Removal and installation of oil coolers (BMW 7 Series E38)

EGR system radiator

1. Remove the engine crankcase guard.

2. Remove the expansion tank of the cooling system (see chapter Engine cooling systems).

3. Remove the intake manifold.



4. Disconnect all wiring harness connectors between cylinder banks.

5. Slightly lift the engine wiring harness, disconnect the connector from the K/L engine oil pressure switch, move the wiring harness to the side and secure it.



6. Disconnect the water hose (1) from the EGR cooler, loosen the clamp (2) and disconnect the water hose (3).



7. Loosen the clamps (1), remove the right (3) and left (2) EGR system pipes.



When installing, place the clamps (1) in their original positions. To install the intake manifold, the clamps (1) must remain loose.



8. Loosen the clamps (1), unscrew the bolts (2) and remove the EGR system radiator (3).

9. Installation is carried out in reverse order.

Oil cooler

When the oil filter housing is removed, some remaining engine oil will leak out of the housing into the coolant space underneath. To avoid engine damage due to engine oil entering the cooling system, remove engine oil from the coolant space before installing the oil filter housing.

1. Remove the EGR cooler.

2. Unscrew the bolt (1), give the union nuts (2), remove the distribution tube (3).

3. Follow the steps described in paragraphs c 6 to 12 Section Replacing the PCV oil separator.



4. Remove the cover (1) of the full-flow oil filter and take out the replaceable filter element.

Do not damage the cover, loosen and tighten it only with a socket wrench. After removing the cover, the oil drains into the oil pan. When installing, use new cover sealing rings.

5. Loosen the clamps (1) and disconnect the ventilation hoses (2).



6. Loosen the oil filter housing mounting bolts and remove it by pulling it vertically upwards.

7. Remove the oil filter housing gasket and clean the mating surfaces from any remaining sealing materials.



8. If engine oil (1) has entered the coolant, collect it with a clean rag. Also remove any remaining engine oil and coolant from the blind threaded holes (arrows) and from the cavities (2). Clean the mating surfaces.





9. Remove the bolts and oil cooler.



10. When installing, replace the gaskets (1), clean the mating surfaces (2) of the oil cooler (3).

11. Installation is carried out in reverse order. Finally, bleed the cooling system.