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How to make your own BMW special cooling system & drive belt counterhold tools

215K views 150 replies 42 participants last post by  Eedy 
#1 · (Edited)
Are these Bentley-specified special tools really needed for an overhaul of the BMW 525i E39 cooling system and belt-drive components?
1. cooling fan counterhold tool BMW 11 5 030 (I6) & BMW 11 5 040 (V8) [Note: This tool is described with many names!]
2. cooling fan 32 mm wrench (BMW 11 5 040)
3. 24mm hollow thin socket alternator pulley nut removal tool (BMW 12 7 100)

Does anyone have a drawing of the (1) water-pump-pully-counterhold tool dimensions?

REFERENCES:
Bentley pages 020-16, 110-2, 121-2, 170-15, & 170-23.
http://www.samstagsales.com/bmwtools.htm
http://www.pelicanparts.com/BMW/catalog/shopcart/BE39/POR_BE39_TOLtol_pg3.htm
http://www.germanpartsonline.com/bm...cylinder-engines-m50-m52-m52tu-m54-from-1992/
http://www.magnum1.com/BMW-740/740_Pages/Maintenance-Pages/Water-Pump-740.html



 

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#3 · (Edited)
Are these special tools really needed for an overhaul of the BMW 525i E39 cooling system and belt-drive components?
1. cooling fan counterhold tool (BMW 11 5 030) aka "fan pulley holder"
2. cooling fan 32 mm wrench (BMW 11 5 040)
3. alternator pulley nut removal tool (BMW 12 7 100)
Are they all needed, no.... much of this depends on your skill level.....they might help some people.

1. I just a use a hammer and 32mm wrench to loosen nut on fan clutch, everytime, all the time, on time.....for me the tool is a waste of money.

2. Yes, you will need a 32mm wrench. Northern tools wrench plenty good enough for this purpose.

3. Not need for cooling system overhaul. I just use my impact to loosen alternator pulley nuts.
 
#4 ·
So what's your technique for the fan clutch? I have tried hammer and wrench, screwdriver on pulley and wrench and could not loosen without the flat tool made for that purpose. Got the tool and had it loose in 30 seconds or less.
 
#5 ·
The tool shown will work on the six, but not the V8, since the nuts are recessed. If you can't get it loose with a hammer, you need the tool.

Ask me how I know.
 
#6 ·
Are these special tools really needed for an overhaul of the BMW 525i E39 cooling system and belt-drive components?
1. cooling fan counterhold tool (BMW 11 5 030) aka "fan pulley holder"
2. cooling fan 32 mm wrench (BMW 11 5 040)
3. alternator pulley nut removal tool (BMW 12 7 100)

Making your own tool (which confusingly seems to go by various names) is discussed here (for the 740 anyway).

I have a friend who said he'd make whatever special tool I needed out of stock steel if I could provide a full-sized PDF drawing of the part by email & it's thickness.

Do you have a PDF drawing (or a trace of the business end) of the tool dimensions & thickness?

REFERENCES:
Bentley pages 020-16, 110-2, 121-2, 170-15, & 170-23.
http://www.samstagsales.com/bmwtools.htm
http://www.pelicanparts.com/BMW/catalog/shopcart/BE39/POR_BE39_TOLtol_pg3.htm
http://www.germanpartsonline.com/bm...cylinder-engines-m50-m52-m52tu-m54-from-1992/







 
#7 · (Edited)
Wow. Did you draw those perfect diagrams yourself? They are wonderful!

It looks like we can craft the necessary BMW 11.5.030 M54-engine cooling fan counterhold tool out of 5/32" thick steel stock, about 16 inches long and roughly 1 3/16" wide.

We can drill a 15/32" hole centered 11/32" from the end of the tool and then two more for the slot and then jig saw out the hollow.

I'll try to get this done and then post pictures. If anyone else tries it, please post pictures of your handiwork.

Any idea where best to get the stock steel?

 

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#8 ·
I'm pretty sure the tool above from mmm635's original wonderful thread (which I just found doing this research) will fit my M54 engine but I'm still looking for the dimensions for the others (with the V8, for example).

We should probably mention the bolt spacing for the BMW E39 "holder wrench for fan hub" tool is different depending on what engine you have (according to this incomplete reference and this more complete reference).

- Holder wrench for fan hub bolt spacing 45mm. Applicable on the following engines: M10, M20, M30, M50, M51, M52, M52TU, M54, M56, M70, M73, S14, S38, S50B30, S50B32, & S54; 394mm in length. Old BMW P/N 88.88.6.115.030; new BMW P/N 83.30.0.491.046

- Holder wrench for fan hub bolt spacing 38mm. Applicable on the following engines: M40, M41, M42, M43, M44, M60, M62, N62, & S62; 400mm in length. Old BMW P/N 88.88.6.115.050; new BMW P/N 83.30.0.491.048

 

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#9 · (Edited)

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#11 · (Edited)

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#16 ·
not trying to be a $%^& for most people who doesn't have tools or experience in cutting steel, it's just easier and faster to buy the tool itself. I tried making one but it didn't work, so I got my WP counterholder for around $25 from ebay. It's double ended, so it fits almost any BMW. Already used in my 525i, 540i, and friend's 745i. Makes removing a fan clutch a 10 sec. job.
 
