Roku gets hands dirty...

[Roku35]

With my business and work really bearing down on my time, I finally hit my breaking point. I noticed a coolant leak with Polaris a month ago, so in my usual fashion, I started acquiring the parts needed to do a complete coolant hose, T-Stat, gaskets replacement job. I noticed coolant on one of the belts (which sprays the coolant around) only when the car is running. No leak when car is not running. The belts were spreading coolant to the bonnet foam and making it deteriorate out (its old and rigid).

So my plan was to acquire all my parts and take her in for the annual coolant and oil service. OR SO I THOUGHT. Wanting desperately a break from all my stress, I usually take Polaris out for a 20-30 minute spin (loud and proud driving) and then I'm good. However, my loud and proud lady is leaking fluid and I don't want to make it worse than it is. The weekend is here, work is still killing me....I finally hit the point of no return in my patience and want to get THIS gal back on the road.


I think to myself. I'm a very handy guy with tools and construction, how hard could it be? Hoses, thermostat, radiator...? I can see and reach everything. I know where everything goes and have all the parts for a one for one replacement. AWWWW $#!+, just go for it!

I dig in... drain fluids, undo hoses (damn theres lots of fluid everywhere) Haha. Thermostat...damn radiator is in the way. Fine then, pull the radiator, damn fan shroud, pull that to (I hope I can get this in the same way it came out) Haha... Hey this is actually more fun than I thought. What else can I pull...STOP! Haha (don't get carried away). Inspecting the old hoses, I couldn't find where coolant would be coming from. Fingers crossed, the parts and new hoses start to go back in. Radiator and fan shroud slip in...hmmmm how does this align properly...wait let me attach the new hose at the bottom of the radiator and then slide this puppy in. Bingo! Alignment of fan and radiator amazingly fit right into place, screws and bolts...check. 80 degree-Thermostat and gaskets okay. Wait a minute, this part looks different (it is) :(:(:( All hands stop! What a real bummer. Just like coordinating construction projects, missing material just doesn't cut the mustard when trying to get a job done. So off to the local parts store to find a replacement (even though it is not OEM). I got to get this girl back in circulation for my own sanity.

Standby for my "hands dirty" conclusion...it better be a happy one :D

[Freshbread]

Good for you to turn some wrenches, makes ownership very rewarding in the end. May not seem that way all the time though:D

Something to maybe address considering your description of how it is leaking "only when running" makes me automatically think water pump. Might want to address it "while you're in there". Pelican has the pulley tool needed to get the fan clutch off.
Good luck Carl!

[ShapeShifter]

Good for you! When your done and driving down the road thinking "yeah, I fixed it!" you will realize how rewarding DIY can really be. Some days I find the "stress" of working on cars a great way to relieve the real stress of life.

Just remember, it's only kinky the first time. A little job here, a little job there, and before you know it, you're ready to take on major surgery.


Now, only of I could go for a twenty minute stress relieve drive in my shark....

[tlister67]

Right on. I have learned quite a lot on my 633. Pretty easy to work on with lots of room to operate.

[e24uard]

I had a broken bleeder bolt on my t stat housing and had to replace it. Annoyingly, the replacement part pointed the coolant hose in a different direction, which means that the hose is now <1mm away from the fan.

[RSheiman]

Anyone have ideas on how to make coolant change a little more enjoyable? I just did this and well, some of my neighbor's plants may mutate. Also my waterpump is 6 years old, but only about 8k miles old. Opinions on putting in a new one?

[Roku35]

Good for you to turn some wrenches, makes ownership very rewarding in the end. May not seem that way all the time though:D

Something to maybe address considering your description of how it is leaking "only when running" makes me automatically think water pump. Might want to address it "while you're in there". Pelican has the pulley tool needed to get the fan clutch off.
Good luck Carl!


Okay, let the grunting begin...I was able to put everything back together just fine yesterday afternoon with a new T-stat and gaskets and everything looked good. I did another tight down of all the hose links and was ready to get the coolant back into the car, bleed the system and be back on the road again......OR SO I THOUGHT! :mad

I decided to check how great a job I did...(leak test). I pour in a couple quartz of the green coolant and figured that I better check all the seals before pouring everything in. GOOD THING! I noticed that now the leak started from somewhere behind the belts. This time, the car is off and the leak is continuously on. Very slow, maybe a drop a minute, but it never dripped when the car was off. :mad:mad

Water pump? Does this mean even more of an over haul? Is this something that I can tackle myself? Getting frustrated with what I think should be a easy replacement job. How can I check the water pump?

[Freshbread]

Anyone have ideas on how to make coolant change a little more enjoyable? I just did this and well, some of my neighbor's plants may mutate. Also my waterpump is 6 years old, but only about 8k miles old. Opinions on putting in a new one?

Sorry RSheiman I meant to answer your inquiry too! Kitty litter boxes! Seriously! They work awesome and are cheaper than any automotive equivalent.



Water pump? Does this mean even more of an over haul? Is this something that I can tackle myself? Getting frustrated with what I think should be a easy replacement job. How can I check the water pump?

