Mari Maglio

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Subject: ENTIRE COOLING SYSTEM REPLACEMENT Tips and Tricks (Very Long, Enjoy!) Author: cn as CNN-090 : member since July, 2004 : 1090 posts Posted on: 2006-05-14 04:27:25

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 Department. After everything is removed then it was clear that nothing has been replaced thus far.
I am the 4th owner and did the entire cooling system. Parts List and places bought from:

1. BMW Dealer:
Thermostat Plastic Housing. This sound funny but both Aftermarket Aluminum Brands (Ronak and MTC) are known to leak at 6-12 months later. My BMW mechanic recommends only Dealer Plastic Tstat Housing.
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
* WP-Alt-PS belt 6PK1560 $13
* Rollers x 2 PN 11281748131 $17/each
(for AC belt and for between Crank and WP Pulleys)
* Idler Roller PN 11281738605 $23/each
(this sits between WP and Alternator Pulleys)
* Hydraulic Tensioner PN 11281717210 $39/each
(for AC belt)
* Hydraulic Tensioner PN 11281717188 $50/each
(for Roller between Crank and WP Pulleys)
* Coolant Reservoir "Mounting Clip" PN 17111723580 $2.20/each
* Fan Clutch by "Sachs" PN 11521719269 $94/each
* Fan Blades by "MTC"� PN 11521712058 $23/each
* Radiator by "Nissens" PN 17111702969 $173/each
(many people think this is better than Behr Radiator)
* Bypass Hose from Radiator to Reservoir PN 17111427156 $5.60/each

3. www.bmw-parts-direct.com
* Coolant Vent Screw PN 17111712788 $2.80/each
* Reservoir Cap PN 17111712669 $10.60/each
* Reservoir by OEM PN 17111723520 $56/each
* Water Pump by "Hepu" PN 11511740241 $67/each
(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 love Hepu Water Pump so I go with "Hepu".

GENERAL NOTES
* My car has Hydraulic Tensioners. Some E39�s are equipped with Mechanical Tensioners, check before buying parts.
* Go with your budget, I will discuss what needs to be replaced and what is an option.
* 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 cap, dipsticks, PS cap (which has a vent hole so cover it with ziplock bag). Keep tools away from water!
* Apply small amount of "Antiseize" on all these nuts and bolts for easier removal later.

* 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:
- Factory WP bearing has a little play but no leak yet.
- All 3 Rollers have some play, grease dried out. If tight on budget, one can re-grease them, be careful not to damage the seal (use a picking tool). However, I used New rollers x 3.
- 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.
- The belts were cracked and overdue (but I am not these are original or have been replaced before)!

* One can use BMW OEM Antifreeze but it is a bit pricey. From my own research, Prestone "Extended Life" Antifreeze is excellent and it is rated up to 5yr/150K whatever it means: 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 frequently than 5yr/150K! So I will flush somewhere in between 2yr/24K and 5yr/150K.
Note: Antifreeze Capacity for 528i is 11.1 quarts. To ensure 50-50 mixture, after flushing with water, fill with approx. 5.5 quarts of pure Antifreeze, then add water later. This is because after flushing, there is always some water remaining in the engine block.

* This is good opportunity to tackle the PS hose that leaks by cutting short section and reposition it.
* Drain and refill x 2. For each cycle, run engine, turn steering wheel right and left twice to mix fluid then drain and fill with Mobil Synthetic ATF.

-------
Let start:
1. Drain Antifreeze and dispose properly
2. Study the 528i Belt System Layout:

In reality, this is what it looks like:

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???

DIY Guide: N54 335i Serpentine Belt, Tensioner, Upper and Lower Pulley Replacement
First DIY Guide for me
Just paying it back to the community for all the knowledge I learned here.
Being a Realtor; I don't mind getting my hands dirty.

I am by No Means a Mechanic, but had my share of experience owning my 2007 335i Sedan for over 2 years. So I take no responsibility for any errors, and your own mistakes.....I take no responsibility for providing this guide, whether you follow it or not.

