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6 Series DIY
6 Series Do It Yourself (DIY) forum.

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  #1  
Old 03-10-2011, 01:35 AM
brown370 brown370 is offline
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Location: Atlanta, GA
 
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Mein Auto: 07 BMW X5 4.8i
DIY: Coolant Leak Repair ( Cap w Seal and Expanding Coolant Pipe) w Pics

BMW 645 Coolant leak repair (Cap with Seal Repair and Expanding Coolant Pipe Installation w Pics)
By Michael R. Brown
(Estimated time to complete the job is 6-8 hrs)

****See the PDF document attached for the complete job details!
- The PDF contains the following:

- List of Parts needed to do the jobs
- List of Tools to complete the jobs
- Detail Pictures while completing the jobs
- Lessons Learned while completing the jobs


** SORRY For some reason my pics are not showing up. If you can't view the PDF send me a message on the forum or an email to the address below and I will send you the word document version.


* This job will save you $2000 on the Cap with Seal Job and $9000 on the Coolant Pipe Job. Both of these parts fail around 80,000 to 100,000 miles and are known problems with the N62 engine. If you have any questions or you live in the Atlanta area and would like for me to complete the jobs for you, shoot me an email at robe370@aol.com.
Attached Files
File Type: pdf BMW 645 Cap w Seal Expanding Coolant Pipe Repair New.pdf (6.88 MB, 5907 views)
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  #2  
Old 03-10-2011, 05:38 PM
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Yorgi Yorgi is offline
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Wow I'm speechless. This is a seriously good DIY.

I pray I never have to do this job.
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  #3  
Old 03-10-2011, 07:36 PM
brown370 brown370 is offline
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Thanks! I tried to lay the jobs out as clear as I could. Hopefully, the DIY will help a lot of 6 Series owners save plenty money, although the parts alone are about $1100. I will pay $1100 over $9000 anyday.
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  #4  
Old 03-11-2011, 05:16 AM
WGMc WGMc is offline
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What are the symptoms of this leak problem? Very good DIY, thanks.
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  #5  
Old 03-11-2011, 05:36 AM
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TxTaz TxTaz is offline
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Very good write up. Thanks.
I notived you disconnected the battery. Did you lose any programming?
Thanks,
Wes
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  #6  
Old 03-11-2011, 10:36 AM
brown370 brown370 is offline
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The symptons was water coming from the front of the engine (valley plate) BMW calls it the Cap with Seal. When I took off the Cap with Seal, the rubber seal was totally flat and hard. I changed the coolant pipe too, because I was told by a BMW technician, that the pipe will start to leak next around 100,000 miles and it will cost about $9000 to repair.

As for unpluging the battery, I did have to reset all of my setting, but it only took about 15 min. Also, the active steering has to reset itself and it will after driving for a few.
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  #7  
Old 04-29-2011, 07:56 PM
the6dude the6dude is offline
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I just want to say...THANK YOU!!! Using your "how-to" I successfully completed the cap and expanding coolant pipe installation yesterday. The total cost was approxiametly $900! A lot better than $9,000. I'm in South Carolina and visit the ATL often...I owe you a 6 pack! BTW, this was the first time I attempted anything this indepth so it took me about 9-1/2 hours. I wanted to make sure I did't jack something up. Thanks again!!!!!!!!
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  #8  
Old 04-29-2011, 09:27 PM
brown370 brown370 is offline
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No problem bro! Glad I could help!

Especially for a common job that cost so much to repair. I figure it will prevent most 645/650 owners from getting rid of their rides once they find out how much it cost to fix the leaks.

I have used a few DIYs on the forum and just wanted to return the favor.
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(Previous rides)
04 BMW 645 CiC Auto
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  #9  
Old 05-29-2011, 05:00 PM
HerbP HerbP is offline
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Great writeup from Augusta!
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  #10  
Old 06-03-2011, 11:50 AM
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DBLAZE DBLAZE is offline
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Dayum! That is an impressive write-up and an impressive job all together! I hope I never have to do this either because paying $9k is out of the question for anything on this car!
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  #11  
Old 06-29-2011, 07:28 AM
adell5092 adell5092 is offline
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Brown370 you are a god sent my friend, i was over in another forum just asking if there was any means of preventing the coolant pipe from going haywire but with your detailed instructions my best bud who is very car savvy will be able to do the job for me if something does go bad, thank you! @ dblaze im torn between picking up the 645 or the 650 only things that really matter to me are performance, sports and cold package and premium sound any advice for me?
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  #12  
Old 06-29-2011, 10:39 AM
brown370 brown370 is offline
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No problem just returning the favor as other guys on this forum have helped me out. As for the 645 vs 650, go with the 650, because it has 30 more horsepower and MP3 capabilities. Also try to avoid the BMW Ellipsoid 121-Style wheels. They crack easily under normal driving. I had 2 cracked and one bent. I could not claim them under the class action lawsuit because my car was out of warranty. I hope this helps.
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12 VW CC 2.0T [/B] stock
05 VW GTI 1.8 T 5 Spd, Coilovers, Big Brakes,

