Welcome to Bimmerfest -- The #1 Online Community for BMW related information! Please enjoy the discussion forums below and share your experiences with the 200,000 current, new and past BMW owners. The forums are broken out by car model and into other special interest sections such as BMW European Delivery and a special forum to voice your questions to the many BMW dealers on the site to assist our members!

Please follow the links below to help get you started!

Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

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

Reply
 
Thread Tools Display Modes
  #1  
Old 03-11-2011, 06:17 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Rexgo's '97 528 Cooling O'haul

Just replaced the cooling system items that have been causing me to loose sleep. I made my decisions based on the work that has already been done (dealer receipts).
Recently done:
thermostat, PS hose, Vanos, belts, tensioners, alt, ambient air sensor, and prob more.

Also, saw too many posts here about failed cooling systems, and CL adds with E39's for sale that need a head.

Thks to bluebee, and CN90, and several others for their information.

Here's the work I did on my 1997 528i, auto with 65k orig:

Ordered everything from Autohaus - IMO great prices, website, and delivery < 1 week to Chicago:

..
Here's the typical signs that you need to do work:

..

..

..
Current expansion tank:

..
Removed shroud & fan - needed screwdriver wedged to WP bolt to break fan free.
..
..
..
Here's a tool I've used for years to remove hoses:

..
New parts:

..

..

..
Expansion tank comparison - old / new - only 1 outlet used on my 1997:

..
backside:

..
Some jello in the old one:

..
Re-used the old cap on the unused hose outlet with teflon tape:

..
Ready to go:

..
Old fan assy:

..
Removed blade assy, and cleaned alum finned hub:

..
Installed new fan blades:

..
New expansion tank ready for install:

..
Current thermostat was just replaced, but the housing is leaking:

..
With the hsg removed - you can see they used some black silicone:

..
removing the gasket:

..
I replaced the housing with an OEM ($55), and the new looked very similar to the old - except for minor differences:
old is on top:

..

..
old on right - bleeder screw location slightly closer too hose shoulder / stop:

..
I'm old school when it comes to sealing water passages, and surrounding bolts. I had to use some Permatex form-a-gasket on the t-stat hsg, and bolts. I like to see a little ooze around the housings.

..

..
radiator - no date codes?? - this also had me worried from the posts I read:
:
..

..
Installed old radiator mounts & sensors:

..

..
New one installed:

..
I love my air ratchet - made this job uber fast:

..
Used the dental floss trick on the fan - worked great:

..
New expansion tank looks great:

..
Followed the: open both bleeder screws, and fill the t-stat one first - then the expansion tank one - worked great!
..
Done:

..
After I'm done I feel great, and it wasn't bad at all - plus I can sleep at night.
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
Ads by Google
  #2  
Old 03-11-2011, 06:27 PM
filon102 filon102 is offline
Be american, get a bimmer
Location: Chicago, IL
 
Join Date: Aug 2009
Posts: 639
Mein Auto: 00' 540i, 87' benz 300DT
Great Job! How much was the total?
__________________
Reply With Quote
  #3  
Old 03-11-2011, 06:38 PM
bobdmac bobdmac is offline
Officially Welcomed to the 'Fest
Location: Back in Oaktown, Yay Area
 
Join Date: Feb 2011
Posts: 2,466
Mein Auto: 2001 540i/6, '90 BMW k75s
Nice. I got a kick out of you starting with the packages at the door Anything you'd change or add to in the DIY's?
Reply With Quote
  #4  
Old 03-11-2011, 06:43 PM
cn90 cn90 is online now
Officially Welcomed to the 'Fest
Location: Omaha NE
 
Join Date: Mar 2006
Posts: 12,735
Mein Auto: 1998 528i 5-sp 140K+
Glad you did the homework, incl the dental floss trick LOL!