Yes water pump no better time to do it. With everything you have out if it was my car I would do it...not something you want to wait until it fails, just do it while you have a great opportunity. I think a large portion of this forum can do 75% of all maintenance required on this car, the other 25% may not have the tools. A new repair often means an excuse to buy new tools...makes the job that much easier:)
Don't get frustrated...take your time and spray penetrating fluid all the bolts if you decide to do it. A 32mm wrench is require for the fan clutch. I'll let Chris post the details;)

This is a side view of the pump...basically right below the t-stat housing. Use a mirror to look under the pulley as you may see evidence of coolant leaking.
http://www.r3vlimited.com/board/attachment.php?attachmentid=1815&stc=1&d=1143042517

Water pump pulley tool
https://encrypted-tbn2.google.com/images?q=tbn:ANd9GcRlNxsEopUWCyy2vc1h3mSNpqwTSZ_ZK 9ITetuXVwRQ5Z6-VnxMuQ

[espoe]

Be sure to have a thin 32mm wrench and the pulley tool. I have been battling from improvising without them. A rookie mistake. Turned a simple job into a real problem.

[M6csi]

Okay, let the grunting begin...I was able to put everything back together just fine yesterday afternoon with a new T-stat and gaskets and everything looked good. I did another tight down of all the hose links and was ready to get the coolant back into the car, bleed the system and be back on the road again......OR SO I THOUGHT! :mad

I decided to check how great a job I did...(leak test). I pour in a couple quartz of the green coolant and figured that I better check all the seals before pouring everything in. GOOD THING! I noticed that now the leak started from somewhere behind the belts. This time, the car is off and the leak is continuously on. Very slow, maybe a drop a minute, but it never dripped when the car was off. :mad:mad

Water pump? Does this mean even more of an over haul? Is this something that I can tackle myself? Getting frustrated with what I think should be a easy replacement job. How can I check the water pump?

Underneath the water pump body, there is a small weep hole under the internal bearings (covered by some semi-solid material), that will eventually fail. Once this happens, a new replacement pump will need to be installed. Feel under the water pump, if you feel dampness, then most likely this is the culprit.

It is a faily straight forward job, not at all difficult. A series of bolts are used to mount the pump, there is one bolt that is longer than all the others, pay particular attention where this longer bolt is located. When installing pump gasket, use a small amount of gasket sealant to hold in place, then mount pump. Remeber to scrape away and clean all the old gasket material prior to installing new pump and gasket.

BMW factory water pumps are very expensive. Suggest you get the Graf water pump (about $55), excellent quality and made in Germany. Stay away from the Bosch water pumps...they are usually third world made junks.

Roku, I have a feeling that soon you will become a automitive tool junkie. :stickoutt Have fun and be safe! There is great satisfaction in working on and maintaining your own car.

[TJC1]

I agree with Freshbread and M6csi, you can do this job without too much drama.

As to a gasket sealant may I suggest Gascacinch. It's a liquid that comes in a can with a brush applicator and is very easy to use. I've used it for many years and I much prefer it to the silicone or RTV type of sealers for this application.

[Layne]

I would probably buy new bolts for the water pump before beginning. They tend to corrode and breaking one off would be bad news. These are about the easiest engines to change a water pump on, so I say go for it.

[Bentsdl]

And grease the bolts with coppergrease to prevent future corrosion, you will thank yourself later.

[MrtnEbb]

I would probably buy new bolts for the water pump before beginning. They tend to corrode and breaking one off would be bad news. These are about the easiest engines to change a water pump on, so I say go for it.


And grease the bolts with coppergrease to prevent future corrosion, you will thank yourself later.

+1

[TEZA]

If it leaks behind the belts it is the water pump. and it then sprays everything as the coolant gets picked up by the fan. I just went through this. You have already done everything to get to the water pump. No just do it all over again.

[Roku35]

:shifty Well the leak has been realized. It is at the water pump. $@%#! Oh well, the decisions to do it myself or drive her down to my guys is weighing in on me. Not like I have much time to tinker in the garage, let alone do a major overhaul of the water pump. How much time for a newbie to pull this off? I am almost ready to press the button on purchasing all the parts and tools I would need (via Pelican Parts), but the removal and replacement of the belts and fan clutch are a concern to me. After the radiator and fan shroud comes out, I guess the fan and associated parts are next. I'll have to start researching the links/threads here. Looks like the wifes car will be outside for a while until I can get this taken care of. Could get ugly really fast...:nono

[Bert Poliakoff]

Wopn't get ugly. Once radiator and shroud are out/off, remove the fan clutch and the water pump is right there. it isn't a nightmare job.

[ShapeShifter]

Should take under two hours for a first timer.

[dm635]

Do it yourself. If time is a concern, just do a little at a time, you'll be done before you know it. Saved $$$ & learned more about your ride along with the satisfaction of doing it yourself. These cars are easy to work on, but every car has something that's a royal PITA. But the water pump isn't one of them on the M30. I got a cheap 32mm wrench at a bicycle shop. It's thin, about a foot long, works great & been using it for years. With what you just did you were right at the water pump. I think it can be done without removing the radiator again. As stated, use new bolts.

