E30 318i: Water in rear footwell - windscreen cowl leaking? Koi carp anyone??

After heavy rain I noticed the rear passenger foot well in the E30 is full of water. Can't see any signs of water ingress through the door seals or any stains in the headlining, but am told a common cause of this is the windscreen-cowl, so will be looking into this soon. For now, I have drilled a nice drain hole so at least it won't be filling up again.

BMW E30 Heater Matrix Hoses Configuration - Right and Wrong way round + how to bleed matrix / remove air-lock

My E30 had little or no hot air from the blower inside the cabin. I have heard it is common for the two hoses running to the heater matrix to be fitted back to front, so the flow of coolant through the core is reversed. This causes air locks and severely reduces the amount of coolant flowing through the heater matrix, thus no hot air. 

The reason these hoses so often get fitted incorrectly is due to their location and the way they look when fitted. It appears obvious that the upper hose (back of cyl.-head to heater) goes to the upper stub on the heater-matrix and the lower hose (side of block to heater) goes to the lower stub on the matrix. The hoses look happier this way round, but the matrix and heater-valve are designed in such a way that flow is interrupted and causes the air-lock. 

The correct way round is actually with the upper hose connected to the lower stub and the lower hose to the upper stub, which does of course appear to be back to front, but is essential for correct flow of coolant round the whole engine, not just the heater-core. The correct and incorrect hose configurations are shown in the pictures below.

RIGHT:

WRONG:

How to Bleed system and remove air-lock from Heater-Matrix:

** This is not the normal air-bleeding process when refilling an empty system with coolant, this process is to bleed a system with the air-lock at the back of the head and / or the heater-matrix full of air. **

1. Ensure heater-matrix hoses are fitted the correct way round, if not swap them over. [You should notice if there is an air-lock that no coolant comes out of the hoses when removed from the matrix and the stubs appear dry].

2. Fully tighten the lower [inlet] hose.

3. Leave the upper hose disconnected from the matrix. 

4. Remove the radiator bottle cap. Assuming the coolant level is up to the halfway / max. mark, there should be some gulps of air and the coolant level should drop slightly in the rad. bottle.

5. Cut the bottom off a 2-litre drinks bottle and fill it with water, holding your hand over the lid.

6. Dump the water from the drinks bottle into the radiator bottle, allowing the weight of water to push the remaining air though the system. Water should start to come out of the upper heater-matrix hose from the head. Block this hose with a finger.

7. Continue to top up the radiator bottle with water until water begins to flow out of the upper stub on the heater matrix and quickly refit the upper hose, which can now be fully tightened.

8. Drain the radiator bottle back down the halfway /max. / fill line.

** You should be good to go, but can now bleed / top-up the system using the usual bleeding procedure if necessary. **

F10 530d: Water in Battery well / Bootwell / Trunkwell - where is it leaking?

I lifted the boot/trunk floor to jump-start a friends car and noticed that my battery well / spare-wheel well is full of dirty water.... oh dear. I’ve got a leak... but where? Boot seal? Bottom of the rear windscreen? There was a second aerial / antenna fitted in the roof that I removed, so figured it might be leaking through there and running down the C-pillar into the boot, but no water marks in the headlining or signs of ingress... Think I will have a proper look this weekend and try get to the bottom of it!

E46 318i - Broken Coolant Hose! [11537572158]

 After about 650 miles in the E46 Touring the radiator light came on. Just the amber warning, to let me know it was getting low, not the red warning when it is running out and I refilled about 1.25 litres of water / coolant to the engine. This seemed about right to me, as I feared it may be using a bit of water and there was plenty in when I bought the car so 1.25L in 650 miles isn't catastrophic and can be lived with.
About two weeks later the radiator light came on again and I dutifully refilled 1.25 litres, but the car had only covered 120 miles so I knew something was now amiss, only for the light to come on yet again after just five miles of my six mile round trip to work. Under the hood with the engine running I could see a huge pool of water in the under-tray and a drip, which after much tracing turned out to be coming from a slim rubber hose that connects to the left side of the cylinder-head [N42 engine]. It was a constant drip, but when I wiggled the hose-end the coolant began to spray round the engine-bay, so here was the culprit. Turns out the hose-connector into the head was completely sheared off, as you can see in the pic, and should extend about half an inch into the housing. The only thing holding any water into the upper engine at all was a single M6 thread screw.

The hose in question was BMW Part No. 11537572158, shown in the diagram connecting the thermostat to the cylinder-head. This is a common fault I am told on N42 and N43 engines, along with several other coolant hoses that have plastic end connectors, particularly in the US where kits can be purchased to convert the brittle plastic ends to aluminium ones. This seemed unnecessary for me, given the cost of a replacement part and the age of the car.

