Problems with the radiator, water pump, radiator cap, water / coolant flange and batter drainage?

Tiny
CHRISTIANP
  • MEMBER
  • 1998 BMW Z3
  • 1.9L
  • 2WD
  • MANUAL
  • 80,000 MILES
Hi there.

I wanted to enquire regarding some work that my mechanic carried out recently. All issues appear to be resolved now but I need to assess what happened at each stage.

The problem originated whilst I was stationary with the engine running. There was a loud bang from under the bonnet, steam came out of the bonnet, and water leaked out onto the ground.

I had the car towed to my mechanic who, after some time, replaced the radiator and the water pump. (If I recall correctly, he had to return the first radiator he ordered as it developed a crack in it (or so he claimed)). Within a few minutes of picking the car up from him, I was driving along and heard a grating/grinding noise coming from under the bonnet again. Once again smoke/steam started coming out from under the bonnet. When I stopped the car, there was anti-freeze leaking out onto the ground.

I telephoned my mechanic who seemed to think the smoke was just from burning off excess anti-freeze that he had just added. He suggested that the problem should resolve itself in about 10 mins and I could continue to drive it.

The problem only got worse as the engine overheated with the temperature gauge up to the max. I managed to drive it home which was about 5 mins away, stopping and starting along the way. After some delay, my mechanic came to collect the car, applying a temporary fix to the flange in order to drive it back to his garage. He replaced the water (coolant?) Flange and the radiator cap, both of which had broken.

On collecting the car from him, a new problem had emerged which he told me about just before releasing the car to me, which was battery drainage. He seemed to think this was due to the car stereo seemingly not turning off. I took the car to another mechanic to sort this issue out whose diagnosis resulted in disconnecting the car stereo; he considered there was an internal fault with the car stereo. I have replaced the car stereo with a new one and there is no further battery drainage.

I would like to know two things:

(i) Whether the failure of the flange and radiator cap has anything to do with the work of the mechanic who replaced the radiator and water pump - i.E. Whether it could be due to him not testing the car properly before releasing it to me, or a failure to bleed the system after he had replaced the radiator and water pump, or something else he may have done. The car admittedly is about 25 years old (BMW Z3 1998) but I can't help but think that it is too coincidental that the flange and radiator cap should break within minutes of picking up the car from him, particularly if he had checked and tested the system properly, and if the replacement radiator had been supplied with a new radiator cap.

(ii) Could my mechanic have done anything whilst carrying out the replacement of the flange and radiator cap, to cause the problem with the car stereo that then caused the battery to drain. I appreciate that replacing these items may be unrelated to the car electrics. If so, can you offer any thoughts as to why the car stereo could have malfunctioned in this way. The stereo is not new, but it is also not the original stereo that came with the car. It is probably about 10 years old.

Any thoughts / advice you can give would be much appreciated.

Many thanks in advance,
Christian
Wednesday, February 1st, 2023 AT 3:07 AM

10 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,192 POSTS
Hi,

The idea that the radiator flange and cap failed really makes no sense to me. Certainly, they can fail, but on a new radiator, I wouldn't expect it and it wouldn't be something easy to damage. It was the radiator outlet flange, correct? Also, was the radiator cap damaged, or where it attaches? Did he replace the radiator with a new one? If the output flange failed, it is likely plastic and not repairable.

Here is the thing, when a radiator is replaced, testing is simple. First, you need to make sure there are no leaks by allowing the engine to reach operating temp. At that point, it pressurizes the system and if something is damaged, it should leak. Once that is done, then the coolant level is checked.

As far as the water pump, it is very possible that a wire may have been pinched and shorted when the work was done. However, if the radio replacement stopped the issue, then I doubt anything happened when the pump was replaced.

Let me know if this helps.

Take care,

Joe
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Wednesday, February 1st, 2023 AT 2:36 PM
Tiny
CHRISTIANP
  • MEMBER
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Hi Joe,

Thank you so much for your reply, which is really helpful.

Re: the flange: the liquid that leaked out when the flange failed was anti-freeze. The mechanic listed "water flange" on his invoice; it is one that goes into the engine. If that is another name for radiator outlet flange (or coolant flange) then yes that is the item. The mechanic claimed that he had not worked on that part of the car when he replaced the water pump and radiator. He said all the work he did was at the front where the radiator and water pump are located, and he did not touch the part where the flange was.

