How to make your own BMW special cooling system & drive belt counterhold tools

Are these Bentley-specified special tools really needed for an overhaul of the BMW 525i E39 cooling system and belt-drive components?
1. cooling fan counterhold tool BMW 11 5 030 (I6) & BMW 11 5 040 (V8) [Note: This tool is described with many names!]
2. cooling fan 32 mm wrench (BMW 11 5 040)
3. 24mm hollow thin socket alternator pulley nut removal tool (BMW 12 7 100)

Does anyone have a drawing of the (1) water-pump-pully-counterhold tool dimensions?

REFERENCES:
Bentley pages 020-16, 110-2, 121-2, 170-15, & 170-23.
http://www.samstagsales.com/bmwtools.htm
http://www.pelicanparts.com/BMW/cata...TOLtol_pg3.htm
http://www.germanpartsonline.com/bmw...m54-from-1992/
http://www.magnum1.com/BMW-740/740_P...-Pump-740.html

Bloobs, you're definitely the tool master.

Originally Posted by bluebee

Are these special tools really needed for an overhaul of the BMW 525i E39 cooling system and belt-drive components?
1. cooling fan counterhold tool (BMW 11 5 030) aka "fan pulley holder"
2. cooling fan 32 mm wrench (BMW 11 5 040)
3. alternator pulley nut removal tool (BMW 12 7 100)

Are they all needed, no.... much of this depends on your skill level.....they might help some people.

1. I just a use a hammer and 32mm wrench to loosen nut on fan clutch, everytime, all the time, on time.....for me the tool is a waste of money.

2. Yes, you will need a 32mm wrench. Northern tools wrench plenty good enough for this purpose.

3. Not need for cooling system overhaul. I just use my impact to loosen alternator pulley nuts.

Originally Posted by xraye39

Are they all needed, no.... much of this depends on your skill level.....they might help some people.

1. I just a use a hammer and 32mm wrench to loosen nut on fan clutch, everytime, all the time, on time.....for me the tool is a waste of money.

2. Yes, you will need a 32mm wrench. Northern tools wrench plenty good enough for this purpose.

3. Not need for cooling system overhaul. I just use my impact to loosen alternator pulley nuts.

So what's your technique for the fan clutch? I have tried hammer and wrench, screwdriver on pulley and wrench and could not loosen without the flat tool made for that purpose. Got the tool and had it loose in 30 seconds or less.

The tool shown will work on the six, but not the V8, since the nuts are recessed. If you can't get it loose with a hammer, you need the tool.

Ask me how I know.

Originally Posted by bluebee

Are these special tools really needed for an overhaul of the BMW 525i E39 cooling system and belt-drive components?
1. cooling fan counterhold tool (BMW 11 5 030) aka "fan pulley holder"
2. cooling fan 32 mm wrench (BMW 11 5 040)
3. alternator pulley nut removal tool (BMW 12 7 100)

Making your own tool (which confusingly seems to go by various names) is discussed here (for the 740 anyway).

I have a friend who said he'd make whatever special tool I needed out of stock steel if I could provide a full-sized PDF drawing of the part by email & it's thickness.

Do you have a PDF drawing (or a trace of the business end) of the tool dimensions & thickness?

REFERENCES:
Bentley pages 020-16, 110-2, 121-2, 170-15, & 170-23.
http://www.samstagsales.com/bmwtools.htm
http://www.pelicanparts.com/BMW/cata...TOLtol_pg3.htm
http://www.germanpartsonline.com/bmw...m54-from-1992/

Originally Posted by mmm635

Wow. Did you draw those perfect diagrams yourself? They are wonderful!

It looks like we can craft the necessary BMW 11.5.030 M54-engine cooling fan counterhold tool out of 5/32" thick steel stock, about 16 inches long and roughly 1 3/16" wide.

We can drill a 15/32" hole centered 11/32" from the end of the tool and then two more for the slot and then jig saw out the hollow.

I'll try to get this done and then post pictures. If anyone else tries it, please post pictures of your handiwork.

Any idea where best to get the stock steel?

I'm pretty sure the tool above from mmm635's original wonderful thread (which I just found doing this research) will fit my M54 engine but I'm still looking for the dimensions for the others (with the V8, for example).

We should probably mention the bolt spacing for the BMW E39 "holder wrench for fan hub" tool is different depending on what engine you have (according to this incomplete reference and this more complete reference).

- Holder wrench for fan hub bolt spacing 45mm. Applicable on the following engines: M10, M20, M30, M50, M51, M52, M52TU, M54, M56, M70, M73, S14, S38, S50B30, S50B32, & S54; 394mm in length. Old BMW P/N 88.88.6.115.030; new BMW P/N 83.30.0.491.046

- Holder wrench for fan hub bolt spacing 38mm. Applicable on the following engines: M40, M41, M42, M43, M44, M60, M62, N62, & S62; 400mm in length. Old BMW P/N 88.88.6.115.050; new BMW P/N 83.30.0.491.048

For the record, here is a documented attempt at making the BMW 11.5.050 tool to hold the V8 water pump pully in this drive-belt-replacement thread for the 740i (M62 Engine, E38).

This guy got his steel stock from Lowes 1/8" thick, 1" wide, and 2+ feet long.

I made one as per the dimensions on the diagram, works a treat, cheers to OP.

Originally Posted by gibo27

I made one as per the dimensions on the diagram

A picture would be wonderful!

Originally Posted by bluebee

Wow. Did you draw those perfect diagrams yourself? They are wonderful!