(Previous rides)
04 BMW 645 CiC Auto
97 VW Jetta Jazz 5 SPD
06 Mazda 6 Grand Sport Auto
05 BMW X5 3.0 6 SPD
05 Infiniti G35 6 SPD
04 Volvo S60 "R" 6 SPD
99 Nissan Maxima 5 SPD
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  #13  
Old 06-30-2011, 04:24 AM
wlin2001 wlin2001 is offline
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Thumbs up

Quote:
Originally Posted by brown370 View Post
No problem just returning the favor as other guys on this forum have helped me out. As for the 645 vs 650, go with the 650, because it has 30 more horsepower and MP3 capabilities. Also try to avoid the BMW Ellipsoid 121-Style wheels. They crack easily under normal driving. I had 2 cracked and one bent. I could not claim them under the class action lawsuit because my car was out of warranty. I hope this helps.
wow... this writeup is really impressive. BMW techs should look up to you and learn from you lol
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  #14  
Old 06-30-2011, 06:57 AM
adell5092 adell5092 is offline
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Silly question. But will this diy work on an 08' also
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  #15  
Old 07-01-2011, 02:05 AM
brown370 brown370 is offline
Big Mike Brown
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Quote:
Originally Posted by adell5092 View Post
Silly question. But will this diy work on an 08' also
Yes I believe so, you have different heads, but I think the 08 is the same engine. N62
Shoot me the last 7 digits of your VIN and I will double check the EPC.

robe370@aol.com
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12 VW CC 2.0T [/B] stock
05 VW GTI 1.8 T 5 Spd, Coilovers, Big Brakes,

(Previous rides)
04 BMW 645 CiC Auto
97 VW Jetta Jazz 5 SPD
06 Mazda 6 Grand Sport Auto
05 BMW X5 3.0 6 SPD
05 Infiniti G35 6 SPD
04 Volvo S60 "R" 6 SPD
99 Nissan Maxima 5 SPD
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  #16  
Old 07-04-2011, 07:26 AM
sigma95 sigma95 is offline
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Will the Cap and Seal and Expanding Coolant Pipe problems occur in the 650 also? My understanding is the 645 had the coolant leak issue around 80K to 100K miles, but not so much for the 650. Please, someone shed some light on this issue. I'm going to be sick if my 650 starts leaking.
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  #17  
Old 07-04-2011, 12:59 PM
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Yorgi Yorgi is offline
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Quote:
Originally Posted by sigma95 View Post
Will the Cap and Seal and Expanding Coolant Pipe problems occur in the 650 also? My understanding is the 645 had the coolant leak issue around 80K to 100K miles, but not so much for the 650. Please, someone shed some light on this issue. I'm going to be sick if my 650 starts leaking.
It happens to all N62 motors, which includes the 645Ci, 650i, 550i, 750i, X5 4.8i, etc...

It's bad but not a catastrophic problem. An independent shop can fix it for ~ $2K which is a similar price to a complete brake and rotor job.
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  #18  
Old 07-25-2011, 09:39 AM
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Jah Rastafari Jah Rastafari is offline
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"Note: Price quotes are from the link below and would be much
higher if you purchase the parts from the dealer. You may be able
the find the parts cheaper at other sites too
.


