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Discussion Starter · #1 ·
Hello gentlemen I am new to the forum as I have recently purchased a 2005 325CI , sadly while doing some maintenance I.E a new thermostat and a purge valve replacement. I had the two bottom bolts of the thermostat break in half inside the engine block. It is being towed to the shop now to be repaired.
 

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It probably having a leak at the Tstat housing for sometime, leading to corrosion on the bolts. To avoid this next time, tapping the bolt head with a hammer before wrenching it out.
 

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Discussion Starter · #3 ·
It probably having a leak at the Tstat housing for sometime, leading to corrosion on the bolts. To avoid this next time, tapping the bolt head with a hammer before wrenching it out.
Well the bolts that had come off of the thermostat felt a bit cheap, I made the mistake of putting them back onto the housing (and over torqueing) i should have used the OEM bolts.
 

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I think you need to ask your momma for a torque wrench for Christmas. :ROFLMAO::LOL:
Or tighten them with a quarter inch ratchet and one hand by feel...

"Tight is right, any more and it's broken"!

On the thermostat, the gasket does most of the sealing..no need to go gorilla on the bolts.
 

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E30M3 Race F10 535 R1150Rt M Coupe
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Also take into account that almost all of the nylon bits that bolt to an engine either have bolts with a shoulder or metal inserts inside the openings. Going tighter does not stop leaks (see valve cover and why it's important to replace the seals) it only tests the fastener's ductile strength.
 

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I did the first one and then my uncle tried the next...
You guys have any ideas how much torque the bolts need? The Tstat housing on E46 has an O-ring seal and not paper gasket like the old days that needs more torque. As soon as the Tstat housing is bottomed to the block, more torque won't help to seal the leak.
 

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You guys have any ideas how much torque the bolts need? The Tstat housing on E46 has an O-ring seal and not paper gasket like the old days that needs more torque. As soon as the Tstat housing is bottomed to the block, more torque won't help to seal the leak.
It doesn't have an O ring. It has a built in rubber gasket.
 

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'03 325iT Mystic Blau
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Let's just not go any further into the semantics of what constitutes an o-ring vs what constitutes a rubber (or other material) gasket please.
It's not important to the conversation and there's been too much arguing here today already.
 

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"Profile Gasket" Done....
 

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OP, sometimes it can be helpful to ease the bolt out, especially for h2o / tstat applications. Once you break the bolt free, let it out a little, then put it back in, back out, back in a bit. This usually contributes to success in these scenarios.
 

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Discussion Starter · #17 ·
You guys have any ideas how much torque the bolts need? The Tstat housing on E46 has an O-ring seal and not paper gasket like the old days that needs more torque. As soon as the Tstat housing is bottomed to the block, more torque won't help to seal the leak.

yes just got quoted $900 for removal of two broken bolts replacement of therm. and reassembly of the 325ci.
 

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Discussion Starter · #18 ·
Or tighten them with a quarter inch ratchet and one hand by feel...

"Tight is right, any more and it's broken"!

On the thermostat, the gasket does most of the sealing..no need to go gorilla on the bolts.

my mistake was not having a proper gasket on the replacement to tell me when to stop torq
 
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