__________________ Maint: Liqui Moly 10W60 Race Tech GT1 Engine Oil, Pentosin MTF2, Mobil1 Full Synthetic ATF Steering Fluid, ATE Super Gold Brake Fluid Wheels: Style 65 18x9.5" Squared 275/35/18 Dunlop Direzza Z1 Sport Star Spec, 3mm Front Spacers, Turner Motorsports Extended Bolts Braking: Genuine BMW Rotors, Pagid Yellow RS 19 Endurance Racing Compound, Titanium Backing Plates, Open Brake Ducts, FTE Lines Handling: Intrax Racing Springs, Bilstein B8 Monotube Dampers, Ground Control Camber Plates, Dinan Strut Tower Brace, Dinan Rear Sway Bar, X5 Thrust Arm Bushing Power: Is Nothing Without Control, Stock Motor Dyno'd @ 341WHP, 319LB-FT Dynojet. Aero: None Yet Race: email@example.com Englishtown, Lime Rock Park 1'09.9", New Jersey Motorsport Park Lightning Circuit 1'23.420", Thunderbolt Circuit 1'44.2", Watkins Glen International *tbd, Monticello Motor Club *tbd. Gear: Bell SA2010 Sport Helmet, Sparco Tornado Racing Gloves, Sparco Speed+ Racing Shoes, OMP Balaclava Winter: Style 66 17x8, 17x9 Staggered 235/45/17-245/45/17 Bridgestone Blizzak WS70 Studless Snows Interior: E60 SSK, ZHP Shift Knob, MK4 Navigation, Umnitza VXX Angle Eyes, Brushed Aluminum Trim Swap Favorite Quote: "Understeer is when you hit the wall with your front end. Oversteer is when you hit the wall with your back end. Horsepower is how hard you hit the wall. Torque is how far you move the wall when you hit it. "
Thanks guys for your ideas, there was a smaller gasket on the temp sender, that I had to sort of unscrew off the threads to put on the new one, could there have been a bigger one as well? I have just done a complete blank on where it came from...
You most probably nicked the new o-rings for the TStat housing. I went through a few before I realizes BMW were giving me the wrong size O rings! I ordered some nitrile ones in the correct size from another supplier and no more probs.
I could probably get a tstat out in 20 minutes depending on how tight it is sealed to the engine block. The most time consuming step is draining the coolant, or in my case, pumping it out from the expansion tank.
There should only be the one crush washer with the temp sensor. I just changed mine and have the old one so will have a quick look. So not sure what your left over part could be?
If you find the source of the leak it may tell you, but it does sound like a nicked o-ring, it's super easy to do. See if you can feel around the back around the three pipes if there is moisture or even a bit of o-ring that was trapped and protruding.
Also, I'd suggest using KY Jelly on the o-rings if you do need to re-insall, water based lubricant is better for their long term life from what I've heard : )
PITA that this happened just before you head of on a road trip!! It's always the way...