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BMW 3-Series (E90 E92) Forum > BMW E90/E92/E93 3-series General Forums > General E90 Sedan / E91 Wagon / E92 Coupe / E93 Cabrio > Broken head bolts, too!?!



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      07-29-2012, 12:14 PM   #89
Alliedacid
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Took about an hour but I got it out with two picks and an alligator forcep
Bolt is a M9 x1.25 length 70mm... Which is too long to get out if the intake manifold is still connected.

Had to take out the two air box out and the 6 bolts/ nuts off the intake cover

Could not find a steel bolt that Wouk fit since it is 2:30 on a Sunday.

Toyota caliper pin bolt is the right thread pitch but a bit long!

I am takin the am offf to hit up a local dealer ship for part...

Last edited by Alliedacid; 07-30-2012 at 12:29 PM.
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      07-29-2012, 04:59 PM   #90
Brad from the OC
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Quote:
Originally Posted by Alliedacid View Post
to start;
everyone great photos and info, thank you!!

Well last week my 06 325i (97k) over heated... water pump intermittently failing... so this Saturday I:

- replace the water pump
- thermostat,
- did a full coolant flush (5 gallons of distilled water through the system)
- tossed in some new plugs (cleaned the coils)
- battery
- changed out the rear diff fluid.

(extended warranty clock ran out )

In the process, I too found the random bolt in question to be snapped.

(FYI/e: Also i did have my AL Valve Cover Bolts done by dealer under my extended warranty; around 86k I think)


so in reading all the posts i came up short on some item of info:
1. how long is the bolt?


2. is it short enough can it be removed without taking off the intake manifold; please consider the new bolt will be longer (it will still have it's head

3. Regardless what is the torque?

4. Personalized; my snapped bolt is broken just below the bolt hole machined flange, it wiggles back and forth with a screw driver, so there is no torque on the threads.

The plan was to use a dremmel tool and notch the screw and back it out with a flat head (please DON"T comment on dremels and bs about chips getting in the engine; I know what I am doing; a rag with grease and a well place shop vac are the best chip collectors.

The issues;
it is Sunday, I do not have a new bolt and Stealer-ship is closed... so my question is:

those that have the broken bolt head which is not leaking, have you noticed if the bolt moves under driving vibrations?? if so further in or out ??

Thank you in advance!




FYI my Bmw service manager is a not well educated on his product! claimed he had no idea about it, sent a picture, had no clue as to what it was or what it did for engine... also his tech had changed the oil 4 days earlier, post the over heating (had a coupon) and did not notice a broken bolt right next to the oil filter housing!
After reading this thread, I looked at my 2006 325i and observed that I also have this same broken head bolt. I found the broken off head laying in a crevice adjacent to the broke bolt. I did not see any oil leakage and I was able to wiggle the broken bolt with a mechanics pick. I tried to back it out, but it didn't rotate out.

Let me know how your repair went as I will probably need to do this fix soon before oil starts to leak.
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      07-29-2012, 08:31 PM   #91
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Repair is simple; 2 picks, 1 straight and 90 deg pick, used to turn the bolt til it was high enough so i could use the forceps; so if your not turning it; you are not backing it out!

Completely unscrewed the remaining bolt, learned that it is too long I remove with the intake manifold in place... Equally the manifold will not clear the bolt if it is not screwed in

What did we learn:
0. Remove everything as if you where doing a spark plug job...
1 see if you can get the bolt high enough to grab it, do so if not you're drilling and tappin it
2, with the bolt up ( no more than 1/2 in)….
Remove the 2 bolts holding the air box; disconnect the front intake...
Unbolt the 3 bolts and 3 nuts...
3. Move it by gentle pulling the intake up, the studs will be a guide... The air box and throttle body will move with it!

4. Completely remove bolt, I you need to drill it, put rags over the intakes on the block.…
Easiest way to remove this bolt would be to use a left direction drill bit… in a drill going in reverse…

5 insert new bolt/
6 te I install everything back on the car
Sorry I don't have torque number
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      07-30-2012, 09:48 AM   #92
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I had the same issue !!
http://www.e90post.com/forums/showthread.php?t=461241

follow the steps on what Alliedacid posted.
easy fix. nothing happened since the screws replaced..
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      07-30-2012, 11:27 AM   #93
Brad from the OC
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Quote:
Originally Posted by Alliedacid View Post
Repair is simple; 2 picks, 1 straight and 90 deg pick, used to turn the bolt til it was high enough so i could use the forceps; so if your not turning it; you are not backing it out!

