I am attempting to replace my 1996 840 broken radiator. I printed out the instructions from the BMW 8 Series-E31 repair website, but found them lacking in detail since they refer exclusively to the 850. Is there a site that discribes the operation for an 840? I got as far as disconnecting the expansion tank but can't get the associated bleeding hose off! The clip/clamp is of a type I am not familiar with (See pic). What is the trick to removing it?

The clamp looks like a "crimp" clamp. There is probably another name for it. Just cut the crimp and peel off the clamp. They can be replaced with conventional clamps. I have used a dremel with a cutting wheel or simply some wire cutters to cut these clamps.

Hope this helps.

The clamp looks like a "crimp" clamp. There is probably another name for it. Just cut the crimp and peel off the clamp. They can be replaced with conventional clamps. I have used a dremel with a cutting wheel or simply some wire cutters to cut these clamps.
Hope this helps.

Thanks. It was in fact a crimp clamp. I finally removed the air filter cover and MAF assembly to get at it with a dremel tool after pulling the resevoir aft to have the right angle access to the clamp. Now I have two other problems. In trying to disconnect the radiator temp sensor (see pic) I can't figure out if the wire connector plug is a straight pull out from the brass sensor or if it is being held in place by an unseen plastic tab. Does the entire black plastic portion come off leaving just the brass nut with its prongs showing? Been pulling with all my hand strength and can get it off! The other question is how to remove the fan and viscous coupler. Is it the large nut aft of the fan and viscous drive between the hub that has to be unscrewed? It is a very large nut that looks like it needs a slender wrench to remove it. What size is the necessary wrench if that is the case? The crescent wrench that I have that is large enough is too wide to fit in between.

Large nut on fan is left hand thread 32mm (on the 850), some tools are available on loan at parts stores to help with removal.

The temp sensor threads out of the radiator and the electrical connection has a small clip to hold the plug into the sensor. Some removal of local brackets was necessary to gain access if I recall.

Hope this helps.

Whale, Keep taking pics as you progress. I have a feeling I will be doing this in the near future...

Fan removal tool part # 11 5 050

Looks like a flat bar with a notch rounded out to go over the nut area and two holes for the 10mm bolts to attach it to the assembly.
One can be fabricated kinda easy. Just don't use a clamping tool to hold the pully!!! It's a composit plastic and WILL break! Don't ask how I know this.. :(

Whale, Keep taking pics as you progress. I have a feeling I will be doing this in the near future...
Apparently a 1996 840 came standard with metal water pump impeller and metal thermostat housing. Removing mine, I answered my own previous part purchase inquiry as to whether I could just purchase a thermostat without the housing, which was considerably cheaper $25 versus $80 for the complete housing/thermostat assembly. With a 96 M62 engine the thermostat does not seperate from the housing. It is a one unit assembly so you are stuck with buying the more expensive option replacement.

Whale, Keep taking pics as you progress. I have a feeling I will be doing this in the near future...

I am just passing this info on for those that may be forced to purchase a new radiator. I was advised by members that because of the recurrent failure of the BMW plastic radiators, BEHR had made a modification to sleeve the inlet/outlet nozzles. Apparently this was not the case as reflected by the reply to a new BEHR replacement that I received that was without:
Hi Gregg,
Thanks for the photo . The brass sleeve was apparently in the overflow tube next to the inlet so, yes, we do not have a radiator with the reinforcement to which you are speaking . I contacted Behr's US distribution center and they are not aware of any recall or upgrade on the inlets . Do you have documentation from Behr ?


BMW SPECIALIST
PELICAN PARTS, INC.


Is there anyone on the forum that has installed a replacement radiator with metal sleeve modification? If so what manufacturer?