BMW Morristown http://bmw-accessoriesonline.com/



Part Number: 11727508270 List Price Core Price Your Price
Emission system - A.i.r. system - Hoses Hoses, 545i, pressure hose, to diverter valve 2004 - 2005
$60.41 $0.00 $48.33
Part Number: 11617547185 List Price Core Price Your Price
VENT PIPE
$52.65 $0.00 $42.12
Part Number: 11617547186 List Price Core Price Your Price
VENT PIPE
$52.65 $0.00 $42.12
Part Number: 17127542540 List Price Core Price Your Price
Cooling - Hoses and pipes - Vent hose Vent hose - 4.4 & 4.8 liter 2005
$72.42 $0.00 $57.94
Part Number: 11617521181 List Price Core Price Your Price
Engine - Cylinder head & valves - Valve grind gasket kit Valve grind gasket kit, 545i, w/o cyl.head gasket - 4.4l, 4.8l 2004 - 2005
$37.60 $0.00 $30.08
Part Number: 11517507717 List Price Core Price Your Price
Cooling - Water pump - Water pump assy - O-ring O-ring - 4.4 & 4.8 liter 2004 - 2010
$2.52 $0.00 $2.02
Part Number: 11531710048 List Price Core Price Your Price
Cooling - Hoses and pipes - Water pipe - Gasket Gasket Left - 540i 1999-03 1999 - 2003
$2.85 $0.00 $2.28
Part Number: 82141467704 List Price Core Price Your Price
ANTIFREEZE
$20.95 $0.00 $16.76
Part Number: 11147507278 List Price Core Price Your Price
CAP
$79.42 $0.00 $63.54
Part Number: 07119905400 List Price Core Price Your Price
Cooling - Water pump - Outlet pipe - Bolt Bolt - W/335d 2009 - 2011
$0.71 $0.00 $0.57

Part Number: 11517508535 List Price Core Price Your Price
Cooling system - Water pump - Gasket Gasket, x5 - 4.8l 2007 - 2010
$7.37 $0.00 $5.90
Part Number: 11511439976 List Price Core Price Your Price
Cooling - Hoses and pipes - Outlet pipe Outlet pipe - 4.4 & 4.8 liter 2004 - 2010
$16.83 $0.00 $13.46
Part Number: 12311439988 List Price Core Price Your Price
PIPE
$14.77 $0.00 $11.82
Part Number: 07119903596 List Price Core Price Your Price
O-RING
$2.62 $0.00 $2.10



Total : $339.04 (Excludes Cooling pipe kit)



OP parts list: 464.38 (Excludes Cooling pipe kit)


Save 125.34


Just realized i didnt factor in Quantity, but still cheaper
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Last edited by Jah Rastafari; 07-25-2011 at 10:42 AM.
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  #19  
Old 10-08-2011, 06:58 PM
brown370 brown370 is offline
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I just did another Cap w/ Seal and Expanding Pipe job yesterday on a 2004 545i E60 and the job was exactly identical to the 645. I have done this job 4 times without any leaks, but since you can't get the tool to test for leaks, it is a good idea to go ahead and remove the water pump. I will be updating this DIY to include the removal of the water pump( includes removing the Harmonic Balancer). It adds another 2 hours to the job, but you can verify that the seal is not pinched after the front seal is installed. See pic.



Also in the DIY, I stated that you should check for leaks, but good luck finding the tool. Note: You can pressurize the system by driving the car until it fully warms up. Then park the car and let it sit for 3 hours to fully cool down while pressurized.
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12 VW CC 2.0T [/B] stock
05 VW GTI 1.8 T 5 Spd, Coilovers, Big Brakes,

(Previous rides)
04 BMW 645 CiC Auto
97 VW Jetta Jazz 5 SPD
06 Mazda 6 Grand Sport Auto
05 BMW X5 3.0 6 SPD
05 Infiniti G35 6 SPD
04 Volvo S60 "R" 6 SPD
99 Nissan Maxima 5 SPD
91 Nissan 300ZX 5 SPD
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  #20  
Old 11-03-2011, 06:07 PM
Khabar Khabar is offline
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i have 745i. your engine looks almost the same as mine, but in reality is it big difference between 745i and 645i ? thank you
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  #21  
Old 11-03-2011, 09:16 PM
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Yorgi Yorgi is offline
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Quote:
Originally Posted by Khabar View Post
i have 745i. your engine looks almost the same as mine, but in reality is it big difference between 745i and 645i ? thank you
The engines are almost identical, so this DIY can easily be used on a 745i.
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  #22  
Old 11-07-2011, 08:06 AM
Keif Keif is online now
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+1. The engines are the same, and enough of the peripheral pieces are identical or nearly identical to those on a 745, so this DIY is definitely usable for them. I just did this on a 745i the long way (not using the expanding pipe), and am now putting it all back together, so I can verify this does look the same.

For additional information on doing it the long way using the stock pipe, poke through Wilson's "How to replace your coolant pipe, valve covers, timing gaskets and more" thread --> here.
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Last edited by Keif; 11-07-2011 at 08:12 AM.
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  #23  
Old 12-01-2011, 08:20 PM
Khabar Khabar is offline
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coolant pipe

It is even easier on 7. less staff to take off
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  #24  
Old 12-01-2011, 11:52 PM
hipertec hipertec is offline
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wow...amazing writeup. Great job!!!!
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  #25  
Old 12-14-2011, 11:53 AM
stevelee203 stevelee203 is offline
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this is awesome DIY
thank you Great Job
(i don't know if i could do this my self ^^)
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