BMW 1 series main thermostat removal (Diesel) e87 e90 e60
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Hey guys. Welcome to yet another Regis garage video. And today we are going to change the main thermostat for this BMW 120D. Don’t worry if you engine is different than mine because this procedure is really similar in most BMW diesel engines.
Thing you need to know: before you start
1. You are going to spill coolant on the ground
2. 2. You will have your hands in the engine bay so best to do this when the engine is not so hot!
3. Disconnect the - battery to avoid any electrical problems

So let’s start by removing front air guide. It’s held by two T20 screws.
Then I tried to remove turbo air feed pipe. It‘s held by two 5mm allen bolts at the top and turbo end is a push fit and there is a breather pipe half way down. IT is also a push fit.
In order to remove that pipe and have some more space we need to remove the electric fan.
So first unplug the connector. There is one T20 bold at the top L/H side and there is a little plastic catch half way down on the R/H side you need to hold open as you slide the fan upwards.
So now we can remove turbo feed pipe.
This is EGR thermostat and the main thermostat is hidden behind the EGR cooler, As you can see it‘s held by 4 bolts.

Undo and remove the Hose Clamp that hold the ERG exhaust pipe on.
Disconnect the EGR air feed.
Undo and remove ERG thermostat hose.
Remove 2 x H5 bolts that attach the EGR cooler to the front of the engine
And one H5 bolt on the left hand side
Remove 2 x T40 bolts that attach the EGR cooler above the turbo.
Don‘t forget to disconnect the bottom coolant hose.
Now you can carefully remove the EGR cooler

Release the retaining clips that hold the hoses on to either side of the thermostat and disconnect them.
Remove the 4 x 10mm bolts that attach the thermostat to the waterpump.
As you can see there‘s some dirt. It‘s a good Idea to clean the surface before you install the replacement item. Now you only have to put everything back and don‘t forget to fill the system with new coolant and bleed the system. Here is a video for that. Thanks for watching. Don’t forget to subscribe. See you.