If you feel you can contribute to this guide; please by all means PM me, and I will edit as needed.
No Oil Cooler on my car.

Additional tasks I had to do at the same time. (not covered here.....but this gave me a lot of room to work with.)
Inspect Spark plugs.
OFHG (Oil Filter Housing Gasket).......2nd time after 11 months.
Removing Radiator Fan Only.

Required Tools.
Torx bits.
T20
T25
T50
T60

Sockets:
6mm
10mm - for belly Pan
1/2inch breaker bar, 15 inch or longer.
New Tensioner and Pulleys should come with new Bolts.....Mine did...and all OEM.

Total Cost of Parts to me at least:
Tensioner Part# 11287563927: $104.16
Belt Part# 11287628652: $50.11
Upper Pulley Part# 11287556251: $44.07
Lower Pulley Part# 11287557851: $44.07

Step 1. (Lots of DIYs) on how to do the following
Get your Car up on Ramp. or jacked up front end on jack stands.
Remove belly pan....15-17,,,,,10mm screws. (give you move light while working)
Remove engine cover. (optional.....I did....which means removing Remove charcoal filter and cowling.)

Work on a cold car so you don't have to worry about burning yourself on a hot engine.

Step 2: Remove 2 screws using T20 on Air Intake and remove air intake duct to Air Filter Box.

Step 3:
6mm to loosen Hose clamp off of Air Filter Box and remove air duct.
Also turn and release the other pipe shown in picture below.

Step 4:
2 Arrows on the Right on the picture, Simply unclip the Coolant hose and AC Line.....just pull it gently.
The Arrow on the left is optional but this clip is Latched.....press on the front to release the right side of the clip.
The 2 Circles are T25 that need to be removed. These hold the Air Duct. When removing, they will be accompanied by an metal grommet that is inserted in a rubber housing on the air duct support. you will have to pull them out.
Now the Air duct can move out of the way....just barely to give you access to the job at hand.

Step 5: Extremely Important step:
Draw the Map of your Belt.....else you won't know how it goes back on.
here is what I drew.....Man I am an Artist.

Step 6: Remove the Belt by turning the Tensioner T60 clockwise to release the Tension and Slide Belt off of Tensioner.....breaker Bar really Helps here.

Step 7: Remove the Dust Caps off of the Tensioner and Both Pulleys by prying the Dust Caps off using Small Flat Head.
Place your other hand in front of each dust cap, else they will fly off. Also NOTE: all 3 are different sizes.....so note which goes where.

Step 8: Remove the Tensioner and Both Pulleys....you will need a T50 for all.
here are the Torque Specs officially from Dealer.
http://www.convertunits.com/from/N+m/to/ft+lb
when installing the New Tensioner, DO NOT pull the lock pin, untill you have torqued The Tensioner and both pulleys. Finally using Breaker bar on a T60 remove the lock PIN and Mount your New Belt. (Don't forget the to Put the Dust Caps Back on).

Keep in mind and double check that the grove in the Belt is in the grove on each wheel.
Finally when you are ready to add the belt to the tensioner.....do it last.....alternator first, tensioner Last.

Reverse Order to complete.
Have a Friend or Wife at the Wheel and ask them to Start the Car once all is done. and advise them to turn off immediately if any issues arise.