I bought the Fan Blade by MTC, it broke after a year so I installed BMW dealer Fan Blade.
Reply With Quote
  #5  
Old 03-11-2011, 06:58 PM
WagonTheDog's Avatar
WagonTheDog WagonTheDog is offline
Officially Welcomed to the 'Fest
Location: San Diego, CA USA
 
Join Date: Oct 2010
Posts: 202
Mein Auto: 2000 528iAT
NICE

Feels good, doesn't it???
__________________
"Experience is a hard teacher because she gives the test first, the lesson afterwards."
Reply With Quote
  #6  
Old 03-11-2011, 06:58 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by filon102 View Post
Great Job! How much was the total?
~ $350

Quote:
Originally Posted by bobdmac View Post
Nice. I got a kick out of you starting with the packages at the door Anything you'd change or add to in the DIY's?
Thks - I've got a unique take on things

Quote:
Originally Posted by cn90 View Post
Glad you did the homework, incl the dental floss trick LOL!

I bought the Fan Blade by MTC, it broke after a year so I installed BMW dealer Fan Blade.
CN90 - thks very much - your posts, and PM's helped me greatly.

I found the '97 to be a little different than other posts.
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #7  
Old 03-11-2011, 07:06 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by WagonTheDog View Post
NICE

Feels good, doesn't it???
Absofrickenlutely - I feel good enough to shift it now - lol
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #8  
Old 03-11-2011, 07:27 PM
nyclad's Avatar
nyclad nyclad is offline
Officially Welcomed to the 'Fest
Location: Orange County, CA
 
Join Date: Dec 2007
Posts: 477
Mein Auto: 2002 530i Sport
While you're at it...

Good job!

One additional thing to consider, get the brass bleeder screws, as the plastic ones will fail over time, like mine did...

Check it out here: http://www.bimmerfest.com/forums/sho...d.php?t=520253
Reply With Quote
  #9  
Old 03-11-2011, 07:35 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by nyclad View Post
Good job!

One additional thing to consider, get the brass bleeder screws, as the plastic ones will fail over time, like mine did...

Check it out here: http://www.bimmerfest.com/forums/sho...d.php?t=520253
Thks - I did on the exp tank - see last pic - will get another for the t-stat hsg - good advice for all.
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #10  
Old 03-11-2011, 07:56 PM
bobdmac bobdmac is offline
Officially Welcomed to the 'Fest
Location: Back in Oaktown, Yay Area
 
Join Date: Feb 2011
Posts: 2,466
Mein Auto: 2001 540i/6, '90 BMW k75s
You know, I've been thinking about that "Jello" photo of the coolant reservoir. It bothers me and doesn't seem normal. because it's evidently not water soluble, as coolant should be. Have others found this? I wonder what this substance actually is, given the history of head gasket problems in the 6-cylinder.

How many months and miles since a coolant flush? Do you know?

Reply With Quote
  #11  
Old 03-11-2011, 08:05 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by bobdmac View Post
You know, I've been thinking about that "Jello" photo of the coolant reservoir. It bothers me and doesn't seem normal. because it's evidently not water soluble, as coolant should be. Have others found this? I wonder what this substance actually is, given the history of head gasket problems in the 6-cylinder.

How many months and miles since a coolant flush? Do you know?

Yes - < 10k miles ago / 2 yrs from a BMW dealer. Yeah, surprised me too. Prolly more the reason to do flushes, or the cooling system O'haul. Don't really like jello - lol
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #12  
Old 03-11-2011, 08:08 PM
cn90 cn90 is online now
Officially Welcomed to the 'Fest
Location: Omaha NE
 
Join Date: Mar 2006
Posts: 12,735
Mein Auto: 1998 528i 5-sp 140K+
Don't throw away the old stuff yet.

I cleaned my old reservoir and throw it in my trunk.
Ditto for the old belts as well as the tstat housing.
Reply With Quote
  #13  
Old 03-11-2011, 08:10 PM
bobdmac bobdmac is offline
Officially Welcomed to the 'Fest
Location: Back in Oaktown, Yay Area
 
Join Date: Feb 2011
Posts: 2,466
Mein Auto: 2001 540i/6, '90 BMW k75s
Maybe it's a by-product of the cold winter weather.
Reply With Quote
  #14  
Old 03-11-2011, 08:24 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by cn90 View Post
Don't throw away the old stuff yet.

