Cooling system overhaul

I am currently searching for any DIY's on a complete cooling system overhaul and am finding a plethora of information.

I drive a E46, 99 323i automatic transmission.
I've replaced the Clutch Fan and the Expansion Tank 10k miles ago. The Clutch Fan failed and caused the Expansion Tank to burst. The work was done by an Indy shop, and at the time I didn't have the cash to completely overhaul the entire cooling system. I'm pretty sure that I do now though.

I have a leak in the system somewhere. There is a bunch of coolant on top of the expansion tank which leads me to believe that it's getting to hot and the fill caps breather is releasing fluid.

In any case I have 124k and have only replaced the Expansion Tank and Clutch Fan. I know I've been skating on thin ice and it's time

As I look and dig through a million posts. Maybe it would be faster if someone could point me in the direction of a complete list of parts, and tools needed for the job. DIY threads would be nice too. I've found Smolk's water pump video on his Youtube channel. But I'm still looking.

Thank you for stopping in!

Go to oembimmerparts.com....they sell a complete kit for a cooling system refresh and have all the parts you need.

Odds are when your expansion tank was replaced, it didnt receive a new expansion tank cap to go with it. So the old one was used and the gasket on it is old and perished.

They replaced the cap, I'll scan up the work order.



Thank you Hexy27 for the tip on the oembimmerparts.com kit, that definitely helps.

I'm almost positive that I will not be needing everything on that list for the master cooling kit.
I've replaced the belts already less than 5k ago,
I already have the BMW antifreeze.

Are the belt tensioners something that are a normal replacement? It almost seems like they wouldn't go bad. Same with the water pump pulley, How would these parts go bad?

I've heard of the Idler pulley being a common replacement part though.

And a few other coolant related parts were replaced in this work order

You can always use my Ultimate Refresh kits (LINK) as a guide for the most common parts replaced when doing a full cooling refresh. From there if you don't want to get a complete kit I'd be happy to help piece together everything you need/want.

wow.. the fan clutch cost $210? and it's on "SALE".. do the cooling overhaul and best if you DIY it..

yeah, they robbed me on the Fan Clutch. I called them on it too.

Their reply was... "We have to warranty our parts and work so that is why we charge more".

My car was already at their shop, so I just let them do the work.

And my car has never seen a shop since then, (aside for alignment and tires).
I've gotten real hands on really quick. Indy or stealership, it doesn't matter. Mechanics labor and parts markups are ridiculous period!

not sure if cross posting from other forum is allowed but here you go..

http://forum.e46fanatics.com/showthread.php?t=914109

really depends on you and your budget on what parts you will replaced..

edit: i also suggest you replaced your water pump and pulley..

look at what happened to me a few days ago http://forum.e46fanatics.com/showthr...950&highlight=

WOW, I'm sold!
Thank you for setting me straight on the WP pulley!
This is Exactly the type of information I am after!

hit me up via PM if you're doing this anytime soon.. looks like were just a few miles away.. couldn't be much a help though coz i have only done a WP, pulley, belts and clutch on my car.. no experience on ET,radiator and other parts - but would love to be an audience hahaha..

I'm up in Placer county now. And I need to do this as soon as my parts arrive because I'm not mobile atm.

I'm just about to start ordering parts really. I'm trying to figure out what I already have replaced and what I will need to purchase.

But I'm beginning to think I should just buy the entire kit, and in the worst case I'll have extra replacement parts for the future.

I need to stop trying to cut corners and just replace the entire system, I just didn't want to have 2 gallons of BMW coolant, and a few duplicate parts that I have recently replaced. Plus I was " iffy" about the need to replace some belt tensioners and pulleys.

Originally Posted by stevenj

They replaced the cap, I'll scan up the work order.



Thank you Hexy27 for the tip on the oembimmerparts.com kit, that definitely helps.

I'm almost positive that I will not be needing everything on that list for the master cooling kit.
I've replaced the belts already less than 5k ago,
I already have the BMW antifreeze.

Are the belt tensioners something that are a normal replacement? It almost seems like they wouldn't go bad. Same with the water pump pulley, How would these parts go bad?

I've heard of the Idler pulley being a common replacement part though.

And a few other coolant related parts were replaced in this work order

Wow, you might puke when I tell you this, but I charge $200 for a complete cooling system overhaul. You got hammered on that repair! OUCH!

Originally Posted by stevenj

But I'm beginning to think I should just buy the entire kit, and in the worst case I'll have extra replacement parts for the future.

