Subject: My Observations Author: dan : member since May, 2006 : 1 post Posted on: 2006-05-14 23:04:28

Well done description of the work you did. If you don't mind, I would add a couple of observations I made when I did some of this same work.

1) The plastic t'stat housing on my car ('97 528) began to "seep" coolant around 35K miles after its installation (it was a replacement). It was such a small leak that it took me literally weeks to figure out from where the few drops of coolant on my garage floor were coming. When I removed the old housing I found the innermost wall of the groove holding the o-ring for "cold" water return to the engine was broken in a single spot and the housing was distressed in this area. In the process I also found corrosive pitting of the aluminum on the front of the cyl head directly under the "cold" water return o-ring. Interestingly, these areas were not yet apparently leaking. However, before installing the replacement t'stat housing (aluminum), I carefully cleaned the pits in the cyl head and filled and filed flat these areas using JB Weld. At the time (middle of the winter, garage dark and around 25F) I had no idea if this would be a permanent repair, but 17 months have now passed and everything is leak free (a temporary condition for BMWs).

2)The aluminum t'stat housing that I used is still leak free (see temporary above), but I did have trouble with the bleed screw that came with the housing. The threads between the housing and the screw "galled" and I eventually had to drill-out the aluminum plug, re-tap the housing and use a modified plastic bleed screw.

3) I also installed the Nissens radiator, but be careful of one thing. Protect the drain plug with your life. If you should happen to break this plug, or lose it during future service, you are not able to run to the local BMW dealer to buy a replacement. In fact, I tried to get a "spare" drain plug from Nissens and they told me they don't service this part. But if I really needed one, perhaps they could help. I hope so...but that will probably mean the car is out-of-service for a few days at best.

4) I notice that you had the same problem with PS hoses that I had when I was replacing them. Namely, ATF in the alternator. I haven't had any problems, but who knows.... Now I know to throw a sheet of plastic over the alternator before starting this work.

Thanks for your hard work.

Dan

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