[ckev70]

2006 325i (E90 NA).
Today's project started while the sun was out and before the showers came.
The main project is to replace the starter as well as replacing the OFH Gasket.

3 hrs latter and i'm suck on both.
1. I'm stuck on removing the intake manifold rear crankcase vent hose. I just can't get my big hands in there to squeeze both sides. I believe once i get this done, the starter remove and replace should be doable.

2. OFH Gasket: Using E-10 to remove bolts. The one under the intake manifold did not seat as well as the other 2. Of course it slips and no longer able to get a good hold. I tried a vise grip but because of the slight taper, the head is getting mangled.

Should i just cut the head off and remove the rest of the bolt with the vise?

[HiRev335i]

Had the same issue on a buddy's OFHG bolt though not the same one. At this point when it's stripped not much else to do other then cut the head off. We used a Dremel with the ext attachment to cut the head off took all in about 45 min but finally got her off. good luck

[Speedy_12139]

If you have a Dremel. Trycutting a slot in it's head, and turning it out with a flathead screwdriver, tapping on it with a hammer (lightly) . That's so you don't risk marring the housing. Unless you don't care.

[lowrydr310]

I had a similar thing happen, but mine started to strip because I was using a 1/4" drive 8mm socket and swivel instead of the correct E10 socket. I hammered the E10 socket onto the head and I was able to get it out. Yours looks pretty smashed up, so I'd try the dremel trick first and cut a slot in the head. In the worst case scenario it snaps and you just have cut the head of the bolt off.

[ckev70]

I'll try the doing the slot cut 1st. If not, i'll cut the head off so the housing can be removed. Then i'm hoping the rest of the bolt can be removed with vise and not continuing tearing. Else, i'll need to drill out the remaining and back it out with a screw extractor.

For the rear crankcase breather hose, i was attempting to remove it from the rear of the vent valve which is probably impossible. The correct location to separate is behind the valve cover but of course i fubar'd this as well...cracked.

Still need to remove the bottom crankcase breather hose that the starter power line. Hoping to get the manifold and OFH out in the next day or 2 before placing parts order.

[HiRev335i]

Once you get the head off there wont be any tension left on the bolt the remaining comes out super easy . I did the same with the slot first then chippiping it out another slot and chipping it out and so on with no damage to surrounding area

[ChuckThomas]

Needle nose vise grips and a flat head will pop all those hose connections for you.

[ckev70]

Originally Posted by ckev70

2006 325i (E90 NA).
Today's project started while the sun was out and before the showers came.
The main project is to replace the starter as well as replacing the OFH Gasket.

3 hrs latter and i'm suck on both.
1. I'm stuck on removing the intake manifold rear crankcase vent hose. I just can't get my big hands in there to squeeze both sides. I believe once i get this done, the starter remove and replace should be doable.

2. OFH Gasket: Using E-10 to remove bolts. The one under the intake manifold did not seat as well as the other 2. Of course it slips and no longer able to get a good hold. I tried a vise grip but because of the slight taper, the head is getting mangled.

Should i just cut the head off and remove the rest of the bolt with the vise?

Here's the update: Intake removed after breaking the crankcase vent hose (why so expensive). Waiting on replacement. Hope i remember all the connections later.

OFH: After creating sparks with the dremel, that last bolt is out. Not a great grinding job but made sure the surface stayed as flat as possible on OFH. The base of the bolt unscrewed by hand. Gasket replaced and bolts back in.

[ckev70]

Originally Posted by ckev70

Here's the update: Intake removed after breaking the crankcase vent hose (why so expensive). Waiting on replacement. Hope i remember all the connections later.

OFH: After creating sparks with the dremel, that last bolt is out. Not a great grinding job but made sure the surface stayed as flat as possible on OFH. The base of the bolt unscrewed by hand. Gasket replaced and bolts back in.

All done...and running again!

[Fritzer]

Originally Posted by Speedy_12139

If you have a Dremel. Trycutting a slot in it's head, and turning it out with a flathead screwdriver, tapping on it with a hammer (lightly) . That's so you don't risk marring the housing. Unless you don't care.

I was going to recommend doing this.