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E60 (2004 - 2010)
BMW 5-Series (E60 chassis) was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E60 is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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  #1  
Old 12-02-2012, 07:18 PM
Julio_Lujambio@ Julio_Lujambio@ is offline
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How to replace Water pump and thermostat E60 - 535 xi

Hi, recently the radiator fan went crazy and 2 minutes later a yellow temp icon come up and 1 minute later a red temp icon telling overheating come up and I have to stop my car wait for it to cool down and drive by segments to my home. Basically every-time the yellow icon will come up I stopped not letting the red icon to show up.

Long history short. I found out 2 trouble codes with my scanner (2E82 AND 2E83). Note: if you find any combination of the codes below:

FC 2E81 Electric coolant pump, speed deviation, speed outside the tolerance
FC 2E82 Electric coolant pump cutoff, over-current
FC 2E83 Electric coolant pump, power-reduced operation, dry run
FC 2E84 Electric coolant pump, communication
FC 2E85 Electric coolant pump, communication, no voltage at emergency operation input of pump

the bulletin from BMW tells to replace the water pump.

Car millage: 66K.

Below is what I did. BTW, a digital phone camera will help you to remember how to assemble parts back :-)

Expected time to perform for home mechanic: 3-4 hours. Pro: 2 hour max.

Tools: Phillips crew drivers and flat screw drivers, wrenches or sockets from 4 to 16 (you will need 8 - 10 - 17), special torx socket tool for the aluminum screws for the water pump - max torque 10NM.

Parts: 2 gallons of coolant (424), water pump ($420), screws ($8), Thermostat ($110)

Water pump (WP) and thermostat are located in the non-driver side below the engine. Sorry, you will have to remove both to replace the WP.

Procedure:
1- rise your car so you can reach all the lower splash panels/cover in the bottom of the car
2- secure the car so it does not move and disconnect the battery (rear of the car non- driver side).
3- take out front and back splash (around 20+) screws
4- remove lower protector plate ( 6 big bolts). You will need air powered tools or heavy and good wrenches.
5- remove bolt and move hydraulic hose to the left so you can make room.
6- remove hoses from the thermostat
6.1 - start removing the ones that have the secure wire to keep them in place. Take out the wire lock (you can pry it with a small screwdriver) and then pull the connector out of the each one. (you can drain your system at this time :-) ) thus, have a handy container to collect the cooling fluid.
6.2 - remove the 2 bolts that keep the thermostat in place
6.3 - pull the thermostat to the side so you can see and reach the other 2 hoses
6.4 - gently unscrew the clamp that holds the small hose - fluid will drain when you remove the hose- and then pull to the side to remove the hose.
6.5 - gently unscrew the clamp that hold the big hose - fluid again - and with one hand reach the hose from the back of the frame and pull with your other hand the thermostat.
7. now you can reach the top bolt to remove the WP. Remove the 3 bolts.
8. pull the water pump and detach the hose that connect the thermostat - make sure you remember of have a picture of the position of the hose.
9. now you can reach and detach from the WP the hose that connects the WP with the engine - make sure you remember of have a picture of the position of the hose.
10. remove the electrical connector to the WP.
11. Installation procedure is the opposite from 10 to 1.
12. Make car level in garage.
13. Fill fluid to top, close cap, initiate bleed process: key in, then press ignition on (do not press the break) - then accelerator pedal to the floor - 5-10 seconds and you should heard the pump working - and wa-la, pump operated for a minute or less, loosen cap and refill; repeat process until level is OK. note: When the pump operated, I smiled.

good luck!.

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Last edited by Julio_Lujambio@; 12-19-2012 at 05:14 AM. Reason: minor updates
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  #2  
Old 12-02-2012, 10:20 PM
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luckydog luckydog is offline
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Great post Way to save the engine cooling periods and detailed COR= Car Owner Repair .

Last edited by luckydog; 12-02-2012 at 10:23 PM.
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  #3  
Old 12-03-2012, 06:12 AM
HPIA4v2 HPIA4v2 is online now
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Julio, great write up.