[Roku35]

Okay guyz, I'll dig in and get the job done myself. Will get my order into Pelican tonight. I'll go check our bike store for a 32mm thin wrench as well on my way home. At least I know my confidence is about 20% there :rolleyes

[ShapeShifter]

I use a craftsman 32mm without problem. A quick firm smack with a hammer gets it loose.
Don't forget the fan clutch is right loosey, lefty tightie.

[Freshbread]

At least I know my confidence will be 100% through the roof after i do this :rolleyes

Fixed


I use a craftsman 32mm without problem. A quick firm smack with a hammer gets it loose.
Don't forget the fan clutch is right loosey, lefty tightie.

Same here.

[Roku35]

Okay, it has been a month and I have not been able to uncover my project to get it done. All parts have been taken off and connections cleaned. I haven't had a moment to get the new parts back on. Any dangers in leaving my pipes open for this long? Life has just got me by the b@!!$ right now. New contracts are brewing and working at all hours is not helping. Spending time with my son/family before he starts school is great on weekends so one day or another I just got to say #%$^! it and get this done. I was afraid this was going to happen when I started and it happened. Oh well, I had good intentions. The bad part is after I do this…my car better be good to go and my leak taken care of. Fat chance right??

[gaspump]

As you said, if all the stuff is off; ie, radiator, belts, gasket's, then just take your time and take the water pump off. It's not hard. Just put the things back in the order they came off. A water pump just bolts on to the motor, that's all. Gaskets are easy, as are the belts. Take your time and you'll be fine.

[88m53453]

clean the water pump mating surface on the block, note the water pump pulley bolts holes are not equidistant ,but rather rectangular spaced

[Roku35]

As you said, if all the stuff is off; ie, radiator, belts, gasket's, then just take your time and take the water pump off. It's not hard. Just put the things back in the order they came off. A water pump just bolts on to the motor, that's all. Gaskets are easy, as are the belts. Take your time and you'll be fine.

Oh yeah, I forgot about that...I hope I remember what goes on first, second, third...haha. I know I changed out the clutch fan already. This is getting funnier each day that passes (not really). I know I have all the parts in some orderly arrangement, I just hope I remember the arrangement order...hahaha. Maaaaaaybeeee this weekend???:eyecrazy

[TJC1]

What is the labor rate at your regular mechanics place?

[wokke]

What is the labor rate at your regular mechanics place?

My local BMW dealership in Duesseldorf (Germany) has a discounted rate for classic BMW: €uro 120,- plus 19% VAT which is roughly US$175.- per hour.
Regular price is €uro 170,- plus 19%VAT (=US$249,- per hour).
Pretty sick, isn't it?

[Roku35]

Hey, hey, hey…project done! (I think?) It was really easier than I thought it would be. I just took her out for a spin and no leaks and running as smoooooooth as ever. I did want to know how I could tell if the thermostat is working and if there was a way to be sure that there was no air in the coolant lines. I did bleed coolant from the thermostat screw and seems like the hoses are heavy and full. BTW, where does the coolant overflow line (going back towards the dash) end up? Trying to trace that now so I can replace with proper length.

BIG thanks to all who helped with those special tips and product recommendations to make this venture a reasonable lessons learned. My addiction remains as strong as ever and now I am looking at my new "hands on" task.

SI Board replacement! Okay, where does this thing go? What do I need to take out to get it in there? Please tell me this is a 30 minutes project :D

[Freshbread]

Hey, hey, hey…project done! (I think?) It was really easier than I thought it would be. I just took her out for a spin and no leaks and running as smoooooooth as ever. I did want to know how I could tell if the thermostat is working and if there was a way to be sure that there was no air in the coolant lines. I did bleed coolant from the thermostat screw and seems like the hoses are heavy and full. BTW, where does the coolant overflow line (going back towards the dash) end up? Trying to trace that now so I can replace with proper length.

BIG thanks to all who helped with those special tips and product recommendations to make this venture a reasonable lessons learned. My addiction remains as strong as ever and now I am looking at my new "hands on" task.

SI Board replacement! Okay, where does this thing go? What do I need to take out to get it in there? Please tell me this is a 30 minutes project :D

See man you could do it...easy stuff.
The expansion hose is just a 700mm dump hose. Just follow it with a flash light.

SI board is cake use these gear instructions to remove the cluster. Once you open it up just locate the battery board, you'll be swapping that whole board. Just unplug the wire harness and plug your new board in...
http://www.odometergears.com/documentation/BMW_6_Series_E24_Instrument_Cluster_Light_Upgrade_ Odometer_Gear_Replacement.pdf

[ShapeShifter]

Good for you! Like I've said before its only kinky the first time. Every little repair you do, builds knowledge and skill for the next bigger job.

The over flow hose exits in the fender well with the brake lines.