E90 N46 Coolant Leak Behind Engine

[Craig B 0]

Hi All

As a follow-up to my previous coolant woes, I've added some pictures on how to replace the 'Camshaft Cover Plate"

Quick Recap, used a cheap top coolant hose, leaked from day 1 and I put very small crack in radiator plastic header tank, I then used radiator stop leak (DON"T DO THIS....), gummed up thermostat, pressurized coolant system.   I finally replaced all hoses, new thermostat, new radiator, still got a small coolant leak, seemed to be coming from behind the engine at the firewall, sealed itself for a while, but I over filled the coolant tank (DON"T DO THIS...), and it started to loose coolant again, also smelt out the car with coolant smell through aircon.

Step 1: Found video on youtube by a polish guy who traced his 'back of engine coolant leak" to the camshaft cover, American stuff is no use as they don't seem to have the 2.0L engine

Step 2: Order replacement cover from e-bay

Step 3: Remove the top cover with aircon filter - 6 screws

Step 4: Un-clip and remove small plastic panels on both sides

Step 5: Un-clip cross engine cable holder and release cables, unlcip back cable holder from plenum (they un-clip and pull towards the front)

 

Step 6: Undo two screws on plenum panel and lift up and out to release, remove weather sltrip

Step 7: Unclip cam cover breather an cable tie out of the way

Step 8: Undo hose clip on ali block at back of engine, and undo quick connect on brake aster cylinder - remove whole hose

Step 9: Use Torque socket to undo the tower strut

Step 10: Unscrew cap and use torque socket to undo bolt, remove brace

Step 11:  Now that the area is relatively clear, you're going to have to squeeze down behind the engine between the fire-wall with a 10mm ratchet spanner and loosen/remove the 4 bolts holding the camshaft cover in place. 

NOTE: Make note of orientation before removing

You are probably going to need to pry it off with a screw driver. 

NOTE: You are going to loose a bunch of coolant so be prepared.

I tried several times to get a photo, but it's too cramped, I got a clip of the corner...

Down here....

It's probably going to look a little like this

Step 12: Fit new one, brace yourselves, it can take a while to get the bugger lined up, and all the bolts in holes...  Brace yourself for hand cramps

Step 13: Reassemble the rest of the car

Step 14: Refill coolant (DON"T OVERFILL...)

Step 15: Run engine, check for leaks

 Fingers crossed you'll be coolant leak free, happy days

 

[Eagle 1669]

Nice writeup, but most here are savvy enough not to ever own this engine so you efforts maybe a bit in vain. Be prepare to play a game of wac-a-mole with the numerous other coolant fittings. Luckily you can do repairs as ive seen multiple people sink money into these and end up taking it out on the workshop.

[Craig B 0]

Thanks Jared

Yes, I agree entirely, I should have held out for the 6 cylinder as I'm am inline 6 kind of guy (HR 186S), but in my defense for the e90 series, 

MECHANICAL....WATER......PUMP........