My E39 touring is coming up on 200k, which means the cooling system is due for another refresh. The car was nice enough to remind me of this by cracking its upper radiator hose earlier this week.
After grabbing a new hose from the dealer just so I can keep getting to work and back, I have begun plotting the latest cooling system refresh. My dilemma is that I can either cough up some serious coin, know it's bulletproof and basically never have to do it again (EMP Stewart pump, Zionsville aluminum radiator & expansion tank, electric fan conversion, about $1500 said and done) or just do the "refresh" with another crappy plastic radiator & expansion tank, cheap water pump, etc (under $500).
The conventional wisdom would say to just keep doing the refresh with cheap parts, as I would have to do it three times to equal the cost of the serious upgrade. HOWEVER, people have been saying that the E39 replacement expansion tanks and radiators have taken a nosedive in quality lately, with many people saying they are now experiencing 2-3 radiator failures a year. The OEM-branded parts are supposedly a marginal amount better, but nearly double the cost of a basic refresh to the point where it almost makes sense just to do the bulletproof upgrade.
I know that $700 for a radiator and $400 for a shroud with an integrated expansion tank is a pretty ridiculous sum of money relative to what most other people pay for aluminum radiators. But, compared to spending money on a rental car when a cheap radiator blows or being stranded, or possibly cooking my motor from an overheat, it could be worth it; especially considering that I drive about 750 miles for work some weeks and I may be relocating cross-country for work in this car later this year. I would also love to swap an S52 in someday, which the upgrade would certainly benefit, but that's a far off dream at this point.
What do you guys think? In my situation, is it worth the peace of mind?
http://www.zionsvilleautosport.com/store/screen/prod/store_code/6134/product_code/E39SDCKII.htm
I slapped a $140 ebay fully aluminum radiator on my e36 after breaking a plastic end tank. It didn't fit quite perfect (had to trim my shroud a bit with a knife), but solved all my problems. I didn't replace the waterpump at the time cuz it wasn't leaking.
For a DD especially (and it being middle of winter), I would be mighty temped to just throw an all metal ebay one on there and call it good for now. If you're going to do the water pump, get the $200 stewart or whatever, but I would not put a plastic end tank radiator back on, nor would I be looking to spend a ton of money on the best rad available.
I will say, part of the Zionsville cost is that they will overnight you new parts of anything fails, and they also bolt right up with 100% OEM hoses, hardware, aux water pump, etc. The excellent customer service and lack of any messing around is a big draw. Still not 100% set on the option, but it has its advantages.
I have a dead E39 taking up space in my garage because the engine overheated then seized. If you plan to keep the car, don't cut corners on the cooling system.
Yeah, if the Zionsville part was half as much, it'd be a viable option. I vote OEM quality parts, and you'll be set for another 100k.
SlickDizzy wrote:
I will say, part of the Zionsville cost is that they will overnight you new parts of anything fails, and they also bolt right up with 100% OEM hoses, hardware, aux water pump, etc. The excellent customer service and lack of any messing around is a big draw. Still not 100% set on the option, but it has its advantages.
True true, and you are probably supporting a like-minded individual in the USA.
I would do the Zionsville upgrade if I was going to do an engine swap. $700+ for an aluminum radiator is pretty steep.
Mr_Clutch42 wrote:
I would do the Zionsville upgrade if I was going to do an engine swap. $700+ for an aluminum radiator is pretty steep.
For E46s they're over $1k. 
In reply to unevolved: Don't the E46s have other aluminum radiator options? After a quick look, a couple of vendors only had Zionsville as a producer of an E39 aluminum radiator.
In reply to Mr_Clutch42:
They are the only option for non-M E46s, yes. The M3 guys have a few different options (Mishimoto, etc).
Mr_Clutch42 wrote:
In reply to unevolved: Don't the E46s have other aluminum radiator options? After a quick look, a couple of vendors only had Zionsville as a producer of an E39 aluminum radiator.
Nope. Looked long and hard.
You gonna keep it for another 100k? I mean, if you are then do the aluminum radiator, otherwise no.
Personally, I think the added cost to do it "once and for all" is money that will come back to you if you ever sell the car. Any potential buyer who knows E39s will instantly be more comfortable with the deal (and your asking price) if that particular issue is already taken care of.
If this car pooped out, would you get another one? If you found another car with a cooling system of unknown provenance, and this kit is as bulletproof as you say, you could just transfer it over to the next car and take care of one of the biggest initial expenses.
I bet you could come up with an option that's nearly as good as the bulletproof option for a lot less. $700 for an aluminum radiator would even make Mishimoto raise an eyebrow, get a cheapo all-aluminum radiator or even a custom one for less. If you don't think you're likely to smash the front of the car, that warranty won't come in handy. I assume the expansion tank from the same manufacturer is also madly expensive, so maybe you should look into hooking up a custom solution in its place - it's just a tank.
You know what's almost as good as a spiffy new high-end electric fan and costs 1/10th as much? A used electric fan from a junkyard. I'll admit they don't last as long but they're vastly cheaper to replace - often you can just replace the motor.
The last time I did this sort of thing ... I bought a $140 26" chevy radiator from Speedway and TIG'd some tabs and sensor bungs on it to fit into an E36, put a 16" SPAL electric on it and used a generic aluminum bottle with a return nipple welded on for an overflow/expansion. OEM water pump, hoses (alterations required) and t-stat. I did have to buy some beer for a friend to do the more important TIG stuff but I've got more practice now. Next time I'll be able to just drink the beer.
I would absolutely not spend $1500 on the cooling system of a $4000 200k mile car.
The car has a value of nothing at 300k. So if it is at 200k, and the cheap stuff gets you to 300k, you have your answer.
And if you cant tell that you are overheating your car because your rad cracked, you probably shouldnt be driving a bmw. My point is that seizing ANY motor due to dumping the coolant is what the mouth breathers of the world do.
I put a $130 ebay aluminum radiator in my e36 and have had zero issues. I haven't put many miles on it yet but its doesn't have on auto-x with no problems.
I hadn't heard of the vendor until this thread. Now I am ogling his M3 kit. I will be due for a cooling system refresh in about two years (unless something happens of course) and I will bite the bullet and put his stuff in.
The difference is, of course, that I believe my E46 M3 has bottomed out on the depreciation curve, and this upgrade likely would add value if I ever sell the car.