Bash Shah
Sutton Premier Realty

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4. Hiring Trends in the Fintech Sector Presentation
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6. Meeting Agenda Presentation
7. Sales Report Presentation
8. Press Release Presentation
9. Statistical Presentation
10. Product Presentation
11. Market Analysis Presentation
12. Business Annual Report Presentation
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14. Minimalist Fashion Design Presentation
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16. Marketing Plan Presentation
17. SWOT Analysis Presentation
18. Best Workout Apps Presentation
19. Architecture Studio Presentation
20. Financial Report Presentation
21. Digital Marketing KPIs Presentation
22. Technology Research Presentation
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25. Consulting Presentation
26. Business Case Study Presentation
27. Wedding Photography Presentation
28. Investor Pitch Deck
29. Mobile App Pitch Deck
30. Travel Pitch Deck
31. Cab Service Pitch Deck
32. SaaS Pitch Deck
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34. Influencer Marketing Pitch Deck
35. Visual Brand Identity Presentation
36. LittleBlue Brand Guidelines Presentation
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39. HanaEatery Brand Guidelines Presentation
40. Atmoluxe Brand Guidelines Presentation
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42. Project Management Presentation
43. UX Strategy Presentation
44. Web Development Proposal Presentation
45. Human Resources Presentation
46. Team Project Update Presentation

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This project status update presentation template is designed with teams in mind, and helps project teams of all kinds and sizes report their progress in a visual and engaging way. Use this template for your own needs, and change the colors, fonts, text, visuals, icons and more in Visme's drag-and-drop editor.

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Best Presentation Templates for Training & Education

In this section, we have put together a list of the best presentation templates for business trainings, webinars, courses, schools and educational institutes.

Scroll down to find your pick or click through the menu below.

1. Business Studies Presentation
2. General Culture Presentation
3. Literature Presentation
4. Current Events Presentation
5. Entrepreneurship Presentation
6. History Presentation
7. Science Presentation
8. Health Presentation
9. Media Presentation
10. Worldschooling Presentation
11. Life Skills Presentation
12. Book Report Presentation
13. Training Plan Presentation
14. Science Trivia Presentation
15. Lesson Plan Presentation
16. Group Project Presentation
17. Graphic Design Course Presentation
18. Technology Webinar Presentation
19. Entrepreneurship Course Presentation
20. Public Speaking Workshop Presentation
21. Digital Marketing Webinar Presentation
22. Remote Team Training Presentation
23. Sales Training Presentation
24. Organizational Culture Presentation

47. Business Studies Presentation

This simple digital marketing presentation template is great for presenting in class by a student or a teacher. It has a useful "what is" layout that helps with explaining definitions and how something works. Perfect for educational purposes and you can customize it however you want.

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48. General Culture Presentation

This creative presentation template is based on the topic of art and graffiti, but you can customize it for any other subject or topic. It features 5 beautifully designed slides with ample visual elements, including a pros and cons comparison table, to make any kind of information look instantly engaging.

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49. Literature Presentation

Educate your class on the life of a famous author, poet or personality like William Shakespeare with this creative presentation template. It features 4 well-designed slides, including one with a detailed timeline perfect for highlighting important events or details of someone's life.

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50. Current Events Presentation

Want to present a global, national or social issue in class? This current events presentation template for students and teachers is the perfect fit. It has 5 complete slides with a pros and cons table, and also a quote that you can swap for your own with just a few clicks.

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51. Entrepreneurship Presentation

This is the best presentation template to introduce a concept or idea, especially if you're presenting to students in an entrepreneurship or business class. It has a visually appealing design with background images, graphic elements and a bright color scheme that you can edit.

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52. History Presentation

This dinosaur timeline presentation template is great for use in history class or even biology class. It features 4 creatively designed slides, including one with a colorful timeline, which you can customize with your own images, fonts, colors and content in the Visme editor.

53. Science Presentation

Present science topics in class with this engaging presentation template that focuses on a space exploration theme. You can customize this presentation template with your own colors, icons and text. Add animations and interactive links, duplicate slides and do more with Visme.

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54. Health Presentation

Customize this how-to presentation template for your next project in health class. This is the best presentation template to create awareness around an important health issue or even for educating the general public on first-aid or other health-related knowledge.

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55. Media Presentation

Need a fancy timeline? This media presentation template has got you covered. Show how an idea, concept, product or any other object has evolved over time with this creative timeline presentation. Customize the colors, add your own images, change the font and much more.

