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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 01-20-2012, 08:37 AM
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redbull713 redbull713 is offline
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Options to repair broken valve cover stud

In the process of doing a valve cover replacement I got too wrench happy when torquing the nuts down and off comes the nut with the stud! Snapped clean off. It is right above cylinder #6 under the ignition coil plug. so for the mean time i have fashioned a make-shift seal with some silicone. I think it is pretty air and oil tight. I know in the course of all of the v8 guys doing vcg jobs SOMEBODY else has made this mistake too. Now what are my options for repairing this the right way, so that I can put a proper nut/washer/grommet on there. Thanks everyone!

Last edited by redbull713; 01-20-2012 at 08:39 AM.
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  #2  
Old 01-21-2012, 08:17 AM
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redbull713 redbull713 is offline
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I know someone has done this too, any ideas?
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Old 01-21-2012, 09:17 AM
Ed Cheung Ed Cheung is offline
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I did the same thing when putting back the vanos unit back, all I did was check if it is leaking oil, so far so good for a week, no leak. So I am not too worry about it. That is just my way of doing it ---the lazy way, LOL.

I bet your local Sears should have some kind of broken studs extraction tools available. And you may need to drill it out, re-thread and tap a new one in.
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Old 01-21-2012, 07:54 PM
Jimmys 530i Jimmys 530i is offline
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If a small portion is still sticking out, remove it with vise grips. If nothing is showing, drill it out and get a new stud from the dealer, it should be less than a dollar.
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Old 01-21-2012, 08:00 PM
Wayne's World Wayne's World is offline
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You could jb weld (walmart) the broken bit back on then twist.

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'nuff said
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Old 01-26-2012, 02:27 PM
dpatel1026 dpatel1026 is offline
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You may be better off taking the valve cover off and then using the double nut method back it out and replace it. If it is broken flush then you might want to drill a small pilot hole and then use an extractor bit. I had this happen to couple of my studs before, good luck
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Old 01-26-2012, 08:52 PM
charlie boy charlie boy is offline
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well if it makes you feel better, I did my vanos and VCG relatively cheap at the end of the job guess wha happen? Yea I broke the F N Valve Cover. $239 for that sum b!itch. Still havent got around to replacing it yet, my cabin smells like an oil refinery. The worst part is that everytime the air come on it blow all that burnt oil smell in the cabin. Oh well at least I'm in AZ for the winter. no heat = no oil smell.
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Old 01-26-2012, 08:55 PM
charlie boy charlie boy is offline
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oh I also rounded off the aluminum hex nut in the back right corner under the pasenger side cabin filter. yea no freaking fun, had to shut down shop and take it over to a mechanic that cursed me out cause it took him most of the day to get it off and he didnt know how to charge me for a ten minute job he spent the day on. lmao
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Old 08-09-2014, 12:27 AM
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For the record, I appended this experience to this thread today, so that others can watch out for the gotchas ...
> E39 (1997 - 2003) > If you accidentally broke the valive cover when replacing the VCG, please add value
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Each repair should invariably add to our knowledge base by the process of inexorable incrementalism.
Your job, in return, is to read the suggested threads, where the best people will always add value to those threads, either by pictures or by descriptions, so the next person with the same problem stands on your shoulders.
See also: E39 Bestlinks & How to easily find what you need
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