Home | BimmerBoard on AMAZON | 5 Series E39 Forum | Post New Message | Search | Contact Moderator | Sign In

5 Series E39 Forum

This message is marked as Important.

Subject: ENTIRE COOLING SYSTEM REPLACEMENT Tips

and Tricks (Very Long, Enjoy!)
Author: cn as CNN-090 : member since July, 2004 : 1082 posts
Posted on: 2006-05-14 04:27:25
Follow BimmerBoard

1998 528i Entire Cooling Department Tips & Tricks

(E39 5-speed with 89K miles)

Car seems to have good maintenance service but I could not find records of service for the Cooling Cooling System
Department. After everything is removed then it was clear that nothing has been replaced thus far. Solutions
I am the 4th owner and did the entire cooling system. Parts List and places bought from:
Understand the
complex
1. BMW Dealer:
Thermostat Plastic Housing. This sound funny but both Aftermarket Aluminum Brands (Ronak and dynamics of
MTC) are known to leak at 6-12 months later. My BMW mechanic recommends only Dealer Plastic complete cooling
Tstat Housing. systems
www.flowmaster.com
PN 11531740478 $28.00

2. www.Autohausaz.com:
* Behr Thermostat 88 deg C (factory is 92 deg C, I just want something a bit cooler). Now the temp sits
just a bit LEFT of 12 o’clock when warmed up.
PN 11531721002 $17.00
* Radiator Hoses (Upper and Lower): $9 and $7
* AC belt 5PK0906 $9 Related Links
* WP-Alt-PS belt 6PK1560 $13
* Rollers x 2 PN 11281748131 $17/each BMW CCA
(for AC belt and for between Crank and WP Pulleys) Indy Mechanics
* Idler Roller PN 11281738605 $23/each
(this sits between WP and Alternator Pulleys) E38.org Wiki
* Hydraulic Tensioner PN 11281717210 $39/each
David's BMW Bookstore
(for AC belt)
* Hydraulic Tensioner PN 11281717188 $50/each BimmerBoard on AMAZON
(for Roller between Crank and WP Pulleys)
* Coolant Reservoir "Mounting Clip" PN 17111723580 $2.20/each E38.org/e39/
* Fan Clutch by "Sachs" PN 11521719269 $94/each
* Fan Blades by "MTC"” PN 11521712058 $23/each Specialty Forums
* Radiator by "Nissens" PN 17111702969 $173/each Deals & Offers
(many people think this is better than Behr Radiator) IBUS Forum
* Bypass Hose from Radiator to Reservoir PN 17111427156 $5.60/each Garage Forum
Navigation A/V
3. www.bmw-parts-direct.com
* Coolant Vent Screw PN 17111712788 $2.80/each Bluetooth
* Reservoir Cap PN 17111712669 $10.60/each For Sale
* Reservoir by OEM PN 17111723520 $56/each Want To Buy
* Water Pump by "Hepu" PN 11511740241 $67/each
Off-Topic
(supplied with O-ring. After some research, "Hepu" Brand seems to be better than "Graf" or
"Geba" (Graf and Geba seems to have leakage after 20-30K miles but I am not sure). The Volvo folks Detailing
love Hepu Water Pump so I go with "Hepu". ///M
Kill Stories
Group Buys

GENERAL NOTES Vanos Forum

* My car has Hydraulic Tensioners. Some E39’s are equipped with Mechanical Tensioners, check
before buying parts. Meet & Greet
* Go with your budget, I will discuss what needs to be replaced and what is an option.
TEST FORUM
* There are many small parts removed, so get a box and place them in there to avoid losing them.
* Use proper torques to avoid over-tightening and stripping the nuts or bolts.
* This is a wet job with water in the engine compartment so make sure the following is tight: oil filler Forums for Current
cap, dipsticks, PS cap (which has a vent hole so cover it with ziplock bag). Keep tools away from Model BMW's
water! 1 Series E81
* Apply small amount of "Antiseize" on all these nuts and bolts for easier removal later. 3 Series E90
5 Series E60
* If you only do the Belts, removing the Fan Shroud and Fan Clutch make the Belts job a lot easier!
* At 89K miles, I found out that: 5 Series F10 NEW
- Factory WP bearing has a little play but no leak yet. 6 Series E63/E64
- All 3 Rollers have some play, grease dried out. If tight on budget, one can re-grease them, be careful 7 Series E65/E66
not to damage the seal (use a picking tool). However, I used New rollers x 3.
7 Series F01/02 NEW
- Both Hydraulic Tensioners appear OK, no leak. I guess one can use them another ? 20-30K miles. I
replaced both of them for peace of mind. X3 E83
- The belts were cracked and overdue (but I am not these are original or have been replaced before)! X5 E70
X6 E71
* One can use BMW OEM Antifreeze but it is a bit pricey. From my own research, Prestone "Extended Z4 E85
Life" Antifreeze is excellent and it is rated up to 5yr/150K whatever it means:
MINI Cooper
http://www.prestone.com/products/antifreezeCoolant.php
The old recommendation of 2yr/24K is probably for old technology, now with newer "Extended Life"
technology, it is probably safe to extend beyond the usual 2yr/24K. I plan to flush Antifreeze more Forums for Past Model
frequently than 5yr/150K! So I will flush somewhere in between 2yr/24K and 5yr/150K. BMW's
Note: Antifreeze Capacity for 528i is 11.1 quarts. To ensure 50-50 mixture, after flushing with water, fill 2002
with approx. 5.5 quarts of pure Antifreeze, then add water later. This is because after flushing, there is 3 Series E21
always some water remaining in the engine block.
3 Series E30

