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I have a 1992 525i with approx 78K miles. I have done the routine maintenance like clock work but still found myself nearly stranded when my car started overheating. I was close to a dealer so I had the car taken there.
What was found:
cracked radiator - It was at the top where the blow off valve is by the cap. There were also cracks in my water pump vanes which everyone should know by now is plastic. Had both of these items repalced in addition to the thermostat and the o2 sensor (my Check engine light would come off and on) so I though you other Bimmer fans would like to know how much these things cost at a dealer.
Waterpump-94.15
gasket-5.5
thermostat-25.50
Radiator-504.90 ouch!
Shroud-47.4
O2 sensor-97.24
these costs were without labor added. If anyone needs part numbers send an e-mail.
The new water pumps are suppose to have a metal vane. I'm in plastics and the plastic vane looked like it was made out of a glass filled nylon. Not a good choice of material. As far as the radiator I am surprised it had a crack in it. I talked to the master mech and he said that repairs on the radiator usually do not last. The shroud looked like it may be made out of a talc filled polypropylene. At least that is what other car makers use. Looks like on some of the plastic parts not enough stabilizers were added to the material for long term durability. Plastics generally get brittle as they age but this acceleration can be minimized with the correct choice of additives.
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