To confirm, he replaced the radiator and pump first, then when I picked up the car from him, the issues with the flange and radiator cap happened which required those items to be replaced as well. It would appear that it was only after he replaced the flange and radiator, that the issue with the radio and battery drainage happened.

As far as I am aware, I do not think that the flange which failed was a new flange that came with the replacement radiator; it was the flange that was already there. Assuming that a replacement radiator cap came with the replacement radiator, it does seem strange that it should have failed; is it possible that my mechanic ordered a replacement radiator that came without a new cap? (E.G. If it was a secondhand radiator that he installed)

In your experience, would the failure of the flange and cap have happened upon carrying out the testing procedure you have described - i.E. If those parts were on their last legs and were due to fail at any moment. Or could some error in workmanship by the mechanic have caused them to fail?

Re: the battery drainage: I did think it was unlikely for this to have been caused by any of the mechanical repair works that were carried out, but it is a bit strange that it happened to occur once again whilst my mechanic was working on the car.

Just to be clear, I don't think he has deliberately caused these problems, but I do wonder whether he or his workers have been negligent and not treated the car with proper care and respect.

Any further thoughts you can offer on the further questions regarding the flange and radiator cap would be very much appreciated.

Many thanks,
Christian
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Wednesday, February 1st, 2023 AT 10:46 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,192 POSTS
Hi,

The only other flange that sounds relevant is the thermostat housing. However, that is at the front of the engine above the water pump. See pic below.

If that was leaking, I would think it would have been seen, but anything is possible.

By chance is that what is indicated?

If you have the receipt from the repair, take a pic of it and upload it for me to see. That may point me in the right direction. Also, I don't feel pressure testing the system would have caused this.

Let me know.

Take care,

Joe

See pic below.
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Thursday, February 2nd, 2023 AT 8:23 PM
Tiny
CHRISTIANP
  • MEMBER
  • 6 POSTS
Hi Joe,

Thank you once again for coming back to me. I believe I have the broken flange that was replaced because the mechanic left it in the car, so I have attached a couple of photos of it. I am also attaching the two relevant invoices - the first for the radiator and water pump replacement: the second for the flange and radiator cap replacement.

Look forward to your further thoughts on this and thank you again in advance.

Best,
Christian
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Friday, February 3rd, 2023 AT 1:24 AM
Tiny
CHRISTIANP
  • MEMBER
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Hi Joe,

I also just remembered that the mechanic sent me a photo of the replacement part he ordered once it had arrived, so I am attaching a photo of that too. It is a bit blurry I'm afraid.

Many thanks,
Christian
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Friday, February 3rd, 2023 AT 1:28 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,192 POSTS
Hi,

That is the thermostat housing, and it is plastic if I recall. I don't feel you have anything to worry about. If that has been replaced, you should be fine. Also, the tests that were done wouldn't cause that to happen.

Let me know if you have other questions.

Take care,

Joe
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Friday, February 3rd, 2023 AT 1:27 PM
Tiny
CHRISTIANP
  • MEMBER
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Thank you very much once again Joe.

I guess my only remaining questions are: (a) what caused the flange and radiator cap to fail? And (b) if they were bound to fail, should that not have happened during testing by mechanic, before he returning the car to me?

Many thanks,
Christian
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Monday, February 6th, 2023 AT 1:50 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,192 POSTS
Hi,

First, you are very welcome. I just hope the info I'm providing is helpful.

First, it's odd for the thermostat housing to fail. They normally last the life of the engine. However, anything is possible. It may have been hit when other work was being done or the thermostat was incorrectly installed.

As far as the cap, when the system is pressurized, the cap is removed, and a pressure tester takes its place. If he hadn't checked the cap separately, he wouldn't have known.

I hope this helps. Let me know if you have other questions or if I can help in any way.

Take care, Christian.
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Monday, February 6th, 2023 AT 8:06 PM
Tiny
CHRISTIANP
  • MEMBER
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Thanks again Joe. My mechanic's perspective is that this is a case of wear and tear due to the age of the car and the parts. I'm not convinced but it's one of those which would be difficult to say one way or another. Your help has been invaluable, very informative and much appreciated. I won't take up any more of your time.

Best wishes,
Christian
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Tuesday, February 7th, 2023 AT 2:10 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,192 POSTS
Christian,

That is very possible. Also, please never feel you are taking up my time. I do this to help. You haven't been a problem in any way, shape, or form. LOL

Regardless, please feel free to come back anytime in the future. You are always welcome here.

Take good care of yourself,

Joe
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Tuesday, February 7th, 2023 AT 7:46 PM

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