You'll also have a little piece of mind knowing you have some spare parts to throw at it incase anything goes wrong.

I've purchased my Cooling Overhaul Kit at OEMBimerparts.com
Like I previously stated, I decided having extra replacement parts can't hurt. And I'm tired of trying to cut corners on my only source of transportation.
At $759.00 my pocket hurts, but I'll be happy to have piece of mind once I complete the labor.

I also bought the Fan clutch removal tools from an eBay seller (wrench & water pump pulley holder) at $35+tax and free shipping.

The kit and the tools should arrive around the same time.
I'm disabled, so I work at a snails pace. What should probably take 4-6 hours to complete, the job will most likely take me about 3 days or so. Especially since I'll be going back and forth from my car to my computer reading DIY threads.

Thanks to everyone who has offered information, it was obviously needed.

I'll provide an update after I'm done with the R/R & Bleeding, and let you all know how it went.

Everything came in today, I wrenched and tugged for about 3 hours.
Of course I didn't open the packages before I started.... And knowing my luck that will screw me in the end...

But I was able to remove upper/lower hose, ET, and Rad. Still have the pulley tensioners thermostat and water pump to go at tomorrow.

Boy were there a few pieces that just DID NOT want to budge! I spent about an hour trying to lift the ET from the lower fitting. And another removing the lower hose from the radiator. The rest was pretty straight forward and went without a fight.

The battle continues tomorrow!

Congrats on your progress! Keep us posted.

OK.

So I spent another 3.5 hours this morning pulling the rest of the components. Everything else was relatively easy to remove, the water pump took me a second to to figure out. after I figured it out that was easily removable as well.

To my surprise. I had the metal impeller version of the BMW OEM pump.. I think I was leaking from the upper elbow of the old RAD.

I just had some Distilled water delivered to me and now I'm on my way back out to mix the coolant and do a bleed. I'm keeping my fingers crossed and hoping that I'll have no leaks.

Under my car is completely wet, and it will be difficult to see any leaks unless I can visually spot the leak. I can always place some cardboard under my car though.

Overall the labor was Easy to Very easy.

Just need a Torx bit set, a Ratchet, 10mm, 13mm, and 5/8in sockets.
Plus the Clutch fan removal tool 32MM wrench and Pulley holder tool.

Here I go to mix the coolant and pray for no leaks!

Well as luck would have it. I have struck a leak!!!

To no fault of my own though, and I have figured out exactly why.
The Auxiliary switch temperature sensor that was sent to me is completely missing the little green gasket .

I saw where the leak was coming from and when I pushed down hard on the sensor the leak was slowed, but was not stopped, but when I removed my finger the leak continued.

I inserted my old sensor and it stopped the leak, but since it leaked so much before I found it I now am short on coolant . What I had in my trunk and thought to be a full bottle of BMW coolant is actually just the remnants of what the indy shop used when they replaced my expansion tank, and its not much...

I guess I'll have to wait until Monday to call Max and let him know what my problem is and hopefully he can come through and make things right.

Nothing ever goes right the first time around for me. It's the story of my life.

Originally Posted by stevenj

Well as luck would have it. I have struck a leak!!!

To no fault of my own though, and I have figured out exactly why.
The Auxiliary switch temperature sensor that was sent to me is completely missing the little green gasket .

I saw where the leak was coming from and when I pushed down hard on the sensor the leak was slowed, but was not stopped, but when I removed my finger the leak continued.

I inserted my old sensor and it stopped the leak, but since it leaked so much before I found it I now am short on coolant . What I had in my trunk and thought to be a full bottle of BMW coolant is actually just the remnants of what the indy shop used when they replaced my expansion tank, and its not much...

I guess I'll have to wait until Monday to call Max and let him know what my problem is and hopefully he can come through and make things right.

Nothing ever goes right the first time around for me. It's the story of my life.

You can get an o-ring from lowes or home depot.

Originally Posted by smolck

You can get an o-ring from lowes or home depot.

There is a couple of problems with that.. My only source of transportation is not running because of this O ring so I cannot drive to pick one up...

Like I said I now need more coolant because of this incomplete part
And I just want the "right" O ring that is supposed to come with the part.

Knowing me I would get one that fits the part but doesn't seal the gap or something.

Thank you for chiming in Smolck! I ALWAYS appreciate your advice!

if you want to see what I really wrote proceed to the quote in the next post by oembimmerparts.

But really I was being irrational.

All apologies.

