Replacement EGR Cooler hoses got delivered mid last week.
New hoses snap tight and do not feel loose or rotate freely as reported by @deptrai in post #254. Vacuum test passed as well.

I put everything back together, filled coolant with vacuum filler.
I had to top off less than 100ml coolant after final venting procedure.

I ran engine for several minutes - it took some time to warm up.
Unlike before thermostat replacement, temp easily passed previous 77C mark and continued to rise. The max coolant temp was 97C, at which point fan kicked in and cooled engine down to 89C. (This was my first time I've seen X5 fan in operation since I bought the car new)

I realized that I have 2 hands only, but to put flange bolts need at least 3
- one to hold mirror
- another to hold flash light
- and another to drive the extension with bolts.
You can hang your mirror and flashlight as shown on the picture below:
Attachment 77734

Once again, huge thanks to entire community.

Below are other resources that could be used as complimentary references to this DIY

newTIS REP instructions
17 11 035 Fan assembly removal
17 00 005 Coolant Drain
11 71 100 EGR Cooler Removal
11 53 000 Main Thermostat Replacement
17 11 040 Transmission Thermostat Replacement
17 00 039 Coolant Fill and Vent

Youtube

Got "lucky" with SCR Cat - it got replaced under federal emissions warranty:

Hi all,

Thanks to sgrice again for the write up!! Did my thermostat and Glow plug module again after 9 years and 110,000kms. Temp was staying 70~72 degC from the last year . Every year it was dropping 2~3 deg since I put new thermostat 9 years ago. Last time I ordered genuine BMW thermostats ( main and transmission cooler ) and right after the replacement it was barely keeping at 88C. I would say 86~87C.

But this time, I ordered Mahle thermostat (made in Italy) from FCP euro and so far its keeping the temp 88C~89C. But time will tell. This time I didn't change the transmission cooler thermostat. The genuine one that I took out was not stuck open. I also tested it by putting it in a hot water and it was opening at around 86~87C. I think even though it was opening at 88C, it's spring looses tension over time and can't withstand the coolant pressure and opens up too early.

Regarding the glow plug module, I was getting Cylinder 2 glow plug error. I checked the resistance and all 6 were same. So i left the glow plugs as is it. It did clear up the error. Hope it stays like that:)

Suggestion: Try to tap the holes (to clean out carbon and debris) of the exhaust manifold where EGR cooler connects and use nickel based anti seize. Also clean the steel screw threads with brush It will help next time.

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