Completely unscrewed the remaining bolt, learned that it is too long I remove with the intake manifold in place... Equally the manifold will not clear the bolt if it is not screwed in

What did we learn:
0. Remove everything as if you where doing a spark plug job...
1 see if you can get the bolt high enough to grab it, do so if not you're drilling and tappin it
2, with the bolt up ( no more than 1/2 in)….
Remove the 2 bolts holding the air box; disconnect the front intake...
Unbolt the 3 bolts and 3 nuts...
3. Move it by gentle pulling the intake up, the studs will be a guide... The air box and throttle body will move with it!

4. Completely remove bolt, I you need to drill it, put rags over the intakes on the block.…
Easiest way to remove this bolt would be to use a left direction drill bit… in a drill going in reverse…

5 insert new bolt/
6 te I install everything back on the car
Sorry I don't have torque number
When you reinstall the intake manifold, did you need a new gasket? Were any of the intake manifold bolts made of aluminum?
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      07-30-2012, 12:24 PM   #94
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Quote:
Originally Posted by Brad from the OC View Post
When you reinstall the intake manifold, did you need a new gasket? Were any of the intake manifold bolts made of aluminum?
no gasket,,, each connection has an O-ring... took a look with a mirror, all in place and in tacked so i left them alone,
intake manifold bolts are all STEEL, combination of 3 bolts and 3 studs with lock nuts.
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      07-30-2012, 12:28 PM   #95
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FYI picked up the bolt kit from BMW dealer this am... 25 min later the car was running !

asked the local SA and tech what the torque setting is and
" I could tell ya the book number, but that shit is wrong! snug it down and then take it another 1/4 to 1/2 turn."

so that is what i did, drove it 100 miles this am, hit 95mph, no leaks no ticks, no nothing. my MPG is up (new NGK plugs and the engine is running real nice!

OH AND IT IS AN M9 x1.25 70 mm bolt

P/n is: 11 12 0 392 547 $6 at parts counter, cheaper online but i did not fell like driving the ML350 (POS) all week waiting for it, the gas i save alone will make up for that few dollars

Last edited by Alliedacid; 07-30-2012 at 12:32 PM. Reason: added info
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      11-05-2013, 09:15 AM   #96
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Morning guys, I actually have the same issue. 99% sure. i have the same oil everywhere and sure enough there is a cavern/chamber behind it filled with a slight amount of oil. and low and behold there is the Damn head of the bolt. sitting in a tiny puddle of oil. Now what are my best options to get this out.

Extractor? the though of drilling and tapping makes me nervous.

Also i just did my oil filter housing gasket and poked arouns a few days later. thinking to my self crap there is still alot of oil.
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      11-05-2013, 11:15 AM   #97
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just noticed this on my car today after wondering where the F the oil was coming from after i did my oil filter housing gasket. will this cause any issues other than making a mess? i plan on fixing this/getting this fixed asap/
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      01-19-2014, 07:25 AM   #98
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Ordered the valve cover gasket set + all the bolts as a just in case. In the middle of changing out my clutch and had to remove the intake manifold anyway for the 3-stage upgrade so did that at the same time as the clutch to make getting the top transmission bolts easy/ier. Checked all of my valve cover and head bolts. They are fine. 2006 325i (Feb 2006 build) 118,000 miles, no broken bolts.
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      03-24-2014, 12:02 AM   #99
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So what years does this broken bolt thing mostly happen to? Mine is an 08 328i and so far it looks to be ok.
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      03-24-2014, 08:14 AM   #100
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Quote:
Originally Posted by mvvette97 View Post
So what years does this broken bolt thing mostly happen to? Mine is an 08 328i and so far it looks to be ok.
This issue is much more common to the early models with metal valve covers, which use aluminum bolts.
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      09-26-2014, 10:27 AM   #101
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i took my 06 325xi in for a valve cover gasket replacement as it was leaking oil. the tech broke one of the engine bolts while removing it. bmw dealership tried charging me an extra 1.5 hours labor at $155 an hour to fix their mistake, on top of the $850 job to replace the gasket.
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