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Old 03-10-2013, 04:00 PM   #1
Mau330i
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Question Wahler Thermostat Leak

Hello,

This is the second Wahler thermostat that develops a leak in 6 months!!!!

The leak comes from the o-ring that "seals" the electrical component of the thermostat and is the second thermostat that fails like this.

I replaced the original at the same time that all the other parts of the cooling system and it failed 2 months after so I bought a new one (same brand) and this week I noticed the same leak as in the previous unit.

I did disassembled the first one and the result is in the attached photo.

Should I replace the o-rings??

Should I replace the full unit AGAIN??

Is this a common problem with Wahler thermostats??

Is there any way to test the electrical component?? (I'm thinking on installing the original again by now if it is ok)

Some extra information:
Cooling system has been renewed (completely)
Bleeded correctly and extra coolant removed form ET before starting
Coolant level ok before leak
Coolant operation temperature from 203F to 210F
Mechanical fan deleted and using the electrical from a manual

Any help or advice will be really appreciated.
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Old 03-10-2013, 04:52 PM   #2
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I'd be either suspicious of your source or wonder if you didn't clean where it mounts well enough. If it was the same source, I'd go to the dealer or someplace different next time. Just saying.
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Old 03-10-2013, 04:54 PM   #3
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Crap, I just bought one
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Old 03-10-2013, 05:25 PM   #4
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I suspect your problem is the cylinder head of the mate. My Whaler stat has never leaked.
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Old 03-10-2013, 06:11 PM   #5
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Does it seem to leak directly at the electrical connection? If so, I've heard of that happening on a few different occasions here. Go with Behr.
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Old 03-10-2013, 06:12 PM   #6
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i'd be either suspicious of your source
+1
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Old 03-10-2013, 10:33 PM   #7
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Originally Posted by Zell View Post
Does it seem to leak directly at the electrical connection? If so, I've heard of that happening on a few different occasions here. Go with Behr.
Yes, it is leaking from the connector... Do you think I should replace the o-ring?????
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Old 03-10-2013, 10:38 PM   #8
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Originally Posted by Mau330i View Post
Yes, it is leaking from the connector... Do you think I should replace the o-ring?????
You could and see if that fixes it, but I'd personally get a Behr which doesn't seem to have that problem. Slightly different electrical connector design.

Wahler:

Behr:

I have no idea if the connector design difference is the actual reason for the leak, but I haven't heard of this leak happening with Behr thermostats.
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Old 03-11-2013, 12:08 AM   #9
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I've never heard of the electrical connector having its own seal. any closeups? if you are certain its leaking there, then I just say buy a thermostat from the dealer and be done w/ it.

i have a Wahler and it's been perfect. would buy again
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Old 03-11-2013, 01:27 AM   #10
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Just return it to where you bought it and have them give you a replacement.
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Old 03-11-2013, 04:18 AM   #11
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Where did you buy it from?

I did a cooling system overhaul and bought parts(non-OEM) from ECS Tuning and a couple of them leaked. Troubleshot and put back my original parts and no leaks.

I returned the parts and bought OEM BMW from the dealer. No leaks.
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Old 03-11-2013, 04:31 AM   #12
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I'm on my third Whaler thermostat - all of them purchased from BMW dealers - one eventually failed to maintain the operating temp above 90 C, but none of them had any leaks.
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Old 03-11-2013, 05:21 AM   #13
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My wahler leaked after 2 or 3 months so I had it replaced with a behr. Haven't had a single problem since.
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Old 03-11-2013, 08:40 AM   #14
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I've heard there's been issues on the Wahler. Unfortunately I did not come across the info until just after I installed one. So far so good (only been a couple weeks) but if it does leak I'll be replacing with a Behr.
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Old 03-11-2013, 11:17 AM   #15
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OP- I had the same exact issue with my Wahler thermostat after 10k miles. I replaced with OE and no more leaks.
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Old 03-30-2013, 06:29 PM   #16
Mau330i
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Wahler Thermostat O-Ring

Today I removed the 3 months old Thermostat and reinstalled the previous one (also a Wahler) but with a new / thicker o-ring.

After analyse this part and because if this leak again it can be detected with no risk to the car I decided to change the original o-ring with an "improved" one to see if this fixes what I think is a design problem. If it doesn't I will use a new Behr thermostat.

Attached some pictures of the disassembled thermostat I just removed so you can see the o-ring I change and let me know what do you think about this.

Lets see if this works....
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Old 03-30-2013, 06:42 PM   #17
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I bought a genuine stat from the dealer a year ago and it's been leaking, not sure for how long. I'm just going to live with it. What a waste of $110.
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Old 03-30-2013, 08:03 PM   #18
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^ BMW gives 2 year warranty on parts... get an exchange
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Old 04-18-2013, 11:23 AM   #19
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Maui330i:

Can you give some details (PN, Dimensions) on the replacement O-ring you used ? Did it work?
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Old 04-18-2013, 11:33 AM   #20
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Maui330I

How did you go about removing the part to replace that o-ring?
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