Originally Posted by stevenj

sooo... Max claims that the O ring should have been inside the box and not attached to the sensor. but I dumped he box into my hand and only one thing came out.

And he says I'm basically SOL on the fluid that was lost by installing the part he sent to me incomplete.

It looks like that was the first and last time I do business with Mr. Max over there at oembimmerparts.com

As far as I'm concerned, the loss of fluid was caused by him sending me an incomplete part. Therefore should be replaced by him. I am not pleased....

Really sorry you feel that way, As I said on the phone, I would have been more then happy to send you one out on monday and you would have had it the following day, Best I can do being thousands of miles away.
As I also stated the oring was checked by 3 people due to the common tactic of many customers claiming its not there and wanting there money back.
Im also sorry you did not know there should have been one for that connection and installed the switch anyway without it and then had a leak. Im sorry its easier for you to lay blame on someone else for you not knowing all there is know about working on a car.
Never did I say you were SOL on anything, When you eluded to the fact that you felt it was someone else responsibility to provide you coolant I declined as its not my or my companies job to follow behind you to make sure you know what you are doing when wrenching on a car. in the end, The oring was in the box when it left, As people claiming the oring was not in the box became a issue as they just wanted the seal with out paying for the switch, Belive me, You are not the first person to pull the switch out and toss the box losing the oring.

Max

Ouch!

Sent from my SCH-R760 using Bimmer App

Originally Posted by oembimmerparts

Really sorry you feel that way, As I said on the phone, I would have been more then happy to send you one out on monday and you would have had it the following day, Best I can do being thousands of miles away.
As I also stated the oring was checked by 3 people due to the common tactic of many customers claiming its not there and wanting there money back.
Im also sorry you did not know there should have been one for that connection and installed the switch anyway without it and then had a leak. Im sorry its easier for you to lay blame on someone else for you know knowing all there is know about working on a car.
Never did I say you were SOL on anything, When you eluded to the fact that you felt it was someone else responsibility to provide you coolant I declined as its not my or my companies job to follow behind you to make sure you know what you are doing when wrenching on a car.

Max

You're right in the fact that I don't know everything about EVERY part on my car, and every project is a learning experience. I willingly admit that.

Since the O ring is such a common issue it should be made VERY CLEAR that it is not installed on the part, It stands to reason that it's a common issue because every other part in that kit has the Gaskets and or O rings pre installed.

One would think instead of checking the box 3 times for the part, why not just install the O ring be done with it, and no longer have the problem?

Sure I took for granted that the O ring would already be there. Just the same as your company taking for granted that your customers will be aware the O ring is not installed. And that is a two way street.

Being SOL on the coolant weren't your words, but you did tell me that I'm on my own as far as the coolant goes.

Everything else was just fine, and I have no complaints otherwise. I'm just upset that I've already paid $760 and now am going to pay another $22 for additional coolant. Right now my car is equipped with the old sensor and more distilled water than recommended because of my overlooking the absence of the O ring.

I pretty much typed that last post in the heat of the moment. I'm sorry Max. Your company shipped very fast and complete (aside from this O ring)

I'll have to eat the cost of the Coolant surely. But I still need an O ring to make my part usable.

Originally Posted by stevenj

You're right in the fact that I don't know everything about EVERY part on my car, and every project is a learning experience. I willingly admit that.

Since the O ring is such a common issue it should be made VERY CLEAR that it is not installed on the part, It stands to reason that it's a common issue because every other part in that kit has the Gaskets and or O rings pre installed.

One would think instead of checking the box 3 times for the part, why not just install the O ring be done with it, and no longer have the problem?

Sure I took for granted that the O ring would already be there. Just the same as your company taking for granted that your customers will be aware the O ring is not installed. And that is a two way street.

Being SOL on the coolant weren't your words, but you did tell me that I'm on my own as far as the coolant goes.

Everything else was just fine, and I have no complaints otherwise. I'm just upset that I've already paid $760 and now am going to pay another $22 for additional coolant. Right now my car is equipped with the old sensor and more distilled water than recommended because of my overlooking the absence of the O ring.

I pretty much typed that last post in the heat of the moment. I'm sorry Max. Your company shipped very fast and complete (aside from this O ring)

I'll have to eat the cost of the Coolant surely. But I still need an O ring to make my part usable.

Please email me your order# and I will get a oring and gallon of coolant sent out monday and it should be there on tuesday. Please email your order number to admin@oembimmerparts.com and just ref. temp sensor seal / coolant in the email.
Max