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E60 / E61 (2004 - 2010)
BMW 5-Series E60 Sedan was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E61 wagon followed shortly there after. The E60/E61 5 series is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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Old 03-18-2012, 07:47 PM
Julio_Lujambio@ Julio_Lujambio@ is offline
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Location: Wallingford
Join Date: Mar 2012
Posts: 6
Mein Auto: BMW 535xi
How to replace Thermostat e-60 (535 xi)

Just finished replacing the thermostat in my 535 and I am sharing learnings.

Expected time to perform for home mechanic: 2 hours. Pro: 1 hour max.

Thermostat is located in the non-driver side below the engine.

1- rise your car so you can reach all the lower splash panels/cover in the bottom of the car
2- secure the car so it does not move
3- take out front and back splash (around 20+) screws
4- remove lower protector plate ( 6 big bolts). You will need air powered tools or heavy and good wrenches.
5- remove bolt and move hydraulic hose to the left so you can make room.
6- remove hoses from the thermostat
6.1 - start removing the ones that have the secure wire to keep them in place. Take out the wire lock (you can pry it with a small screwdriver) and then pull the connector out of the each one. (you can drain your system at this time :-) ) thus, have a handy container to collect the cooling fluid.
6.2 - remove the 2 bolts that keep the thermostat in place
6.3 - pull the thermostat to the side so you can see and reach the other 2 hoses
6.4 - gently unscrew the clamp that holds the small hose - fluid will drain when you remove the hose- and then pull to the side to remove the hose.
6.5 - gently unscrew the clamp that hold the big hose - fluid again - and with one hand reach the hose from the back of the frame and pull with your other hand the thermostat.

Installation procedure is the opposite.

good luck!.
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