I cleaned my old reservoir and throw it in my trunk.
Ditto for the old belts as well as the tstat housing.
CN90 - Yes - I've saved all parts for the trunk - just-in-case - I feel goooood now!
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #15  
Old 03-11-2011, 08:40 PM
cn90 cn90 is online now
Officially Welcomed to the 'Fest
Location: Omaha NE
 
Join Date: Mar 2006
Posts: 12,735
Mein Auto: 1998 528i 5-sp 140K+
Many people don't realize the importance of a good cooling system until it fails.
Not only the cooling system goes but it drags along the engine too.
The problem is not so much fixing the cooling system.
The problem is in fixing the engine cylinder head!!!
Reply With Quote
  #16  
Old 03-11-2011, 08:47 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by cn90 View Post
Many people don't realize the importance of a good cooling system until it fails.
Not only the cooling system goes but it drags along the engine too.
The problem is not so much fixing the cooling system.
The problem is in fixing the engine cylinder head!!!
Yes, don't want to deal with the head - so many newbs here start with this problem, and this worries me. Very difficult to recover from this $$$.
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #17  
Old 03-11-2011, 09:12 PM
NoWayJose's Avatar
NoWayJose NoWayJose is offline
Officially Welcomed to the 'Fest
Location: RI
 
Join Date: Mar 2010
Posts: 779
Mein Auto: 00 528ia Sport
great write up, im sure the car runs alot better now.
__________________
00 BMW 528ia Sport
M5 F+R Bumpers, M5 Mirrors with OEM setup, M5 rear sway bar, Cluster Rings, 03 Business player with AUX input, HID fogs slim, OEM 01+ Hella headlights, Euro Lens, EAC Aluminum Adjusters, FX-R low beam retrofit, Umnitza Orion halos, Hella Euro Celis Retrofit Kit, Koni yellow shocks with H&R Sport Springs, 19" M6 Reps, Full LEDs.
Reply With Quote
  #18  
Old 03-11-2011, 11:05 PM
izzyinstl izzyinstl is offline
.........................
Location: St Louis Metro East
 
Join Date: Jun 2009
Posts: 80
Mein Auto: 528i
Stupid question: What is the dental floss trick? I did a search for dental floss but it references the bmw emblem.
__________________
My '97 528i
Reply With Quote
  #19  
Old 03-12-2011, 06:36 AM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by izzyinstl View Post
Stupid question: What is the dental floss trick? I did a search for dental floss but it references the bmw emblem.
It's used to quickly install / thread the fan back on. You basically create a pull-start on the nut. I pulled the dental floss by wrapping it around a socket extension - rawhide would be easier on the hands.

Here's a complete explanation with pics:http://www.bimmerfest.com/forums/sho....php?t=240143&
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
  #20  
Old 03-12-2011, 11:44 AM
izzyinstl izzyinstl is offline
.........................
Location: St Louis Metro East
 
Join Date: Jun 2009
Posts: 80
Mein Auto: 528i
Quote:
Originally Posted by rexgo View Post
It's used to quickly install / thread the fan back on. You basically create a pull-start on the nut. I pulled the dental floss by wrapping it around a socket extension - rawhide would be easier on the hands.

Here's a complete explanation with pics:http://www.bimmerfest.com/forums/sho....php?t=240143&
Errrrr Wish I had known about that trick sooner. I fought with the fan for 20 minutes before getting back on.

I'll know next time (I'm sure there will be one)
__________________
My '97 528i
Reply With Quote
  #21  
Old 03-12-2011, 01:57 PM
bluebee's Avatar
bluebee bluebee is offline
Seek to understand,^Value
Location: San Jose, California
 
Join Date: Mar 2008
Posts: 20,319
Mein Auto: 02 BMW 525i M54 auto 130K
Quote:
Originally Posted by izzyinstl View Post
I fought with the fan for 20 minutes before getting back on
It was even worse for me. Not only did I fight with the fan, but, I stripped the first few threads on the water pump shaft!

Two days later, I was able to get the viscous fan clutch nut on using a string of shoelace rawhide.

I think the dental floss, while harder on the hands, has an advantage of not needing to be taped onto the nut (which is what I did with the rawhide).

Since Rexgo's pictures are so nice, I took the liberty of shrinking them to 640x480 and attaching all 35 photobucket pictures to this thread so that they're not lost over time (I hate when I go to an old thread and all the pics are gone).