* This is good opportunity to tackle the PS hose that leaks by cutting short section and reposition it. 3 Series E36
* Drain and refill x 2. For each cycle, run engine, turn steering wheel right and left twice to mix fluid 3 Series E46
then drain and fill with Mobil Synthetic ATF. 5 Series E12
5 Series E28
-------
Let start: 5 Series E34
1. Drain Antifreeze and dispose properly 5 Series E39
2. Study the 528i Belt System Layout: 6 Series E24
7 Series E23
7 Series E32
7 Series E38
8 Series E31
X5 E53
Z3
Z8 E52
CS E9
Senior Six E3

Model-specific Lounges
E32 Lounge
E36 Lounge
E38 Lounge
E46 Lounge
In reality, this is what it looks like:

Regional Forums
Australia
Canada
United Kingdom
Netherlands

Forums for Local BMW

Car Clubs
Dallas
Southern California
 Minneapolis
Atlanta

3. Loosen the Fan Clutch Nut a few turns but do not remove it yet. Note the Screwdriver trick between
the WP small nut and the large 32-mm nut. NOTE that this is a 32-mm nut REVERSE Thread. It
comes out together with the Fan Shroud.
4. Remove Circlip holding the Reservoir. Disconnect the Overflow Hose at the Reservoir and Remove Fan Shroud as shown, at
this time the Fan Clutch/Blades assembly comes out. If ONLY doing the belts, then suspend the Reservoir temporarily with some
wiring. Otherwise, Disconnect the Heater Hose and remove the Reservoir:
5. Remove Radiator by removing the 2 clips holding radiator (8-mm bolts). NOTE: each clip has 2 rubber inserts, do not lose
them. Also remove the Temp Sensor.
*** Under the Factory Radiator, there are 2 Rubber Pieces, Transfer them to the new Radiator!
6. Remove the AC belt by applying Clockwise tension on the Roller. This puts pressure on the Hydraulic Tensioner. Remove the
Roller and Hydraulic Tensioner and install new parts.
*** NOTE: when installing new Roller, place a small piece of wood between the Roller and Crank Pulley to allow tightening the bolt
without damaging the crank pulley:
7. Remove the WP-Alt-PS belt by applying Clockwise tension on the Roller. This puts pressure on the Hydraulic Tensioner.
Remove the Roller and the Arm that holds the Hydraulic Tensioner (which sits in the back of the Arm). Replace the Hydraulic
Tensioner. Reinstall the Arm with new Hydraulic Tensioner; then install new Roller.
8. Remove Thermostat Housing (Note the Engine Hook) & Remove Thermostat:
9. Remove WP Pulley & Remove WP:

10. Scrape old gasket, making sure mating surfaces are clean and smooth to avoid Antifreeze leak later:
11. Set Heater on HOT and Flush with garden hose as shown:

12. Install Water Pump. Note New "Hepu" WP:

13. Install Thermostat with vent hole UP. O-ring goes on the OUTSIDE.
14. Install Thermostat Housing. Do NOT forget the Engine Hook.
15. Install New Radiator, making sure the Rubber Pieces (transferred from Old Radiator) sit properly on proper locations. Install
the Radiator Clips with 8-mm bolts, making sure the rubber inserts are used. Now install the Temp Sensor, use the copper washer
supplied with new Radiator with Temp Sensor; do not over-tighten as this can crack the plastic and you will buy another Radiator!

16. Install New Upper and Lower Radiator Hoses.

17. Install New Reservoir and new Bypass Hose (snake hose). Do not tighten the reservoir side of the snake hose yet because
this needs to be disconnected later to install the Fan Shroud.
18. Fill Antifreeze through the Bleed Hole. Use 5.5 quarts of pure Antifreeze. The rest is distilled water:
--------
19. At this stage, I redid my PS hose leakage by cutting a small section of the hose and use a fresh area for connection. Use a
new clamp. No more leak. Drain and Fill with Synthetic ATF as noted above. Keep water out of PS reservoir for this phase! Run
engine, turn steering wheel right and left x 2; Drain and Fill with Synthetic ATF x 2 cycles.
---------

20. Reinstall Fan Shroud; slide the new Fan Clutch/Blades assembly in together with the Fan Shroud but do NOT install the Fan
Clutch/Blades assembly yet. This allows movement of the Fan Shroud for proper installation. The Fan Shroud should fit nicely on
the appropriate clips.
21. I broke the fan rim holding the Reservoir’s Bleed Screw (BTW, this system is very flimsy so see my zip ties trick):
22. Go through your check list to be sure nothing is forgotten.

