Recommended parts kits for overhauling cooling, drive belts, CCV/ICV, VANOS, OFH, PSP

Here is the revised list. I changed it to 1 bleeder screw and added the timing chain tensioner. I also added the critical column. When we are done we'll figure out to share the file.

Absolutely beautiful!

We just added the "expansion tank pressure cap" to the critical list (based on the other thread).

And, Quick99Si has done a great job making BMW factory & dealer tools available via his FTP site so maybe he can host this spreadsheet?
- Making sense of ADS, EDIABAS, INPA, NCS, NFS, GT1/DIS, Progman, ISIS, WinKPT, Carsoft

Based on cn90's recommendation today in this thread:
- How not to change your oil in your E39 (stripped drain plug)

Originally Posted by cn90

I have learned this the hard way over the years. Now for every car I have at home, I always go to dealer (it does not matter if it is a BMW, Toyota, Honda, or Volvo etc.) and buy a spare drain plug and store it in the glovebox to save you time/hassle later.

How does this look as a recommended parts list for changing your oil?

• Oil filter (Mann HU925, Mahle, Hengst E106H D34, or BMW P/N 11427512300)
• Oil filter cap O-ring (91x4mm) <-- often comes with the filter
• Oil drain plug copper crush washer (A12X17-CU, BMW P/N 07119963151) <-- often comes with the oil filter
• Hollow oil pan drain bolt (M12x1.5x18, BMW P/N 11131273093) <-- different (solid) bolt for the V8 <-- what size & PN? (BTW, order two!)
• Two oil filter stem o-rings (7x2.5, BMW P/N 11421744001) <-- replace every five years or so
• Two dipstick handle o-rings (9x2.2, BMW P/N 11431717666)<-- replace every five years or so
• 6.9 quarts of motor oil for the I6, 8 quarts for the V8 (BMW LL 2001-approved or equivalent)

NOTE: Pictures are from this thread ...





Note: At the same time you change your oil, some recommend you suction out about 8 ounces (250 ml) of the power steering fluid and replace with Dexron III (realistically Dexron VI) ATF:
- Recommendation to replace power steering fluid at every oil change & periodically clean the PSF filter (1)

So, another related parts list could be:

• Dexron VI ATF (buy 1 quart)
• T20 Torx driver (to loosen the filter screen)
• Power steering fluid reservoir cap o-ring (BMW PN 32 41 1 128 333)
• Power steering hose clamps <-- often you cut off the old clamps, and a half-inch of hose & reclamp to fix leaks

NOTE: Pictures are from this thread...



NOTE: Here is the alternative 'sock mod' in lieu of replacing the power steering fluid reservoir o-ring:

A nice cooling system overhaul parts list was posted today:
> E39 (1997 - 2003) > Cooling system! be safe than sorry?

Originally Posted by George16

Here is the list of parts, prices and sources:

Cooling system Overhaul
11281738605 Ina Idler Pulley $24.68 AutohausAZ
11511436590 Water pump pulley $22.92 AutohausAZ
11517527799 Graf water pump $56.65 AutohausAZ
11531438634 BMW coolant hose $29.45 AutohausAZ
11531705223 Radiator upper hose $25.92 AutohausAZ
11531705224 Radiator lower hose $26.54 AutohausAZ
17111427156 Vent hose from radiator to expansion tank $9.44 AutohausAZ
17111712788aft Aftermarket brass bleeder screw (qty 2) $7.68 AutohausAZ
4PK0865 Ac belt $9.77 AutohausAZ
11537509227 Thermostat with housing $58.78 OEMBimmerparts.com
2100011031 Sachs fan clutch $91.19 AutohausAZ
11281706545 Serpentine belt $17.50 OEMBimmerparts.com
32421740858 Power steering pulley $30.00 OEMBimmerparts.com
11531438632 Expansion tank hose to heater core $27.50 OEMBimmerparts.com
11531438633 Expansion tank hose to aux pump $27.50 OEMBimmerparts.com
82141467704 BMW coolant (need 5.5 quarts plus 5.5 qts distilled water $22.50 OEMBimmerparts.com
11281748832 AC tensioner $53.00 OEMBimmerparts.com
11287512758 Alternator/waterpump tensioner $53.00 OEMBimmerparts.com

VANOS Seals/Valve Cover Replacement
VANOS Seals $60.00 Beisansystems.com
11120030496 Valve cover gasket $24.27 AutohauAZ
11121437395 Valve grommet(need 15) $11.04 AutohauAZ
11361433817 VANOS cover gasket $3.59 AutohauAZ

Keep in mind that my car is a 2003 530 and yours is a 525 so other parts might not be applicable. When you go to the websites, ensure you choose the correct year and model of your car.

