Pic diagnostics

[X5chemist]

What would cause this seal to blow out? It has run fine for several weeks. I know it was seat properly. I looked at it while installing several tank coolant sensors. After installing new OEM dealer seals, it's worse now. It doesn't leak while idling. It does leak when moving. Vibration is causing leaks. The replaced plate may not fit properly. I'll check the lock clip. I wonder if one side is not seated properly.

The tank was replaced too. Unfortunately, the other new tank didn't fix the "check coolant level" warning. I'll check the plug for power. I'll even try a temporary bypass.

[EODguy]

Originally Posted by X5chemist

What would cause this seal to blow out? It has run fine for several weeks. I know it was seat properly. I looked at it while installing several tank coolant sensors. After installing new OEM dealer seals, it's worse now. It doesn't leak while idling. It does leak when moving. Vibration is causing leaks. The replaced plate may not fit properly. I'll check the lock clip. I wonder if one side is not seated properly.



The tank was replaced too. Unfortunately, the other new tank didn't fix the "check coolant level" warning. I'll check the plug for power. I'll even try a temporary bypass.

I had the same problem and mine was that the middle thin flange got a rolled edge on installation. The hard plastic flanges got screwed (twice ) because of angle of entry....

Granted you may have something completely different but at .15 cents each it's worth buying extras.

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[crystalworks]

Originally Posted by X5chemist

What would cause this seal to blow out? It has run fine for several weeks. I know it was seat properly. I looked at it while installing several tank coolant sensors. After installing new OEM dealer seals, it's worse now. It doesn't leak while idling. It does leak when moving. Vibration is causing leaks. The replaced plate may not fit properly. I'll check the lock clip. I wonder if one side is not seated properly.

The tank was replaced too. Unfortunately, the other new tank didn't fix the "check coolant level" warning. I'll check the plug for power. I'll even try a temporary bypass.

If that's what I think it is, that cooler was very difficult to get fully seated on the radiator plate. I had to use silicon spray, a 4ft pry bar, and more leverage than I was comfortable with. It took at least 30 minutes because I was scared I was going to break something. Finally got so frustrated I went hog on it and it popped in.


Edit: And as EODguy mentioned. Going in straight is key. Very frustrating job...

[X5chemist]

Originally Posted by crystalworks

Finally got so frustrated I went hog on it and it popped in.

While installing a new plate and tank, I notice the transmission tank has a bent corner. Someone has taken it off prior to my refresh. Not wanting to cause further damage, I had to find a way to press it in. The clip was installed on the plate before installation. The best tool I had handy was the clutch fan spanner. Reaching from underneath, the frame was used for leverage. One quick tug and the cooler popped in. Enough water was added to test for leaks. Blue coolant was added once no leaks were seen.

[X5chemist]

Finally some free time and nice weather! A new tank and mounting plate were installed. All the work went slow and steady. The fan and shroud were taken off for better access. A break in drive was done too. No leaks were noted! The plate installation during the refresh was probably not correct. It was my first time doing such work on so many plastic parts. I'll check the coolant level every drive for 1-2 weeks.
Attached are oil cooler pictures. Hopefully others will find them useful. Install the mounting clip first. Next, use the fan spanner wrench for leverage. The oil cooler tank will pop right in.


Positive: My missing 19mm ratchet wrench was found. On the wiper cowl! I have no idea how it didn't go flying off for several weeks.

Negative: After all the coolant system refresh, three sensors, and now a third tank with a sensor, the "check coolant level" warning is still active.

[crystalworks]

Originally Posted by X5chemist

While installing a new plate and tank, I notice the transmission tank has a bent corner. Someone has taken it off prior to my refresh. Not wanting to cause further damage, I had to find a way to press it in. The clip was installed on the plate before installation. The best tool I had handy was the clutch fan spanner. Reaching from underneath, the frame was used for leverage. One quick tug and the cooler popped in. Enough water was added to test for leaks. Blue coolant was added once no leaks were seen.

Nice to finally get through a frustrating problem triumphant (excepting the low coolant warning).

That looks very similar to the angle of attack I took with my pry bar. I used a metal plate (or something, old man memory) on the cooler to spread the load so I didn't have a point load crush a corner like that.

For the warning... might be time to trace the harness to look for signs of fraying or rodent chewing. An end to end continuity check should tell you if there is a break in one of the wires.