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56. Worldschooling Presentation

This worldschooling presentation template is perfect for education-related topics. It features 4 well-designed slides with maps, images, fun fonts and other visual elements that make it a great pick for topics that are to be presented in class by students or teachers.

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57. Life Skills Presentation

This visually appealing presentation template is ideal for illustrating tips, tricks, how-to tutorials and other purposes that require several sections. You can easily customize and duplicate each slide, add or remove elements and swap the content for your own in Visme's editor.

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58. Book Report Presentation

This stunning book report presentation template has all the slides you need to dive deep into themes, storyline and other elements. The 10 slides feature a mix of text-based content and graphics, such as a visual timeline and mini infographics. Customize it with ease in Visme.

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59. Training Plan Presentation

This is the best presentation template for training plans and courses. It has a set of 13 slides that help you organize the training, break it up into different sections, and communicate course objectives and training content in a visually engaging, effective way.

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60. Science Trivia Presentation

Whether you want to present some fun facts in the class or quiz your students, this science trivia presentation template is a great fit. You can customize the color scheme, change the fonts, plug in your own content and you're good to go! Make use of data widgets and icons for more impact.

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61. Lesson Plan Presentation

Creating a lesson plan from scratch can be frustrating. Use this pre-designed presentation template with 8 handy slides to help you communicate lesson objectives, methods, assignments and more. You can easily customize the colors, fonts, icons and more with just a few clicks.

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62. Group Project Presentation

This group project presentation template is great for students working and presentation together. It has several slides that are all fully customizable, including one for team members. The data visualizations help you communicate stats and figures in an easy-to-understand and engaging way.

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63. Graphic Design Course Presentation

This colorful graphic design course presentation is ideal for webinars, online courses, training sessions and even the classroom. It's visually engaging with intuitive use of icons, lots of white space and an upbeat, lively design. Use it as it is or customize it to fit your unique design and content needs.

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64. Technology Webinar Presentation

Looking for a creative technology presentation? Look no further than this technology webinar presentation template. Put together an informative and visually engaging presentation with professionally designed slides, lots of technology images and a geometic, futuristic design.

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65. Entrepreneurship Course Presentation

Educate your students and attendees on entrepreneurship with this informative presentation template. This template can be used in classrooms or for business trainings, webinars and online courses. It's chock full of data widgets, icons, charts and other visual elements, and also comes with tailor-made, original content to help guide your own.

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66. Public Speaking Workshop Presentation

Public speaking can be tough, which is why a presentation like this one can help you train the attendees effectively with its engaging design, data visualizations and bold images that instill confidence. Use this workshop presentation template as is, or customize it for any other topic.

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67. Digital Marketing Webinar Presentation

Break down the concept of digital marketing, ads, social media marketing and other concepts using this educational presentation template. This template can be used in schools and universities, or in business trainings and webinars. It can easily be edited to fit your topic, content and design needs.

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68. Remote Team Training Presentation

This remote team training presentation template is incredibly useful for businesses that are transitioning to a partially or fully remote work environment. Your team needs to learn how to effectively manage a remote team, and this presentation can help you do just that. Use it as is, or tweak the content and design inside easily.

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69. Sales Training Presentation

Educate sales teams on how to improve their sales processes, polish their skills and bring in more revenue for the company with this sales training presentation template. This template is designed with a modern corporate look-and-feel with bold colors, lots of visuals and a sleek, sophisticated design.

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70. Organizational Culture Presentation

Nothing is more boring than a dry, plain-looking PowerPoint presentation. So, why not take things up a notch and create a bright, colorful presentation to keep your audience engaged till the very end? This organizational culture presentation template can be used for trainings, webinars and the classroom alike. You can also use it for other purposes by editing the content and design. It comes with a nice process slide, images of people that you can easily replace and other useful visual elements.

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Best Presentation Templates for Nonprofit

We also have a list of the best presentation templates tailored to the needs of nonprofit organizations. Find your pick from a selection of presentation templates on wildlife conservation, pet adoption, nature and environmental issues, and more.

