[Old_Ranger]

I'm done with the repair, and grateful for the information you all put up here. I'm typically lurking on the nam3forum as an E46 addict...so I appreciate the effort it takes to run a forum like this.

I concur with what's in this thread:

1) if your heat stops working, check your coolant expansion tank. If it is empty, then it's probably not because the engine/head gasket is a problem
2) confirm where the leak is coming from, If it is this thing, it can be easily observed after removing the plastic/fiber cover under the engine.
3) I agree, there is no need to remove the fan shroud. Removing the intake, the electric water pump, and getting the hoses out of the way is sufficient.
4) Tools: If you're going to leave the fan in, you will need a flex head ratchet for the lower bolt on the oil cooler assembly.
5) Other parts: just like knightarmor recommended - replace that stubby connector. It is nice to have a 1/4" drive with flex joint and extensions to do this.

[limsheng]

Originally Posted by knightarmor

Congratulations! Terrible OEM design. Are you going with the aluminum replacement?

Yeah, I was asking my friend mechanic about the aluminum type. But it’s a Friday evening and he can order OEM parts Saturday morning and fixed everything back before lunch. So, didn’t get the time to search and I’m glad if it can last another 60k KM ?

[E39M5Dan]

So tackled this job this morning. Buddy John came over to lend a hand. Worked my way down thru the mess... Besides the Oil Filter Housing I got the 4 large coolant hoses to replace. Every connector, whether coolant, electrical or vacuum line was welded in place after 7 years of not being disturbed.

Took a while but managed to get it all apart... replaced the coolant hoses and the OFH... you can see in the last picture, the busted port... cheap plastic crap. New one full metal version.

All back together... runs smooth, no check engine light. Taking it out later for a test drive and fluid leak check. Cross your fingers!