Thanks for all who contributed to this thread, especially you bluebee. I've got a small coolant leak somewhere and I suspect the culprit is the water pump, so having all the information here is a God send.

Originally Posted by Only1Balto

I suspect the culprit is the water pump

This is the list of recommended waterpumps to buy:
- What brand of waterpump to buy (1)

I just ran into this parts list from this thread:

Originally Posted by AZ-528i

I agree with cn90! While you have the fan off, overhaul the whole system. You will be thankful you did. E39 radiators are notorious for going bad around 60K miles.

Here is a cooling system overhaul part list that I made when planning my overhaul (purchased from https://www.autohausaz.com/index.html

There was a clarification comment on this cooling system overhaul parts list over here today:

Originally Posted by BM109R

This is also my next DIY project. I've already replaced all the tensioners and belts recently so I only need the WP, thermostat, hoses and, expansion tank, fan, fan clutch radiator. My question is should I also include the vent hose that goes from expansion tank to radiator? I do not see that listed in any of the recommended parts list. I have attached a picture. The part number is 17111427156.

Originally Posted by BM109R

Just saw the hose I was checking for on the list. On realoem it is called vent hose while on cn90's list it is the bypass hose.

So I am amassing my parts for the coolant overhaul from different sources and i have a couple of questions before I make my last order:

-From the attached image, how critical is it to change the three marked hoses? Are those known to wear out and leak to at around the same time as everything else?
-Does the nissin radiator come with a drain plug and are there any fitment issues different from OEM. Is it better than behr?

Thank you.

Originally Posted by BM109R

how critical is it to change the three marked hoses?

My understanding is that most people do not change them - but it's probably a good idea to replace any and all rubber at the age of our vehicles.

But I would base any deeper assessment on a visual check and the current prices.

Originally Posted by BM109R

Are those known to wear out and leak to at around the same time as everything else?

Looking at this thread, from an anecdotal perspective, these hoses are not unreliable:
- Pictorial look at typical E39 cooling system failure modes (1)

Originally Posted by BM109R

Does the nissin radiator come with a drain plug

IIRC, mine did.

Originally Posted by BM109R

and are there any fitment issues different from OEM.

Getting the Behr out of the vehicle isn't all that difficult:
- Removal instructions for the alternator & drive belt system of a 2002 525i
- Removal instructions for the fan shroud of a 2002 525i
- Tools necessary for a cooling system overhaul
etc.

But, on the automatic I6, getting the Nissens/Behr back in is the hardest part:
- One user's cooling system overhaul: How to get the radiator back on (1)

Originally Posted by BM109R

Is it better than behr?

Methinks they all stink.

Personally, I don't wish to reward Behr for making garbage - so I bought Nissens garbage instead.

Here you see what the Behr looks like inside:
- Behr radiator and Behr expansion (aka surge) tank autopsy (1) (2)

For the crosslinked record, this series of common questions was asked today:

Originally Posted by Guam135i

I have a E39, 525i Touring. I replaced the expansion tank a few days ago after it cracked. Now I need to replace the water pump and since Im at it I will also replace the thermostat. The car has 61K miles.

The question is, is the Stewart warner WP worth he $195? or aftremarket with metal impeller at half the price? same question for the thermostat, OEM or replacement at half the price. Since I am at it would it be a good idea to replace the plastic WP pulley with an aluminum one?

I later plan to go to a zionville cooling system which does not include the WP or the Pulley at 80K miles

Thoughts on this is appreciated

Originally Posted by bluebee

Age old question.

Has been asked a thousand times.

Start by typing /waterpump F3 in the best links, e.g.,
- What brand of waterpump to buy (1)

If, after reading that thread, you still have questions, that is the right place to ask (so that all the erudite questions are kept together for the NEXT person to benefit).

Originally Posted by Guam135i

Thanks, made the decision on the WP now any idea on the Thermostat? and plastic pulley?

Originally Posted by bluebee

Again, these questions have been often asked, so, repeating the same approach should work, shouldn't it?