1. Art Project Presentation
2. Nonprofit Environmental Presentation
3. Nonprofit Annual Report Presentation
4. Pet Adoption Presentation
5. Wildlife Conservation Presentation
6. Animal Background Presentation
7. Education Support Program Presentation
8. Public Health Awareness Presentation
9. Breast Cancer Awareness Presentation
10. Poverty Alleviation Presentation
11. Women Empowerment Presentation
12. Mental Health Presentation

71. Art Project Presentation

This art project presentation is great for all kinds of nonprofit organizations, schools and even businesses. It's full of creative data visualizations that you can customize and even animate. Whether you're presentation an idea of an art competition or just reporting project status, this presentation template can easily fit to your purpose.

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72. Nonprofit Environmental Presentation

If you're looking to create awareness about the environment or just require a nature-themed presentation template for your next project, this green slideshow might be just right. It features several slides designed with the environment in mind, with nature images and even data visualizations to help you communicate your cause and project updates.

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73. Nonprofit Annual Report Presentation

This nonprofit annual report presentation template is perfect for showcasing those strong numbers and building your case for fundraising. You can swap the existing content, colors, images and any other visual element for your own in Visme's intuitive presentation maker.

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74. Pet Adoption Presentation

This adorable pet adoption presentation template can be customized for your own nonprofit organization with a few clicks. It features a handful of cute pet images, which you can easily replace with your own photos or the ones you choose from Visme's free stock image library.

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75. Wildlife Conservation Presentation

Raise awareness about wildlife conservation or any other related cause with this customizable presentation template. The creative slides feature an effective blend of images, text and data visualizations to help you communicate all the right information in a visually engaging manner.

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76. Animal Background Presentation

This is another wildlife or animal related presentation template that you can use for your project, cause or nonprofit organization. You can replace the images with your own, change the color scheme and do much more in Visme's drag-and-drop presentation software.

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77. Education Support Program Presentation

Show how your nonprofit or social project is making a difference in the lives of children with this education support program presentation template. You can also modify this template according to your own content and design needs, add images, icons and data visualizations, and download it in PowerPoint or PDF format.

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78. Public Health Awareness Presentation

This health awareness presentation is a great fit for government organizations, nonprofits and medical institutions that want to educate people on public health topics, such as COVID-19 and vaccines. Use this presentation template as is, or change the colors, text, visuals and icons inside to suit your own needs.

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79. Breast Cancer Awareness Presentation

Educate your audience on the topic of breast awareness, and encourage others to support your cause using this cancer awareness presentation template. This template already comes with a feminine color scheme fit for the topic of breast cancer, but you can modify it easily according to your content and design needs.

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80. Poverty Alleviation Presentation

Raise awareness, funds and support for your cause with this poverty alleviation presentation template. This template can be used by nonprofits, government programs and even businesses running corporate social responsibility projects. Customize the color scheme, fonts, text, images and other features of this presentation template, and use it to reach your nonprofit goals.

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81. Women Empowerment Presentation

Just like the subject of feminism and women empowerment, this presentation template is bold and powerful. Use it as is, or modify the content and design to suit your unique needs. This women empowerment presentation template can be used by nonprofits, feminist organizations and even businesses looking to educate their employees on gender and diversity topics.

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82. Mental Health Presentation

This mental health presentation can help you educate your audience on issues and topics that matter the most, such as psychological well-being and what to do if someone you love is affected by mental illnesses. Use this presentation template as is to generate awareness, or edit the content and design inside to suit your unique needs.

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Find the Best Presentation Template For You

Finding the right presentation template is the first step in creating a powerful slideshow. This list of the best presentation templates will help you get started.

Sign up for Visme's presentation software today (it's free!) and start using your favorite template.

Did you find the best presentation template for your next project? Let us know which one you liked best or if you're looking for something specific.