#18 · (Edited)
I tried making one but it didn't work, so I got my WP counterholder for around $25 from ebay.
Good idea. I bought this tool set from EBAY for about 30 bucks plus about 15 shipping.

It has the 38mm bolt spacing for the V8 and the 45mm bolt spacing for the I6.

 

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#17 ·
Here's a quick price survey from an Internet search for the commercial versions of our home-made water-pump pulley holder.

I could only find three suppliers, which is surprising.

Please add any missing suppliers!

11.5.030 (45mm offset):
Pelican Parts:
PEL-TOL-3038 $36.10 + CA 10% tax + shipping
Samstag Sales: 88.88.6.115.030 $56.99 + CA 10% tax + shipping
Technitool: 115-030 $36 + CA 10% tax + shipping

11.5.050 (38mm offset):
Pelican Parts: PEL-TOL-3037 $36.10 + CA 10% tax + shipping
Samstag Sales: 88.88.6.115.050 $58.00 + CA 10% tax + shipping
Technitool: 115-050/M $41 + CA 10% tax + shipping


 

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#19 ·
For the record, here's another documented attempt on outpost.com ...

Here, they document their use of a standard carpenters "speed clamp" and all they do is enlarge one hole and drill another.

 

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#20 ·

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#22 ·
My 3 cents:
Hi Cam,
Your 3¢ is always better than my 2¢ !
1¢. You located a price HALF of what I found for the counterhold tool!
2¢. You found a freely available alternative (the garage door support!)
3¢. You proved the counterhold job can be done with a sturdy screwdriver!

Note 1: I'm starting to not believe a minority of the people here (generally those with 1 to 50 posts, who post no pictures or links) who outright boldly say controversial (yet wholly unproven except for their words) stuff like they have a two-headed wrench or they made the tool themselves and the job took only 10 seconds, etc. ... but I believe everything you say (mainly 'cuz you back it up and have proven yourself over time).

Note 2: Pelican parts says "The bolts on the water pump are non-symmetric, which means that you need to rotate the fan to find the two that will fit the tool properly. Only one position out of four potential positions will work." I'm not sure why they say that; can anyone clarify what the "gotcha" really is?

 

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#27 ·
Amen brother, I am just not following this obsession tools that are not required. I propose the KISS method. These cars are pretty darn easy to wrench on. Going to do another Besian Vanos seal install next week for my sister, yea I am little OCD with the engine maintenance.
 
#26 ·
The V8 tool



Here's the V8 tool, from AST, BMW 2260. Not simple, probably worth buying. Seems I paid $45 for it several years ago.

The tool is 432 mm long, 8 mm thick, and 25 mm wide. The pulley recess is 5 mm, and nut recesses are each 4 mm.

Have fun in your metalworking shop.
 

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#29 ·
Wow. Edjack's V8 38mm-offset recessed counterhold tool sure looks complicated.

All the others I've seen are muuuuuch simpler (i.e., flatter). What I don't understand is whether the 38mm offset tools that are made out of flat stock are 'equivalent'.

I "see" that they're physically different (the recessed groove and holes being a big difference) ... but they sell the flat ones (presumably in droves) so I wonder if the complex Edjack tool is as necessary as it might seem.

Luckily for me, I have the 45mm offset which seems simpler so this question is for you V8 guys.

PS: I do see, on Ebay, the two headed tool - which might make sense for those of you with multiple BMWs.

 

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#30 ·
The flat tool will simply not fit the V8 pulley. You need to get under the hood to see why. The V8 pump pulley recesses the nuts, so they don't protrude to get ahold of them.
 
#32 ·
That Ebay tool almost doubles from $19 to $32 with tax & shipping.
$18.99 + 1.85 California 9.75% tax + 11.16 shipping = $32.00

 

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#37 ·
I used a adjustable crescent wrench that I already had, 0$.
Oh my! The force in that video is humongous! I would think an adjustable crescent wrench would shatter with all that force applied!

I'm curious why he used the open ended part of the 32mm wrench; wouldn't you have used the box part of the open-end wrench so as to distribute the 3lb hammer forces on the nut?

BTW, in the video, the 'brute' said 32mm is the same as 1 1/4 inches. Doing the math, 32mm is close to 1 1/4 inches (1.26").

When I order the wrench, if I order a 1 1/4 instead, do you think the extra tenth of an inch matters?


 

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#38 · (Edited)
I went to Northern Tools to get the 8mm thick, 14-point 32mm combination wrench but they're backordered for 30 or more days! :(



I think these are the 8mm thick (BMW 88 88 6 11 5 040) 14-point 32mm (1 1/4") crescent wrenches available.

Let me know if there are other good suppliers:
BMW Tools: 88 88 6 115 040 $94.50
Wrench Fan clutch, thin head, 32mm, 3/8" drive, torque limited to 40Nm and 30Nm

Pelican Parts: PEL-TOL-1032T $32.70
Fan Clutch Wrench, 32mm x 36mm, BMW All Models, Each (BMW Service Tool Reference #11-5-040)

Pelican Parts: PEL-TOL-103236T $37.70
Fan Clutch Long Thin Spanner Wrench (32mm open end, 8mm thickness), BMW All Models, Each (BMW Service Tool Reference #11-5-040)

Northern Tools: $8.29 (backordered for 30 or more days)
 

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