BMW 318/325/M3/525/535/M5 1989-1993 Repair Information

Radiator

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REMOVAL & INSTALLATION




CAUTION
Ethylene glycol coolant can be dangerous to animals and small children if ingested in enough quantity. Even a small amount can kill a pet and cause sickness in a child. Keep children and pets away from coolant.E30 3 Series

WITH M42 ENGINE
  1. Disconnect the negative battery terminal. Allow the engine to cool completely.
  2.  
  3. Remove the radiator cap and drain the cooling system at the plug on the lower left side of the radiator.
  4.  
  5. Remove the fan cowl by pulling the expansion rivets out and pulling the cowl out.
  6.  
  7. Disconnect the radiator hoses and the transmission oil cooling lines. Plug the transmission lines. Disconnect the sensor electrical leads.
  8.  
  9. Remove the upper radiator support and the radiator.
  10.  

To install:
  1. Install the radiator. Check the lower supports are in place. Install the upper support.
  2.  
  3. Connect the electrical leads and the transmission lines. Tighten the connections to 13-15 ft. lbs. (18-21 Nm).
  4.  
  5. Install the radiator hoses with new clamps. Install the radiator cowl by pushing the rivets in. Tighten the drain plug and fill with coolant mixture. Connect the negative battery terminal. Start the engine, bleed the system and check for leaks.
  6.  

WITH M20 AND S14 ENGINES
  1. Disconnect the negative battery terminal. Allow the engine to cool completely.
  2.  
  3. Remove the expansion tank cap.
  4.  
  5. Remove the fan cowl by pulling the expansion rivets out and pulling the cowl out. Remove the splash shield if necessary and drain the cooling system at the plug on the lower left side of the radiator.
  6.  
  7. Disconnect the radiator hoses, vent hose and the transmission oil cooling lines. Plug the transmission lines. Disconnect the sensor electrical leads.
  8.  
  9. Remove the upper radiator support and the radiator.
  10.  

To install:
  1. Install the radiator. Check the lower supports are in place. Install the upper support.
  2.  
  3. Connect the electrical leads and the transmission lines. Tighten the connections to 13-15 ft. lbs. (18-21 Nm).
  4.  
  5. Install the radiator hoses with new clamps. Install the radiator cowl by pushing the rivets in. Tighten the drain plug and fill with coolant mixture. Connect the negative battery terminal. Start the engine, bleed the system and check for leaks.
  6.  

E36 3 Series See Figures 1 and 2

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Fig. Fig. 1: Internal workings of an integral expansion tank radiator



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Fig. Fig. 2: The arrow marks the bleeder screw on the integral expansion tank radiators

The E36 chassis 3 series use a radiator with an integral expansion tank. The expansion tank is mounted to the radiator and has hash marks along the side to indicate level.

WITH M42 ENGINE
  1. Allow the engine to cool completely. Loosen the bleeder screw on the radiator expansion tank next to the radiator cap.
  2.  
  3. Remove the splash guard from under the car. Loosen the drain plug and catch the coolant in a container.
  4.  
  5. Disconnect the upper radiator hose and catch the coolant. Disconnect the temperature switch. Disconnect the lower radiator hose and catch any coolant.
  6.  
  7. Pull out the rivets and remove the fan cowl. Disconnect the lower expansion tank hose. Disconnect the automatic transmission oil cooling lines and plug.
  8.  
  9. Unlock the radiator holding clips by inserting a tool in the opening and pressing down. Remove the radiator.
  10.  

To install:
  1. Install the radiator on the mounts and press into the clips until the spline engagement stops.
  2.  
  3. Connect the electrical leads and the transmission lines. Tighten the connections to 13-15 ft. lbs. (18-21 Nm).
  4.  
  5. Connect the expansion tank hose. Install the fan cowl into the slots on the radiator. Press the rivets in to lock. Connect the radiator hoses.
  6.  
  7. Install the splash shield, fill with coolant mixture and bleed the system.
  8.  

WITH M50 ENGINE
  1. Allow the engine to cool completely. Loosen the bleeder screw on the radiator expansion tank next to the radiator cap.
  2.  
  3. Remove the splash guard from under the car. Loosen the drain plug and catch the coolant in a container. Pull the connector off the level sender. Remove the air guide upper section and disconnect from the alternator cooling duct. Remove the cooling duct.
  4.  
  5. Disconnect the upper radiator hose and catch the coolant. Disconnect the temperature switch. Disconnect the lower radiator hose and catch any coolant.
  6.  
  7. Pull out the rivets and remove the fan cowl. Disconnect the lower expansion tank hose. Disconnect the automatic transmission oil cooling lines and plug.
  8.  
  9. Unlock the radiator holding clips by inserting a tool in the opening and pressing down. Remove the radiator.
  10.  

To install:
  1. Install the radiator on the mounts and press into the clips until the spline engagement stops.
  2.  
  3. Connect the electrical leads and the transmission lines. Tighten the connections to 13-15 ft. lbs. (18-21 Nm).
  4.  
  5. Connect the expansion tank hose. Install the fan cowl into the slots on the radiator. Press the rivets in to lock. Connect the radiator hoses. Install the alternator cooling duct and guide.
  6.  
  7. Install the splash shield, fill with coolant mixture and bleed the system.
  8.  

E34 5 Series See Figures 3 through 7

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Fig. Fig. 3: Cooling system schematic for an E34 5 Series with an M20 engine and parked car heating



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Fig. Fig. 4: Cooling system schematic for an E34 5 Series with an M30 engine



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Fig. Fig. 5: Lower radiator mounting



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Fig. Fig. 6: Always check the automatic transmission cooling line connection seals



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Fig. Fig. 7: External cowl mounted expansion tank

WITH M20 AND M50 ENGINES
  1. Allow the engine to cool completely. Remove the expansion tank cap and the splash shield. Drain the coolant into a container.
  2.  
  3. Disconnect the radiator hoses. Remove the right headlight cover. Disconnect the temperature switch plug. Disconnect the automatic transmission cooling oil lines and plug.
  4.  
  5. Pull out the rivets and push back the fan cowl.
  6.  
  7. Unlock the radiator holding clips by inserting a tool in the opening and pressing down. Remove the radiator.
  8.  

To install:
  1. Install the radiator into the mounts and press into the upper clips until the spline engagement sound stops.
  2.  
  3. Install the fan cowl rivets. Connect the electrical leads and the transmission lines. Tighten the connections to 13-15 ft. lbs. (18-21 Nm).
  4.  
  5. Install the right headlight cover. Connect the radiator hoses. Fill and bleed the system.
  6.  

WITH M30 AND S38 ENGINES
  1. Allow the engine to cool completely. Remove the expansion tank cap and the splash shield. Drain the coolant into a container.
  2.  
  3. Disconnect the radiator hoses and expansion tank hose. Remove the right headlight cover. Disconnect the temperature switch plug. Disconnect the automatic transmission cooling oil lines and plug.
  4.  
  5. Pull out the rivets and push back the fan cowl.
  6.  
  7. Unlock the radiator holding clips by inserting a tool in the opening and pressing down. Remove the radiator.
  8.  

To install:
  1. Install the radiator into the mounts and press into the upper clips until the spline engagement sound stops.
  2.  
  3. Install the fan cowl rivets. Connect the electrical leads and the transmission lines. Tighten the connections to 13-15 ft. lbs. (18-21 Nm).
  4.  
  5. Install the right headlight cover. Connect the radiator hoses and the expansion tank hose. Fill and bleed the system.
  6.  

 
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