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BMW 3-Series (E90 E92) Forum > BMW E90/E92/E93 3-series General Forums > Regional Forums > UK > Thermostat nightmare! :(



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      02-17-2013, 10:14 AM   #1
ssc330d
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Thermostat nightmare! :(

Well as the weather was fine today I thought that I would change my thermostat and flush out the red coolant that was in there. I wish I hadn't started now!

Got everything stripped off and finally got to the thermostat - 2 of the bloody bolts sheared off!

I was using a mini wrench with not much force - so if anyone else is going to do this - be VERY careful!

So what started out as a little DIY job will probably end up costing a fortune.

At least they haven't snapped flush - but I haven't a clue how to get them out - not much room and my mole grips just slip.

Looks like a tow to the garage tomorrow and hope they can some how get them out unless anyone can suggest anything?

BTW - does anyone know where the radiator drain plug is on a E90 330d? Could I hell as find it! I thought it was on the bottom of the radiator - nothing there??

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      02-17-2013, 10:26 AM   #2
Danny.B.
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ahh man thats not nice, puts me off trying it myself! hope you get it sorted!
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      02-18-2013, 03:40 AM   #3
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I did this job at the weekend and the bolts seemed to come out ok. I must admit, i've done them up tight just to make sure it didn't leak. If i have to change it again, hopefully they will come out.

I know its a bit late now, but i took the car for a little drive before i started the job. Not sure if this helps, but everything was warmish.

I would be interested in knowing how you drain all the fluid. Need to do a full change on mine.
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      02-18-2013, 04:01 AM   #4
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Spray some plusgas and leave it for at least an hour, come back to it with your mole grips - over tighten the grip first so you really have to grunt when squeezing it on to the ends of the bolts

Don't forget to order two replacement bolts pn# 07119904169

Your alternative is to remove the water pump and drill and tap the bolts out - last resort really.

I'd have thought if you have to have it towed and rectified it's going to cost you ~200 - your entire cost saving from doing this job yourself and more besides

Last edited by coopersim; 02-18-2013 at 04:14 AM.
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      02-18-2013, 04:48 AM   #5
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Radiator plug looks to be bottom on N/S

http://www.realoem.com/bmw/showparts...18&hg=17&fg=05
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      02-18-2013, 05:12 AM   #6
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Quote:
Originally Posted by coopersim View Post
Radiator plug looks to be bottom on N/S

http://www.realoem.com/bmw/showparts...18&hg=17&fg=05
Thank you.
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      02-18-2013, 05:50 AM   #7
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Certainly try the anti-seize methods, if there is enough stud to grip, but it may not work if there is too much inter-material corrosion.

You may need to get the pump off, a decent workshop should be able to weld a bar on the studs and remove them. A bit of heat works wonders on broken studs.

When I was in the workshop environment, it was one of my specialities and removed hundreds of broken studs that way, saving customers buying new parts.

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      02-18-2013, 08:30 AM   #8
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Originally Posted by HighlandPete View Post
Certainly try the anti-seize methods, if there is enough stud to grip, but it may not work if there is too much inter-material corrosion.

You may need to get the pump off, a decent workshop should be able to weld a bar on the studs and remove them. A bit of heat works wonders on broken studs.

When I was in the workshop environment, it was one of my specialities and removed hundreds of broken studs that way, saving customers buying new parts.

HighlandPete
The cars is an the garage now. The guy who runs it pretty much said what you have HighlandPete - inter-material reaction - the bolts "weld" to the aluminium housing. Heat would be their first course of action.

Quote:
Originally Posted by coopersim
I'd have thought if you have to have it towed and rectified it's going to cost you ~200 - your entire cost saving from doing this job yourself and more besides
Yes I fear that you are right. One of those things though - the garage said they would have sheared for anyone who tried to remove them.

Quote:
Originally Posted by coopersim
Radiator plug looks to be bottom on N/S

http://www.realoem.com/bmw/showparts...18&hg=17&fg=05
Yeah thanks - that is where I thought it was - could I hell as find it though!

Quote:
Originally Posted by GrahamE90
I did this job at the weekend and the bolts seemed to come out ok. I must admit, i've done them up tight just to make sure it didn't leak. If i have to change it again, hopefully they will come out.

