This is a guide I put together for anybody that needs a helping hand. There is a very good video on youtube how to remove and replace but I thought I should put something up on the forum anyway, so here goes.
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What you will need to embarke on the challenge of a life is 1X Flat head screw driver, 1X T-25 Torx bit, 1X No5 allen bit, 1X rachet (i used a small one), and this is optional but i found it helped with a small extension piece. A little bit of ambition and a cup of tea to start with.
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Those are the two parts you will need, 1X EGR Thermostat and 1X O-Ring, I kept them in the packages so you can take the part numbers from them.
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You will now need to remove the Bolts that hold the engine cover in place and also pry the plastic clips that hold the air intake part in place(set of pliers will suffice). To remove the bolts you will need a SIZE 5 allen bolt, there are 5 bolts in total (see below too see the 5th).
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This is the 5th bolt located to right side of the engine cover (about 1inch above the ATF oil fill cap). After removing that bolt, to the immediate right is a hose thats fixed in place with a rubber shroud, with a little bit of effort the will simply come out (push it away from youfor it to release)
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After you have completed the above you can now remove the cover, it simply slides out. Put this to one side or let the dog chew on the edge, up to you
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Now there is the blighter, the black part with a bolt in either side of it. This is what needs to be replaced which i shall now show you.
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Right ok, in the bottom left is the EGR stat but to the top you will see a black pipe with 2 jubilie clips (i believe this is a vacum pipe), there is 1 bolt that holds this in place, I advise you remove this gain access to one of the bolts holding in the EGR stat. Too remove this you will need a T-25 Torx bit to get it out.
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This is the vacum pipe removed and move to one side you may find its a bit of PITA to move over as the pipe is rather rigid but its do-able. You now have clear access to the other bolt to make life a bit easier.
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Before you remove the EGR stat please take off the coolant fill cap to release any pressure in the system, wether the engine is hot or not I recommend this is done carefully so you do not injure your self in anyway. It also stops coolant spraying out of the pipe connected to the EGR stat and going all over the belts etc etc.
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Ok so now you have got the pressure out of the system (sort of) you can now loosen the jubilee clip that holds the pipe into the EGR stat, all you need is a flat head screw driver, but again be carefull incase any coolant squirts and or seeps out of the pipe or stat.
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Now with the coolant pipe removed and vacum pipe out of the way you can now begin to remove the bolts with a 10mm Socket, as you can see in the diagram there are 2 bolts. once they have been removed you can simply pull the EGR stat out (may need a little pull).
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With the old and duff EGR stat gone this is what it looks like when its removed, very simply device but the havoc it causes! anway moving on
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Well here we are, the new stat, you will see on the old stat where the O-Ring is located too, so simply push the O-Ring into place and put the new EGR stat into place, it may need a little push like I had to and you may feel a little jolt as it finds its way home (so to speak)
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With the new EGR stat in place rebolt and tighten them up, they dont need the power of the gods to tighten them up just enough so they are positively in place, after that get the coolant pipe push it back into your new EGR stat and tighten up your jubilee clip accordingly.
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I took this picture so you get a better idea on what the vacum pipe looks like and how the bolt is fitted, be carefull when putting this bolt or any bolt and or screw back, loosing it is like the end of the world and many blue words will be shouted and you may even make some of your own up in the process hehe
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After you have refitted the vacume pipe, tightened it up, made sure all is tight you can now be proud of yourself on a job well done but one thing you need to do before you fire the girl up is?????????
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Yes put the cap back on the coolant fill reservoir, then fire her up, go for a test drive make sure the car is getting up to temp and not living in the blue zone for an age but getting into the 12 o'clock position and stays there
I hope the above helps some of you out and serves well, any edits please tell me or and Qs please ask. My car since doing this little job is so different, its not munching diesel and its getting up to temp nicely. You can obtain this part from our forum vendors, this item is not available from ECP or GSF, you will have to obtain from Hereford BMW and or your local BMW dealer. its only about £35 so it wont break the bank and its a simple fix. It to me approx 45 mins to complete.