hand. I would advise to review maintenance schedule for your vehicle and follow it.

Furthermore, running electrical fan is an invitation to a fire. I hope you carry a fire extinguisher on you at all times.
In case you don't know. BMW went with E-fan on all their E60 and to date.


Quote:
Furthermore, running electrical fan is an invitation to a fire
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  #84  
Old 03-13-2012, 11:47 AM
Schitzo Schitzo is offline
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Quote:
Originally Posted by 1995i540 View Post
This has nothing to do with faulty parts but lack of basic maintenance and vehicle inspection.
I will leave you to speculate all you want.
I have had been around these cars long enough to not trust the stock cooling system parts even when new.
With the electric fan and E30 tank I'm certain I will never have to replace them due to the same faults that plague their stock counterparts.

Quote:
Originally Posted by 1995i540 View Post

Furthermore, running electrical fan is an invitation to a fire. I hope you carry a fire extinguisher on you at all times.
Please please please tell me you are joking!!
Why did BMW switch from a mechanical fan to an electric fan in the E60 yet not include a fire extinguisher as standard?
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Last edited by Schitzo; 03-13-2012 at 01:37 PM.
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  #85  
Old 03-13-2012, 12:36 PM
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AnotherGeezer AnotherGeezer is offline
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Quote:
Originally Posted by 1995i540 View Post
This has nothing to do with faulty parts but lack of basic maintenance and vehicle inspection.
Wow. Judge, jury, and executioner all in one fell swoop.

The OP is the polar opposite of the person you think you're indicting here.
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  #86  
Old 03-13-2012, 02:58 PM
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16valex 16valex is online now
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Quote:
The OP is the polar opposite of the person you think you're indicting here.
I love your choice of words
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  #87  
Old 03-13-2012, 03:55 PM
Schitzo Schitzo is offline
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^^^ If Chris and his sense of humor wasn't around, this place would be rather boring.
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  #88  
Old 03-14-2012, 08:53 AM
Schitzo Schitzo is offline
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Running the return heater hose took some time to figure out as I wanted a clean safe way to secure it to the shroud. After some head scratching, I used these nice threaded inserts.


I initially press fit them onto the shroud but later on added 3/32 rivets that way there is no chance they will move around. I then ground the rivet heads for a flat fit.


I used three of them, 1 to hold the Aux water pump and 2 to hold the hose clamps. I'm very happy with the way they turned out.
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  #89  
Old 03-14-2012, 09:01 AM
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Quote:
Originally Posted by *****zo View Post
^^^ If Chris and his sense of humor wasn't around, this place would be rather boring.
True dat!
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  #90  
Old 03-14-2012, 09:05 AM
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AnotherGeezer AnotherGeezer is offline
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Those inserts are cool but look a lot like the spanner nut on my DA sander.

Awesome work!
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  #91  
Old 03-14-2012, 09:14 AM
Ed Cheung Ed Cheung is offline
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Thanks guys, I just found my next project.
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96 528i AT w/steptronic. => 97 540i w/ steptronic. =>steptronic deleted, 6MT installed.
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  #92  
Old 03-14-2012, 09:52 AM
Schitzo Schitzo is offline
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Quote:
Originally Posted by AnotherGeezer View Post
Those inserts are cool but look a lot like the on my DA sander.
Are you implying my fan shroud is now a DA sander !!

Quote:
Originally Posted by Ed Cheung View Post
Thanks guys, I just found my next project.
DO IT just don't get carried away like have!
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  #93  
Old 03-17-2012, 04:02 PM
Schitzo Schitzo is offline
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Finished putting it together last night and drove the car today. The fan setup works perfect. It is 80F here today so I took her on the highway and in stop and go traffic. Temps ranged between 93F and 101F on OBC test 7.

The fans are working fine and there are no coolant leaks to report. Needless to say I'm very pleased with how this turned out.
I just have to put the engine covers back on and hook up the coolant level switch. At that point I will call it done.

E30 tank with 1.4 Bar cap


ECS pulley. Look at all that space. replacing the belt can now be done with the fans in place.
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Last edited by Schitzo; 03-17-2012 at 04:07 PM.
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  #94  
Old 03-30-2012, 01:21 AM
smakhtar smakhtar is offline
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DIY to renew the high power radiator fan for e60

The radiator fan in e60, 530 series is a variable speed which varies speed depending upon the coolant temperature.

This fan is very expensive, Around 600USD for new and 350USD for used one.

This fan is designed perfectly and can work more tha 200K, It is better to replace the bearing for the motor of this fan to increase the life.