23. Now install the Fan Clutch/Blades assembly (use a small amount of Antiseize here) by using the 32-mm wrench to turn
COUNTER-CLOCKWISE and spin it. Then use the wrench to give it a quick jab. No need to over tightening it. Engine rotation will
tighten it over time.

24. The E39 is notorious for air pocket, so be patient when refilling the Cooling System. Raise the Front End will help. You will
need to go through a few cycles of bleeding air and refill before it is OK.
Check Coolant Level daily for one week.
One week later check to be sure the Antifreeze is 50-50 and protection down to –34 deg F or so (check the Antifreeze bottle for
data).

25. HAVE A BEER (OR WINE)!

----
BONUS: The Hydrualic Tensioners are not hydraulic at all. I did an autopsy on one and it is simply a spring inside, filled with
engine oil. So it works like a spring. The problem is over time, the rubber boot cracks and oil leaks out.
In theory one can save $40-50 by using new rubber boot (where to buy?). Not sure if this can be filled with grease instead???
The 5 Series E39 Forum | Message Thread:

z ENTIRE COOLING SYSTEM REPLACEMENT Tips and Tricks (Very Long, Enjoy!) (pic) - CNN-090 2006-05-14
04:27:25 (131217 views)
{ Re: ENTIRE COOLING SYSTEM REPLACEMENT Tips and Tricks (Very Long, Enjoy!) - xrjunky 2011-03-18
06:28:56 (119 views)
{ The censorship at roadlfy is 'low-class' and disgusting - CNN-090 2006-06-16 23:32:13 (3370 views)
{ HEPU Water Pump holding up nicely 1 month/1K miles later..... (url) - CNN-090 2006-06-02 19:31:04 (3567 views)
„ HEPU Water Pump Info for those who want to know... (url) - CNN-090 2006-06-02 19:47:54 (4859 views)
{ Re: ENTIRE COOLING SYSTEM REPLACEMENT Tips and Tricks (Very Long, Enjoy!) - yrwei52 2006-05-19
12:14:09 (3978 views)
„ My answers to your questions (url) - CNN-090 2006-05-20 15:44:05 (3217 views)
„ Re: My answers to your questions - zona2010 2010-07-08 09:10:00 (257 views)
„ Re: My answers to your questions - yrwei52 2006-05-23 23:24:04 (1612 views)
„ Re: ENTIRE COOLING SYSTEM REPLACEMENT Tips and Tricks - yrwei52 2006-06-14
03:46:05 (2312 views)
{ The mORE rEASONS TO kEEP YOUR Cooling System in Top Shape: The HEAD GASKET (url) - CNN-090 2006-
05-18 12:20:25 (3839 views)
{ That is an outstanding example of documenting your work. Definite e38.org material. (nt) - DavidC 2006-05-
17 02:32:42 (1469 views)
„ It had 'only' 550+ viewings in 2 days! Must have been useful to people! (nt) - CNN-090 2006-05-17 09:32:50
(1349 views)
{ 88C thermostat gauge temp pic (pic) - CNN-090 2006-05-16 09:32:55 (3613 views)
„ BMW and VDO temp gauge (pic) (url) - CNN-090 2006-05-17 15:18:27 (3189 views)
„ The gauge is dead center ... - srr2 2006-05-16 12:37:06 (1830 views)
 „ Re: The gauge is dead center ... - jimcash 2006-05-16 12:47:15 (1550 views)
„ Jim, I may be wrong but VDO makes gauges for BMW (url) - CNN-090 2006-05-16 12:53:47
(1299 views)
„ Re: Jim, I may be wrong but VDO makes gauges for BMW - jimcash 2006-05-17
07:53:17 (1196 views)
„ Ideas for Testing gauge readings (pic) - CNN-090 2006-05-17 09:51:47 (2021 views)
„ Jim, For my info what temp does it have to be - CNN-090 2006-05-16 12:49:19 (1284 views)
{ My Observations - dan 2006-05-14 23:04:28 (2433 views)
„ Great input, the more input the better...... - CNN-090 2006-05-14 23:21:05 (1542 views)
{ Forgot a few pictures (pic) - CNN-090 2006-05-14 20:13:54 (7540 views)
„ MANUAL TRANS FOLKS! When Raising the Front - CNN-090 2006-05-17 10:34:34 (1998 views)

{ Thanks - This should be very helpful (nt) - Roderick 2006-05-14 19:04:52 (1209 views)
{ Re: ENTIRE COOLING SYSTEM REPLACEMENT Tips and Tricks (Very Long, Enjoy!) - jimcash 2006-05-14
07:11:02 (3968 views)
„ From what I understand, Bosch Motronic FI system - CNN-090 2006-05-14 13:01:49 (1890 views)

The 5 Series E39 Forum requires users to register before posting new messages.

Click Here to Sign In / Register

Home | Privacy Policy | Terms of Service | Glossary | Advertising

Questions, comments, problems, please email webmaster@bimmerboard.com

©Copyright 2003-2011 BimmerBoard, LLC, All Rights Reserved.

No content from this web site may be reproduced or copied in any
form without the express written consent of BimmerBoard, LLC.

The BMW name and logos are registered trademarks of BMW AG

and BMW of North America, LLC.