As there are so many coolant hose variants, finding the right used OEM one on eBay and the like can be difficult, but they do pop up. I was able to get a new spurious part through work for just £18, but I'm sure commercial motor factors will not be much more expensive as long as they have stock. Spurious hoses tend to come with a new rubber O-ring fitted. BMW dealerships will charge a premium, but at least fitment is guaranteed and they are revised parts, though these may not come with the rubber O-ring which will also need to be ordered.

E60: Blocked Washer-Pump - Quick Fix.

No water from windscreen washer-jets? Chances are it's a blockage in the pump filter. This is not a difficult job, rather a very easy one, so avoid unnecessary cost and fix it quickly yourself.

Check Fuse: 
Fuse 18 is the corresponding fuse. If the washer pump is dead and making no noise then this is the first thing to check. If it is still making a whining noise, then you have a blocked pump-filter.

** The headlamp washer system only functions when the headlights / sidelights are turned on. **

FIX:

Windscreen Washer System:

** The washer bottle is located just in front of the N/S (passenger) wheel-arch liner. The filler-neck is just behind the N/S headlamp and you can see the hose go down into the bodywork and rise up to where the tank is. The tank CANNOT be accessed from above, even when the headlamp is removed. It is much easier to peel the arch-liner back and work from inside the wheel-arch. **

** Obviously water will spill out of the washer bottle so just allow it to drain. **

1. Remove the 3 screws from the N/S/F plastic wheel-arch liner circled in the photo so that it can be peeled back out of the arch rim, one on the near edge, one along the bottom and one by the brake air-duct. It helps to turn the wheel full-lock one way or the other to give more room.

2. Gently pull the washer-jet hose connector off the spout on the side of the windscreen washer-pump. [It's the smaller grey one, furthest away in photo].

3. Reach in and grip the windscreen washer-pump, then gently turn it from side to side while lifting it upwards until the spout on the pump is free of the tank [it may need tilting towards the wheel to get out].

4. Unplug the wire-connector from the pump by depressing the clip on either side and sliding it upwards. The pump can now be removed from inspection if necessary. [Alternatively, leave the wiring connected and place the pump somewhere out of the way].

5. Gently prise the rubber base the pump sits in upwards out of it's collar in the tank, being careful not to detach the plastic-filter from below it and have it drop into the tank.

6. Remove the white plastic filter from the rubber piece and give it a good clean. [It's usually congealed screen-wash clogging it as in the photo, rather than detritus].

7. Refit the plastic filter to the bottom of the rubber base and carefully lower it vertically back into the tank.

8. Refit the pump as a reversal of steps 4 to 1.

Sticky residue wrapped right around the filter-gauze
had stopped flow into the pump completely.

Headlamp Washer System:
The process is the same for the larger headlamp washer pump, though the hose-connector at the bottom in the second photo is sturdier and needs the clip pushing up from undernath to slide the hose off.

Headlamp washer has a much bigger filter, I guess to get more
water into the bigger pump and higher pressure spray.

E36 316i Compact: New head-gasket.

Well, it's been a busy month again in Beemer Lab and I've just bought a new house which hasn't helped. Firstly, I finally removed the stuck head-bolts from the E60, got the head off and found where my oil leak is coming from... The lower timing case has a big crack in it! It's too big a job to replace that and do the new piston, so it looks like the 530d does need a new engine after all, what a shame after my £500+ spend.

As there is no E46 progress still, I decided a cheap runaround BMW was needed on a temporary basis so I shelled out a quick £200 on an X-reg E36 316i Compact, again in Titansilver. It has 4 months tax and 10 months MOT so seemed ideal as a stop gap. That was until I went to pick up a fridge and it majorly overheated. After I limped home I found oil in the water, water in the oil and a constant bubbling from the radiator. Blown head gasket then!

I had to use it for 2 weeks in this state, only doing the 2 mile trip to work and no further, but still it was getting to max temp as I pulled up on the drive. The gasket was only £18 off eBay and is FAI. The job only took about 4 hours (oh the joys of working with a single cam!) and it is back on the road and running quite cool so far, though I will need to put it through its paces to find out if it was just a dodgy gasket or if there is a real cooling problem that's caused it.

I will cover the poor E60 and it's future in more detail soon. Oh, and I've also bought a new secondary air-pump or the E46 so watch this space. 3 Beemers and counting...

£18 delivered. eBay FTW still.

By gosh, that looks like some hot oil.

The centre two head-bolts [1 and 2] were finger loose when removed!
This has obviously allowed oil and water to mingle. Blast marks round
the front cylinder show where combustion was stopping water entering the head.
This whole head-gasket swap took about 4 hours, so how
hastily the last one was thrown on is disturbing...