I know its a bit late now, but i took the car for a little drive before i started the job. Not sure if this helps, but everything was warmish.
I don't think it would have made any difference to me - according to the garage the bolt and aluminium "react" together like a weld. The sort of heat they are talking to budge it is gas torch.

So just waiting to hear from the garage now to find out what they will have to do, plus the cost .
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      02-18-2013, 08:55 AM   #9
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Hopefully its not too expensive!
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      02-18-2013, 09:05 AM   #10
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Good luck getting it sorted. Mine came out with no issue.
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      02-18-2013, 09:53 AM   #11
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Oh dear

Out of interest, and to build some data on this problem, would you mind sharing the mileage and age of your car? This might help people decide if it's worth a go themselves

Mine is 2008, 53k miles when I changed the stat
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      02-18-2013, 10:23 AM   #12
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Originally Posted by coopersim View Post

Out of interest, and to build some data on this problem, would you mind sharing the mileage and age of your car? This might help people decide if it's worth a go themselves
Not at all - its a 56 plate with 74K

That's a good idea coopersim - maybe people who have successfully completed this (or not) could post their cars age / mileage with any issues.
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      02-18-2013, 12:12 PM   #13
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This happened on my 320D. Slightly different I know but.....

Two of those silly male torx head bolts rounded off and I was lef t with no choice but to to dremel the heads off. This was so I could then use a stud extractor to remove the remainder.
Dremelling near the drive belt was fun!
However once the old thermostat was removed my stud extractors couldn't remove the left overs.
I was forced to remove the water pump, with that than in the vice the bolts came out easily.
A job that should take one hour took 3.

If it's like a 320D you'll need a new gasket for the pump. I didn't have one then so used special sealant to allow me to the get it running again.
I replaced the gasket yesterday, 1 hours work!
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      02-18-2013, 12:49 PM   #14
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Also, you should give the bolts a very small tighten till you hear a click before undoing them, this will loosen them without them snapping them, then you can undo them easily.
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      02-18-2013, 01:30 PM   #15
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I successfully changed both of my stats in November. 2006 330d 128k.
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      02-18-2013, 04:02 PM   #16
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How did you get on buddy?
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      02-19-2013, 01:15 PM   #17
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How did you get on buddy?
Just got it back this evening Danny.

Not too painful in the end. The garage said that to change a thermostat would normally be 1.2 hours, but they charged 1.5 because they had to remove the housing to get the sheared bolts out. Very reasonable I thought.

So all in, including new coolant came to 132 incl VAT .

And the main reason for changing the thermostat has been achieved. I accessed the hidden temp menu before I set off back home from the garage. In the 10 minute drive back home it rose to 92oC and settled there (previously highest was 82oC).

So at least it has all been for something .
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      02-19-2013, 02:53 PM   #18
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thank god for that! was it a bmw garage?
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      02-19-2013, 03:06 PM   #19
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Glad to hear all is well again!
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      02-19-2013, 03:33 PM   #20
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thank god for that! was it a bmw garage?
My God no! I am sure they would have managed to make it cost at least 3 times as much.

It was just a local garage my Dad has used for years.

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Glad to hear all is well again!
Cheers Shane.
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      02-19-2013, 03:48 PM   #21
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Nice one.. I was over the moon.

Mines just finished a full regeneration.. It started on a long drive but i think I turned it off half way through, and again when I got to work the day after..

Just took it out tonight.. Temps were around 91 (this seems to be where it hangs mainly) then it went up to 94 and got quite lumpy for 5-10 minutes before settling back down again.

It's smoother and perkier than ever now. Result.
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      02-20-2013, 03:03 AM   #22
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Nice one.. I was over the moon.

Mines just finished a full regeneration.. It started on a long drive but i think I turned it off half way through, and again when I got to work the day after..

Just took it out tonight.. Temps were around 91 (this seems to be where it hangs mainly) then it went up to 94 and got quite lumpy for 5-10 minutes before settling back down again.

It's smoother and perkier than ever now. Result.
Yes, nice one. Must be good to know the regen has completed and your DPF is ok.
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