But do you have picture for the special tools? is it torx?
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Old 12-03-2012, 11:05 AM
bighead2267 bighead2267 is offline
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that's what i wonder as well
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Old 12-03-2012, 12:01 PM
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legend700 legend700 is offline
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As to item 13. of the above write-up, I would like to point out that the bleed process is different in the Bentley's manual for the N54 turbo engine. It is an automatic sequence initiated after selecting the lowest fan speed and heat set to max. and holding the accelarator down for about 10 seconds with ignition on. The automatic process runs exactly 12 minutes and shuts off by itself. Also coolant reservoir cap needs to be closed.
Attached PDF lists details.
Attached Files
File Type: pdf BMW Coolant System Bleeding.pdf (44.5 KB, 572 views)
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  #6  
Old 12-03-2012, 12:17 PM
Julio_Lujambio@ Julio_Lujambio@ is offline
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Bolts

Attached are a picture of the necessary torx socket wrench and the water pump bolts.
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Last edited by Julio_Lujambio@; 12-03-2012 at 12:19 PM.
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  #7  
Old 12-03-2012, 12:17 PM
Julio_Lujambio@ Julio_Lujambio@ is offline
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Quote:
Originally Posted by HPIA4v2 View Post
Julio, great write up.

But do you have picture for the special tools? is it torx?
see above I posted pictures

Last edited by Julio_Lujambio@; 12-03-2012 at 12:19 PM.
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  #8  
Old 12-04-2012, 04:36 AM
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MachtSchnell MachtSchnell is offline
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Good write up. I replaced mine Friday. Took me much longer but I have big hands getting everything out was the tough part for me. Putting back together was quick. You can drain most fluid out through the petcock valve, I would also suggest a large shallow drain pan as fluids will trickle down other places. I did an oil change while I had her up.
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Old 07-07-2013, 07:18 PM
Jparson Jparson is offline
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Special tools for star bolts not needed

Quote:
Originally Posted by Julio_Lujambio@ View Post
Attached are a picture of the necessary torx socket wrench and the water pump bolts.
The regular sockets will work for the star bolts they fit snug and wont slip if u use the right size. I removed my water pump and thermostat with all regular sockets, u will need the small ratchet to get in the tight areas. Don't waist your money!
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Old 11-15-2013, 05:44 PM
Kmayer20 Kmayer20 is offline
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I'm considering changing my thermostat and water pump too. Did you guys do work at a garage with a lift or is it possible to use a car ramp?

I had 2 hour drive home tonight which is usually a 20 minutes ride because of the red overheat indicator came on every other minute.

Car: 2006 530xi

Where should I buy the thermostat and water pump?

Kevin
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  #11  
Old 11-15-2013, 06:04 PM
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MachtSchnell MachtSchnell is offline
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I did mine in the garage with a jack and some stands. I bought parts from the dealer I couldn't be without the car waiting on parts to be delivered. Getting past the hydronic lines for were the most difficult part of the Job. Loosen the brackets that hold them if you don't want to disconnect them and had to drain refill them.
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  #12  
Old 11-15-2013, 07:11 PM
Kmayer20 Kmayer20 is offline
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Thanks MachtShnell. I assume you did this work on the 08 535xi?
I have an 06 and my indie mechanic told me BMW made some changes to the 5 series in late 06.

I'm not sure what changes we're made, but he told me you can't just replace the thermostat on early 06 530 XI and that the thermostat and pump are sold together for yhst reason. Originally my mechanic was going to replace the thermostat, but then called to say that's not possible!?

Looks like I need to do some more research.

Thanks for the response, I hope that they are the same or close so i can do the work myself and can Julio's great instructions.
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Old 11-17-2013, 01:14 PM
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Sorry replaced it on a 08 535i. no need for AWD in Hotlanta. I am not sure about the 06, but depending on the mileage of the current water pump you might save yourself some time and heart ache by doing them both now. My thermostat went and just replaced it, 3-6 months later my pump went out, woulda coulda shoulda. Hope you have a heated garage, starting to get cold up in CT. I am up there often in Danbury and Shelton and this is not my favorite time of year up there.
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