Lots of burnt oil and split gasket over the head, but it cleaned up well.

Think I will leave cleaning the cooling system for another day though. The head is caked with 'rad-weld' type stuff.

Amazingly, after all that overheating, the head is straight as anything! BMW alloy heads are forgiving to say the least.

10 minutes with a razor-blade and the block is good as new. PIston don't look half bad either.

New gasket on. The re-tightening sequence is 30nm, 90 degrees and
another 90 degrees. I wonder if the last guy to work on it only did
the 30nm and forgot about the torque angling?

The curse continues! 318ti blown head gasket! [E36K]

I don't believe this! Nathan has been using his E36 Compact for work this week while the wheels are off the 330 Clubsport. Yep, the same E36 I was about to borrow so I can get to work with the broken E46 and E60. It's been running like a dream while it's for sale, then this morning he gets 2 miles and the head gasket blows, then he runs round and dries home like a red arrows display, so it looks water related... why? its not like he was ragging it in eco mode. Drat!

It has a minor running fault as it is, where the engine cut out when the auto-box is put in 'D', probably the torque-converter. This I could have lived with, even the 'sport-o-matic' box, but more open-engine is out of the question I'm sure anyone would agree!

3 dead Beemers in 3 weeks! What is going on.

E39: Condensation + Water in the Headlights

Water getting into the headlight units seems to be a pretty common problem on most 90s BMWs, with the E39 5 Series clearly being one of the worst affected - I've seen scores of people with this problem online, ranging from patches of condensation like mine to full blown fish tanks in the lower half of the lens and it would appear that no matter how serious the leak it's still a right pain to get shut of. Unless money is no object don't even consider a replacement, they start at £120 currently and go up from there.

I only began to notice condensation in my n/s light until after fitting the angel-eye rings, so assuming I'd not reassembled it correctly I removed the unit, blew away the droplets with a hair-dryer and reset the seal, as have countless others, to no avail. As the condensation spread over the whole face of the lens I began to scour message-boards looking for a successful fix and believe I've found a technique that does indeed work...

*** If your headlight unit has been damaged in a shunt, the lens is cracked, has a stone chip through it or if the rubber-seal has perished enough to no longer fill the gap then I'm afraid there's no pretty way to fix this problem and you'll have to replace the unit or it'll fail an MOT.

Dismantling the Headlamp unit :

1. Remove the 5 wiring-loom sockets from the back of each headlight.

2. Remove the 4 screws holding the light-cluster in place, located on the slam-panel and down the back of the cluster, using an 8mm wrench.

3. Pull the light-cluster forward from the inner side until the lug on the outer corner can be slid out and the cluster removed.

4. Slide off the strip of body-coloured trim and rubber seal from the bottom of the headlight.

Reverse the process to re-fit.

Drying the Lens :

Use pliers to slide off the 2 metals-clips on each of the round glass inner-lenses. The glass discs should then be easily removable [trickier with angel-eye rings glued to them], to get some air flow through to the outer-lens and, if you have any, mop away any moisture on the main area of the lens with a cloth.

The best way to dry the unit is to place the front section of the headlamp in a warm, arid place and just leave it for a day or two. As time is usually of the essence though, the most popular method is the good old hair-dryer. Condensation on the main lens area is easy to blow away from the rear, but the corner-indicator is in a separate pod where little air gets to it, so heat the outside of the corner-lens for a few minutes, then let it [and the hair-dryer] cool for a few minutes and evaporate and repeat the process until the drops are gone.

Refreshing the Seal :

1. Gently prize the rubber-seal from its recess around the rim of the rear section of the headlight.

2. Wash the seal using cold water, dry it completely and coat it entirely with a thin layer of petroleum-jelly [Vaseline].

3. Carefully press the seal back into its recess facing the opposite way it came out. [The original outer-facing edge should still be visible by the slim indent made by the lip on the front-section.] * Avoid stretching or compressing the seal while pushing it into the groove as this makes it difficult to get the right length to fit and you may need to rearrange it quite a bit to reach.

Sealing around the Corner-Indicator lens :

** If refreshing the seal does not work or the condensation is concentrated around the corner-indicator lens then there may be a minor break in the solid-seal here, so the only solution is to get messy with sealant.

I'd recommend a clear-drying, silicone-based multi-purpose sealant, although any old bathroom sealant will work and it's not too visible anyway with the light back in. Apply sealant into the gap of about 3mm that runs around the rim of the corner-indicator lens and press it right down into the seal with a screwdriver, this should give a nice, tight seal and show up any leak areas where blobs of sealant can be seen inside the lens. Apply more sealant on top and smooth round the entire edge with a finger. Be sure to wipe as much wet sealant from the light as possible, as well as rubbing away any leftover sealant from the lens after it has dried.