It looks like we can craft the necessary BMW 11.5.030 M54-engine cooling fan counterhold tool out of 5/32" thick steel stock, about 16 inches long and roughly 1 3/16" wide.

We can drill a 15/32" hole centered 11/32" from the end of the tool and then two more for the slot and then jig saw out the hollow.

I'll try to get this done and then post pictures. If anyone else tries it, please post pictures of your handiwork.

Any idea where best to get the stock steel?

Yeah, I got carried away on my modeling program one day and figured it would help others out.

Originally Posted by mmm635

Yeah, I got carried away on my modeling program one day and figured it would help others out.

You did a great service to the rest of us. I hadn't seen your post about it until I started digging further. I'm amazed all measurements are in whole numbers (in metric).

Wondering about the two sizes (45mm and 38mm hole offset), I "designed" in MS Paint a new hypothetical tool that handled all engines!

Originally Posted by bluebee

You did a great service to the rest of us. I hadn't seen your post about it until I started digging further. I'm amazed all measurements are in whole numbers (in metric).

Wondering about the two sizes (45mm and 38mm hole offset), I "designed" in MS Paint a new hypothetical tool that handled all engines!

The Germans like to be precise when machining is involved.

If I could just get someone to take measurements of the V8 tool with a digital micrometer, then I could add it in my model. I would just take my original tool and modify the end with the covering/handle to test it out. Once I can get the drawing done, it will be easy to fabricate such a tool with a scaled drawing, as well as the 32mm wrench necessary.

sweet, im soo building one once i finish my subframe bushing tool project

not trying to be a $%^& for most people who doesn't have tools or experience in cutting steel, it's just easier and faster to buy the tool itself. I tried making one but it didn't work, so I got my WP counterholder for around $25 from ebay. It's double ended, so it fits almost any BMW. Already used in my 525i, 540i, and friend's 745i. Makes removing a fan clutch a 10 sec. job.

Here's a quick price survey from an Internet search for the commercial versions of our home-made water-pump pulley holder.

I could only find three suppliers, which is surprising.

Please add any missing suppliers!

11.5.030 (45mm offset):
Pelican Parts: PEL-TOL-3038 $36.10 + CA 10% tax + shipping
Samstag Sales: 88.88.6.115.030 $56.99 + CA 10% tax + shipping
Technitool: 115-030 $36 + CA 10% tax + shipping

11.5.050 (38mm offset):
Pelican Parts: PEL-TOL-3037 $36.10 + CA 10% tax + shipping
Samstag Sales: 88.88.6.115.050 $58.00 + CA 10% tax + shipping
Technitool: 115-050/M $41 + CA 10% tax + shipping

Originally Posted by SpeedsterBek

I tried making one but it didn't work, so I got my WP counterholder for around $25 from ebay.

Good idea. I bought this tool set from EBAY for about 30 bucks plus about 15 shipping.

It has the 38mm bolt spacing for the V8 and the 45mm bolt spacing for the I6.

For the record, here's another documented attempt on outpost.com ...

Here, they document their use of a standard carpenters "speed clamp" and all they do is enlarge one hole and drill another.

My 3 cents:

1. I always use a long screw driver, no issues at all. NOTE the screw driver location:




2. Go to ebay and type in "BMW Water Pump Tool", cough up with $16.95 and you are done with:
http://cgi.ebay.com/ebaymotors/Water...#ht_1437wt_944


3. Don't want to spend any money? Then use the garage door handle, just remember to put it back on the garage door after use LOL!

Originally Posted by mmm635

If I could just get someone to take measurements of the V8 tool with a digital micrometer, then I could add it in my model. I would just take my original tool and modify the end with the covering/handle to test it out.

I hope someone who has done the V8 will take you up on that offer! I'd love to see the results (and have my friend duplicate it if possible).

As for the slot in the I6 tool, would you recommend drilling two holes (and then cutting out the middle) or three holes (one in the middle, and then two on the sides) to create that slot?

Originally Posted by cn90

My 3 cents:

Hi Cam,
Your 3¢ is always better than my 2¢ !
1¢. You located a price HALF of what I found for the counterhold tool!
2¢. You found a freely available alternative (the garage door support!)
3¢. You proved the counterhold job can be done with a sturdy screwdriver!

Note 1: I'm starting to not believe a minority of the people here (generally those with 1 to 50 posts, who post no pictures or links) who outright boldly say controversial (yet wholly unproven except for their words) stuff like they have a two-headed wrench or they made the tool themselves and the job took only 10 seconds, etc. ... but I believe everything you say (mainly 'cuz you back it up and have proven yourself over time).

Note 2: Pelican parts says "The bolts on the water pump are non-symmetric, which means that you need to rotate the fan to find the two that will fit the tool properly. Only one position out of four potential positions will work." I'm not sure why they say that; can anyone clarify what the "gotcha" really is?

$19 bucks from ebay, why go though all the trouble?

http://cgi.ebay.com/ebaymotors/BMW-G...motiveQ5fTools

The four bolts that hold the water pump pulley is not perfectly square, i.e. it is rectangular. therefore, only 2 positions will fit, not one as stated in pelican parts.

Originally Posted by occhis

So what's your technique for the fan clutch? I have tried hammer and wrench, screwdriver on pulley and wrench and could not loosen without the flat tool made for that purpose. Got the tool and had it loose in 30 seconds or less.

Just put wrench on collar of nut, then 1 short, sharp rap with hammer and voila....done.

Takes me about 10 seconds if even to loosen nut then just spin fan off.

This of course is with the belt on which provides more than enough friction to do this.

I'm with you! wrench on nut, slight tap with lead hammer and done. I did the cooling system rebuild without any special tools!