The news came back today. AC fix requires a new compressor, which amazingly worked fine a month ago when my car was still under warranty and they fixed my AC with a new condenser. As for the leak, it came from the expansion tank which needs to be replace. The damage: $2,800. Yikes! Looks like I need to prioritize what I need done. AC can wait, so I'm going to see if I can find how to replace the expansion tank.

Wait a minute... their repair of the correspond may have damaged the compressor!

You should research the BMW procedures for doing the first repair and determine if they followed it scrupulously. I'd really pus them to cover the whole repair...it seems like your AC system was failing and they only replaced part of it.

A

Got my x5 back. Refused all fixes since I believe the compressor was something they should have caught a month ago. Will be taking this up with their service manager and BMW and Facebook (they'll regret having a fan page). As for the coolant leak, it's was the expansion tank with I will DIY with instructions from here. They did replace my fan belt and compressor belt for $85 without any labor charge since they already had the system out (hopefully, this would cure the clicking noises I'm hearing when the engine is idle).

3 1/4 years. Not bad. My tank took almost a full gallon again today. Pretty sure it's the rad again, but we shall see. Monitoring it for now with a gallon of BMW COOLANT in the trunk!

check the expansion tank first for leaks if you changed your rad the last time. easy DIY

Don't think it's the rad. I drove the car a bunch over the weekend and the coolant level only dropped a bit (coolant was up to the MAX level, and is now a half an inch below MAX). Local driving didn't make it lose any coolant. Highway driving for an extended period of time caused the drop. Going to go to my indy and get them to add the dye to be able to trace where I'm losing it.

Well, another cracked rad

Cracked Radiator here as well. My Indy BMW Mechanic is replacing it with the revised radiator claiming it is a much better design and isn't prone to failures. I am having to add coolant every 10-14 days depending on my driving style. We are waiting on parts right now......

I'd typically do the work myself but working 60+ hours a week, it wouldn't get done until next year. :banghead:

We're gonna attack the 5 oil leaks at that same time which are covered under my extended warranty and the code that it threw (from the water pump/thermostat) when it was low on coolant possibly, to say that was the cause of the radiator cracking. Doubt it will work but....might as well try.