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General E46 Forum
This is the place to get answers, opinions and everything you need related to your E46 (sedan, coupe, convertible and wagon) BMW!

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Old 04-18-2013, 11:47 AM   #21
Mango
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That seal area looks dirty. Try cleaning it and reinstalling
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Old 04-18-2013, 05:01 PM   #22
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My Wahler unit also developed a leak from the o-ring after roughly 15k miles. I replaced it with Behr. So far so good.
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Old 04-18-2013, 05:10 PM   #23
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FWIW, my Wahler has been going strong for 3 years/40k so far
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Old 04-18-2013, 05:33 PM   #24
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I installed my Wahler thermostat in January and 3 months later it's fine. Absolutely no issues. I just installed a Wahler thermostat on an '02 330ci yesterday for a friend. The original thermostat on his car was manufactured by Wahler and had a BMW stamp. Wahler is the original equipment manufacturer.
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Old 04-18-2013, 06:13 PM   #25
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Never had a leak from the many Wahlers I have installed.
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Old 04-18-2013, 07:20 PM   #26
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Maui330I

How did you go about removing the part to replace that o-ring?
Get a fine pick. Right behind the plug, you'll notice a little "latch". Put the pick behind the latch (you're not gonna have any space in front of the latch) and gently pull it up and then twist the plug forward then pull out. I think you have to remove the thermostat from the housing before that plug housing will come out though

Last edited by dznuts007; 04-18-2013 at 07:21 PM.
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Old 04-18-2013, 07:37 PM   #27
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Don't waste your time with the o-ring... it didn't work. at least not for me. I'm going to replace it with a behr unit.

Maybe this problem is limited to a certain manufacture date or defective production lot.

I have just checked and both thermostats were manufactured on Jul/2011

If some of you who had problems with this thermostats still have them maybe you should check the manufacture date and see if it is the same or close to 07/2011
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Old 04-18-2013, 08:04 PM   #28
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Totally possible. Good that you noted the dates on both of them. Have you tried contacting Wahler to see if they knots of any issues with that lot#? Maybe the dealership might have some info too

Also, did you follow the torque specs when tightening the bolts? I ended up cracking one thermostat housing due to a faulty torque wrench. Also you might crush the gasket of you over tighten it. Too loose and it might leak
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Old 04-18-2013, 08:20 PM   #29
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Old 04-18-2013, 09:37 PM   #30
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Totally possible. Good that you noted the dates on both of them. Have you tried contacting Wahler to see if they knots of any issues with that lot#? Maybe the dealership might have some info too

Also, did you follow the torque specs when tightening the bolts? I ended up cracking one thermostat housing due to a faulty torque wrench. Also you might crush the gasket of you over tighten it. Too loose and it might leak
I have contacted Wahler... lets wait for their answer. Anyway I'm going to install a Behr unit next week.

I did follow torque specs.
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Old 04-18-2013, 09:55 PM   #31
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Oh yeah and did you tighten the bolts in the proper order? Not sure if it'll make a difference but always good to follow good practices
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Old 04-19-2013, 07:53 AM   #32
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Oh yeah and did you tighten the bolts in the proper order? Not sure if it'll make a difference but always good to follow good practices
nop, no particular order.... just 10Nm for the 10mm and 20Nm for the 13mm.

I didn't know of a particular order, but if there is one I'm sure Mango will came in with it.
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Old 04-19-2013, 08:55 AM   #33
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I would have done it in a criss-cross pattern
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Old 04-19-2013, 10:34 AM   #34
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I have a Behr thermo. & it's held solid for 48k+ miles so far. I personally prefer the design of the Behr - where there's a big metal C-clip holding down the heater element vs just a tiny plastic latch.

And, as long as you followed the torque specs you should be good to go because all you're doing is seating the rubber gasket - the heat from the aluminum block does the rest (of sealing against the unit) once the motor reaches operating temperatures.

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Old 04-19-2013, 12:31 PM   #35
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I just replaced my Wahler with a Behr. The Wahler was leaking from the o-ring like the one shown in Mau330i's pictures. My Wahler's production date was 06 2011.
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Old 04-19-2013, 04:40 PM   #36
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It seems the OE Whaler thermostats sold by BMW dealers don't leak, while those by other vendors do.
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Old 04-19-2013, 04:41 PM   #37
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Originally Posted by Megalocnus View Post
It seems the OE Whaler thermostats sold by BMW dealers don't leak, while those by other vendors do.
I've installed at least a dozen vendor-sourced OEM Wahlers with a 100% success rate.

Last edited by Mango; 04-19-2013 at 04:41 PM.
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Old 04-19-2013, 05:01 PM   #38
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I've installed at least a dozen vendor-sourced OEM Wahlers with a 100% success rate.
Wow, you must be very popular :-)
I have installed only four, three of them on my car, all of them made by Whaler (purchased from BMW dealers or Pelikan parts). Had a couple of soft failures jfoj has a thread on, but no leaks.
Still, it seems that there must be a bad batch of OEM Whaler thermostats, otherwise there wouldn't be so many people complaining theirs are leaking at the electric connectors. None of the OE Whalers seems to have this problem, so I assume this batch didn't make its way to the BMW dealers.
So far I've seen only one report of a Behr thermostat having the same problem.
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Old 08-06-2013, 02:20 PM   #39
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I installed my Wahler thermostat back in January and a month later I had a very slow leak. The coolant was coming from the bottom between the two bolts. After double checking the torque and adding a little coolant every week or so, I simply called ECS and they are sending a replacement. He said that they aren't having problems with them but we'll see how this one does. I cleaned the area well and torqued the 10mm bolts to 10mn and the 13mm to 20mn, so I thought that I went by the book.
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Old 11-24-2013, 07:47 PM   #40
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Just was checking my car out and noticed my Whaler thermostat is leaking AGAIN from the same area. This is the second one I've put on in a year. Replaced the previous one due to the same leak. Pelican warrantied the part but I don't enjoy doing it and bleeding everything, etc. I don't have much faith putting a Whaler on again as you can understand - OEM supplier or not.
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