So as to always add value, I cross referenced Rexgo's dental floss pic here:
- cn90 fan clutch nut replacement trick

And, I cross referenced the jelly on the bottom of the surge tank here:
- Pictorial look at typical E39 cooling system failure modes (1)

Instead of putting the expansion tank in the trunk, I'd suggest Rexgo autopsy it and post pictures here:
- Behr radiator and Behr expansion (aka surge) tank autopsy (1) (2) & request for another autopsy (1)
Attached Thumbnails
Click image for larger version

Name:	rexgo_cooling_system_overhaul_01.jpg
Views:	37
Size:	108.2 KB
ID:	269979   Click image for larger version

Name:	rexgo_cooling_system_overhaul_02.jpg
Views:	40
Size:	92.5 KB
ID:	269980   Click image for larger version

Name:	rexgo_cooling_system_overhaul_03.jpg
Views:	39
Size:	105.8 KB
ID:	269981   Click image for larger version

Name:	rexgo_cooling_system_overhaul_04.jpg
Views:	40
Size:	97.4 KB
ID:	269982   Click image for larger version

Name:	rexgo_cooling_system_overhaul_05.jpg
Views:	42
Size:	108.5 KB
ID:	269983  

Click image for larger version

Name:	rexgo_cooling_system_overhaul_06.jpg
Views:	3506
Size:	62.7 KB
ID:	269984   Click image for larger version

Name:	rexgo_cooling_system_overhaul_07.jpg
Views:	41
Size:	99.3 KB
ID:	269985   Click image for larger version

Name:	rexgo_cooling_system_overhaul_08.jpg
Views:	41
Size:	82.7 KB
ID:	269986   Click image for larger version

Name:	rexgo_cooling_system_overhaul_09.jpg
Views:	39
Size:	94.2 KB
ID:	269987   Click image for larger version

Name:	rexgo_cooling_system_overhaul_10.jpg
Views:	33
Size:	61.3 KB
ID:	269988  

Click image for larger version

Name:	rexgo_cooling_system_overhaul_11.jpg
Views:	38
Size:	67.1 KB
ID:	269989   Click image for larger version

Name:	rexgo_cooling_system_overhaul_12.jpg
Views:	36
Size:	71.3 KB
ID:	269990   Click image for larger version

Name:	rexgo_cooling_system_overhaul_13.jpg
Views:	40
Size:	49.9 KB
ID:	269991   Click image for larger version

Name:	rexgo_cooling_system_overhaul_14.jpg
Views:	37
Size:	64.0 KB
ID:	269992   Click image for larger version

Name:	rexgo_cooling_system_overhaul_15.jpg
Views:	39
Size:	94.9 KB
ID:	269993  

Click image for larger version

Name:	rexgo_cooling_system_overhaul_16.jpg
Views:	41
Size:	91.6 KB
ID:	269994   Click image for larger version

Name:	rexgo_cooling_system_overhaul_17.jpg
Views:	35
Size:	74.0 KB
ID:	269995   Click image for larger version

Name:	rexgo_cooling_system_overhaul_18.jpg
Views:	43
Size:	79.6 KB
ID:	269996   Click image for larger version

Name:	rexgo_cooling_system_overhaul_19.jpg
Views:	41
Size:	83.7 KB
ID:	269997   Click image for larger version

Name:	rexgo_cooling_system_overhaul_20.jpg
Views:	40
Size:	112.7 KB
ID:	269998  

Click image for larger version

Name:	rexgo_cooling_system_overhaul_21.jpg
Views:	41
Size:	98.4 KB
ID:	269999   Click image for larger version

Name:	rexgo_cooling_system_overhaul_22.jpg
Views:	36
Size:	102.4 KB
ID:	270000   Click image for larger version

Name:	rexgo_cooling_system_overhaul_23.jpg
Views:	38
Size:	96.2 KB
ID:	270001   Click image for larger version

Name:	rexgo_cooling_system_overhaul_24.jpg
Views:	40
Size:	101.4 KB
ID:	270002   Click image for larger version

Name:	rexgo_cooling_system_overhaul_25.jpg
Views:	37
Size:	65.2 KB
ID:	270003  

Click image for larger version

Name:	rexgo_cooling_system_overhaul_26.jpg
Views:	39
Size:	96.5 KB
ID:	270004   Click image for larger version