Steps:

1. Remove the fan from the vehicle and remove the fan balde by removing 03 botls.

2. Remove other three 10mm bolts holding the motor to main plastic frame.

3. Remove the metalic shield cover on backside of the motor. You need to scribe of the seallant to free the cover.

4. You will find a Printed Cricuit Board (PCB) fan speed control module under this cover.
soldering iron
5. Remove small torx screws to loose the PCB.

6. There are four connection points from stator winding connected to this PCB. These points are spot welded therefore need to cut by a small cutter plier.

7. Remove the PCB and place it safely.

8. You will find a small bearing under the PCB.

9. You can remove the bearing by punching the shaft with a small hammer.

10. There are two same type of bearings and one spring. Replace the bearings with new ones and follow the reverse process to assemble.

11. You need a 150 Watt soldering iron to solder the four stator winding connection points to PCB.

Fix the PCB back, and torix screws. Solder the four points with soldering iron.

12. Fix the PCB protection cover and apply any sealant to protect against water entry.

The fan motor is renewed and will work for another 200K.
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  #95  
Old 11-08-2012, 06:15 PM
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bluebee bluebee is offline
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Happened again, over here:
Quote:
Originally Posted by racerx8413 View Post
Well, my first post isn's as cheery as I was hoping it would be.

I picked up a 97 540i in Texas, with roughly 100k, for what I figure isn't a bad price. Thankfully I made it back up to Denver before this happened a few days later.





It shredded the insulation under the hood, punched through the hood in at least one spot, and destroyed the power steering hose and 2 radiator hoses. Fortunately it didn't appear to have done too much damage to anything else except the fan shroud.

I was curious, if anyone has any experience with Uro parts, or bavauto. I figure the fan can only blow up like this for a couple reasons, crappy parts being one of them, although i'm not ruling out that the original mechanic possible overtightened, installed wrong, or even put the wrong setup on.

Just wanted to share, and see if anyone had any recommendations. I may very well buy my own fan to minimize repair costs. It's sitting at the shop right now, and I know I'm going to have them replace the power steering hose at the minimum. The rest, I can install myself if I can source good parts. I don't want to make the mistake of the original mechanic and put the wrong item, or a junk item on.
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See also: E39 Bestlinks & How to easily find what you need
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  #96  
Old 01-01-2013, 12:54 PM
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bluebee bluebee is offline
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Another M54 fan explosion today - this one tracked to a bad fan clutch:
> E46 (1999 - 2006) > What the heck happened to my fan???
Quote:
Originally Posted by christopherr117 View Post
Apparently I forgot to give everyone the final results. The cause WAS a faulty fan clutch. The distributor for the shop that I used said the fan clutch was up to spec when it wasn't. The clutch allowed for the fan to wobble and the engine compartment is tight enough to where the fan blades would knock and break off after hitting other parts of the engine, and then causing the damage. Total cost for the repair was just over $1,000!
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  #97  
Old 01-01-2013, 01:43 PM
Schitzo Schitzo is offline
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Quote:
Originally Posted by bluebee View Post
Happened again, over here:
Quote:
Originally Posted by bluebee View Post
Another M54 fan explosion today - this one tracked to a bad fan clutch:
Eek!!


The electric fans I installed have held up very well. Despite a relatively hot summer (temps 105F+) the fans kept the car cool (100C and below). I highly recommend these fans for anyone considering going this direction.
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  #98  
Old 01-01-2013, 02:10 PM
Makomagnet Makomagnet is offline
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Next update I'm going with the electric cooling fan
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  #99  
Old 02-06-2013, 02:24 PM
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bluebee bluebee is offline
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For the cross-linked record, it happened yet again today:
Quote:
Originally Posted by PatrioticRick View Post
The fan let loose and came through the hood! Doing all kinds of damage under the hood like the radiator, radiator hoses and anything else in the way. I can't believe a plastic fan could actually go through the hood. Thank God this didn't happen while my mechanic was leaning over the engine.

See also:
- What could cause a BMW fan blade to explode or disintegrate (1) (2) (3) (4) (5)
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  #100  
Old 02-06-2013, 03:31 PM
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doru doru is offline
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Apparently the e53 fan & fan clutch have a re-designed fan, that holds the blades together, so the fan would not shatter as it does with the current model.
The 530 with diesel engine have a similar design AND 2 versions: for hot climate & for cold climate. The question is: does the diesel WP (which is different from the gasoline engine WP) have the same threads for the fan clutch as the gasoline WP? below is the exact diesel fan blade that does NOT shatter:

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TMS underdrive pullies - Stewart WP - PSS9 - Beisan Vanos seals - Zimmerman cross-drilled & Akebono Euro - Deka 649 MF - 55w HID headlights - 35w HID foglights - Hualigan double din - ACS (rep) alu pedals - Euro central storage console - Breyton Magic Racing staggered wheels - M5 bumper - M5 steering wheel - Tint
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