For example, typing /cooling system F3 in the best links nets this, among others:
- List & picture of all the cooling system overhaul recommended parts to replace (1) (2) (3)

Likewise with typing /belt drive F3:
- Recommended parts list for a complete belt drive system overhaul (1)

While doing suspension work, I discovered what the big boom was from the week prior. Exploded fan. I had come to stop of driving several hours, floored car hard and it sounds like my rear axle fell off and/or a huge back fire, then what sounded like something fell off of the car. My son and I looked in rear view--nothing. We continued on our way with no isssues. Week later after many miles driven and while doing an unrelated overhaul, I noticed my fan was gone! :-) Car ran fine with no overheating as well. Since replacing it, I notice the needle is ever so slightly more to left of high noon needle mark. I went with Myle clutch and generic fan coolxpert.

Originally Posted by mjbennett9

While doing suspension work, I discovered what the big boom was from the week prior. Exploded fan. I had come to stop of driving several hours, floored car hard and it sounds like my rear axle fell off and/or a huge back fire, then what sounded like something fell off of the car. My son and I looked in rear view--nothing. We continued on our way with no isssues. Week later after many miles driven and while doing an unrelated overhaul, I noticed my fan was gone! :-) Car ran fine with no overheating as well. Since replacing it, I notice the needle is ever so slightly more to left of high noon needle mark. I went with Myle clutch and generic fan coolxpert.

Don't want to bum you out but the sourcing of these parts is critical to avoid a repetition of this event. The Behr fan clutch and OEM (dealer) fan blade are the usually recommended parts. Non-dealer sourced fan blades tend to explode like your previous fan blade. The fan failure is mostly likely due to the fan clutch failing and locking. Do a search to learn more about this.

Hi Fudman.

No biggie, I'm used to being bummed out. lol. I do plan on completing the cooling overhaul this summer from water pump, thermostat, hoses, etc. Maybe I'll just go and replace fan/clutch--again. :-) it's only money, right. :-) worst/best case, I ride the clutch/fan out till next summer and replace them. at least I'll be a guinea pig for longevity of these parts. I had read some on the behr clutch, but thought Myle was a very good brand.

For the record, there is a good thread on locating all the cooling system hoses here today:
-> E39 (1997 - 2003) > Want to replace cooling system heater hoses.

First of all thank you to Bluebee and all the others who have contributed to a great thread. I have some questions about the auxiliary water pump.



ID & Part #

1. Is that the aux water pump in that pic?
2. If it is how do I find the part number for it? I can't seem to find a part number for it on any of the parts diagrams. I wonder if that means my car (model and year) does not have it?

Replacement?
Unless I missed it in this thread no one really discussed whether this part should be replaced during a cooling overhaul. Any thoughts/input on the expected life of this part?

Also if I should be posting this question in a different thread please let me know I don't want to clutter up a great thread with a question that should go someplace else.

Originally Posted by Solo12

Is that the aux water pump in that pic?

Yes. In reality, it's mounted vertically, on the drivers side of the radiator, on the inside edge, almost at the bottom, so the easiest access is from below.

Originally Posted by Solo12

how do I find the part number for it?

Unfortunately I don't know what models have it and what ones don't.
But if you type in your VIN to http://realoem.com, it should tell you if you have it.

I checked my Realoem vin and it's found in Heater and Air Conditioning Water pump, valve, hoses Hoses f pump and valve/autom.air cond.
You can google for my part number to get an idea of prices 64118381989.
http://www.fcpeuro.com/products/bmw-...Fck-MgodH0QARQ
http://www.eeuroparts.com/Parts/2968...Fc9DMgodIBMA9w

Originally Posted by Solo12

no one really discussed whether this part should be replaced during a cooling overhaul. Any thoughts/input on the expected life of this part?

I don't know anybody who has replaced it and it's not a normally replaced part in a cooling system overhaul.

I don't know if anyone has suggested this yet, but for the DISA, you can get square-cross-section o-rings of almost any material you like.

For example
https://www.mfpseals.com/catalog/cat...trong-nitrile-

And, of course, you can get round-cross-section o-rings at lots of places too, for the VANOS or for other parts
1. (easy to use oring warehouse calculator)
2. the o-ring store
3. mfp seals
4. orings usa

What we need is a list of the "trade sizes" for each of the replacement orings, and the material.
1. http://www.allorings.com/size_cross_...nce_framed.htm
2. http://www.marcorubber.com/sizingchart.htm
3. http://www.broadleyjames.com/o-rings-size-chart.html