Name:	rexgo_cooling_system_overhaul_27.jpg
Views:	85
Size:	81.8 KB
ID:	270005   Click image for larger version

Name:	rexgo_cooling_system_overhaul_28.jpg
Views:	88
Size:	90.5 KB
ID:	270006   Click image for larger version

Name:	rexgo_cooling_system_overhaul_29.jpg
Views:	39
Size:	81.1 KB
ID:	270007   Click image for larger version

Name:	rexgo_cooling_system_overhaul_30.jpg
Views:	42
Size:	81.9 KB
ID:	270008  

Click image for larger version

Name:	rexgo_cooling_system_overhaul_31.jpg
Views:	38
Size:	92.4 KB
ID:	270009   Click image for larger version

Name:	rexgo_cooling_system_overhaul_32.jpg
Views:	42
Size:	103.7 KB
ID:	270010   Click image for larger version

Name:	rexgo_cooling_system_overhaul_33.jpg
Views:	45
Size:	89.8 KB
ID:	270011   Click image for larger version

Name:	rexgo_cooling_system_overhaul_34.jpg
Views:	44
Size:	93.0 KB
ID:	270012   Click image for larger version

Name:	rexgo_cooling_system_overhaul_35.jpg
Views:	42
Size:	97.5 KB
ID:	270013  

Reply With Quote
  #22  
Old 03-12-2011, 02:02 PM
bluebee's Avatar
bluebee bluebee is offline
Seek to understand,^Value
Location: San Jose, California
 
Join Date: Mar 2008
Posts: 20,319
Mein Auto: 02 BMW 525i M54 auto 130K
To Rexgo:
For the hose removal trick, did you consider 'exploiting the gap' using successively larger screwdrivers?
- How do you safely remove the upper radiator hose with u-pins?

How would you compare your method (that hook tool) with the method proposed in that hose-removal thread?

Note: I'm not quite sure how you used that tool to remove the hoses so I'm a bit confused.

Reply With Quote
  #23  
Old 03-12-2011, 03:02 PM
bobdmac bobdmac is offline
Officially Welcomed to the 'Fest
Location: Back in Oaktown, Yay Area
 
Join Date: Feb 2011
Posts: 2,466
Mein Auto: 2001 540i/6, '90 BMW k75s
Quote:
Originally Posted by bluebee View Post
...Since Rexgo's pictures are so nice, I took the liberty of shrinking them to 640x480 and attaching all 35 photobucket pictures to this thread so that they're not lost over time (I hate when I go to an old thread and all the pics are gone).
Bimmerfest's reference librarian, on the job.
Reply With Quote
  #24  
Old 03-12-2011, 04:41 PM
rexgo's Avatar
rexgo rexgo is offline
BMW Student
Location: Chicago
 
Join Date: Dec 2010
Posts: 215
Mein Auto: 97 528i
Quote:
Originally Posted by bluebee View Post
To Rexgo:
For the hose removal trick, did you consider 'exploiting the gap' using successively larger screwdrivers?
- How do you safely remove the upper radiator hose with u-pins?

How would you compare your method (that hook tool) with the method proposed in that hose-removal thread?

Note: I'm not quite sure how you used that tool to remove the hoses so I'm a bit confused.

bluebee - I always wondered why there were pictures shrunk in threads - now I know.

I might do an autopsy on the exp-tank in a little while. It was recently flushed??

My hoses had already been changed to BMW hose clamps, so I didn't have the u-clips.

The tool is a Tool Aid S-70 - available on ebay: RADIATOR HOSE TOOL # S-70

..
The point is tapered:

..
And you insert it in the hose to break the bond between the hose and mating part, and then work it around the hose - works great on heater hoses in close quarters against a firewall:

..
Here's some better pics (staged):

..
__________________
Tom

'97 528i, 99k DD
'91 CRX Si, 114k
'83 Supra, 109k
Reply With Quote
Reply

Bookmarks


Forum Navigation
Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)
Today's Posts Search
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On



Forum Jump


All times are GMT -7. The time now is 07:55 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
© 2001-2011 performanceIX, Inc. All Rights Reserved .: guidelines .:. privacy .:. terms