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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 09-08-2019, 07:40 AM
away_one away_one is offline
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Broken Valve Cover Bolt!

So I'm in the midst of replacing the valve cover gaskets on my N62, and one of the "one-time use" bolts on the bottom front of the motor broke off as I was trying to remove it. I was removing it gently, I swear! :-) I suspect that the last guy overtorqued it.

It broke with about three threads left on the top. Might be enough threads sticking out to get Vice Grips on it and twist, but I'm not optimistic that will work.

Any advice would be appreciated!
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Old 09-08-2019, 07:46 AM
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Is the valve cover off? I was able to Dremel a groove for a flathead screwdriver even with a super small amount to work with. Click image for larger version

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Old 09-08-2019, 08:05 AM
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Originally Posted by BabyUnicornTaco View Post
Is the valve cover off? I was able to Dremel a groove for a flathead screwdriver even with a super small amount to work with. Attachment 863799
I've got the valve cover off now, I have 4mm of the bolt sticking out.

Cutting a groove with a Dremel sounds like a good idea, what sort of cutting wheel did you use?
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Old 09-08-2019, 08:10 AM
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Old 09-08-2019, 08:30 AM
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Ok cool I've got one of those. Thanks!
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Old 09-08-2019, 08:33 AM
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Protect the area with a towel or something. Take it slow. It didnít take much of a groove to get grip with the flathead.


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Old 09-08-2019, 09:36 AM
twh twh is offline
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If the groove doesn't do it, use the moto-tool to flatten two sides so you can get an open-end wrench on it - you will get more torque.
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Old 09-08-2019, 10:45 AM
audiophool audiophool is offline
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If it broke due to over-torque, it shouldn't be 'stuck' in the head. I'd try vice grips first - 4mm should be plenty to grab if you have a straight shot at it from above. Turn it CW a little, then CCW out.
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Old 09-08-2019, 11:47 AM
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Originally Posted by audiophool View Post
If it broke due to over-torque, it shouldn't be 'stuck' in the head. I'd try vice grips first - 4mm should be plenty to grab if you have a straight shot at it from above. Turn it CW a little, then CCW out.
Yes, I can get my Vice Grips on it (from the top) and have been spraying it down with Liquid Wrench. Doesn't want to budge either way. Tapping it with a hammer also. Going to try a smaller ViceGrip to see if I can get at it sideways. Will try cutting a screwdriver slot in it after that. Thanks!
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Old 09-08-2019, 12:38 PM
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If it won't turn with vice grips it'll probably split (I'm assuming it's an alumimium bolt) if you cut a slot for a screwdriver and try turning it. You may be forced to drill it. If so, left hand drill bit.
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Old 09-08-2019, 03:06 PM
jparnes1 jparnes1 is offline
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An Easy Out will make short work of that.


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Old 09-08-2019, 03:58 PM
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Originally Posted by jparnes1 View Post
An Easy Out will make short work of that.

Itís a fairly small bolt (just over 5mm), will an Easy Out work?



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Old 09-08-2019, 04:01 PM
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Itís a fairly small bolt (just over 5mm), will an Easy Out work?



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Yes. Get the smallest one and itíll work. Just drill into the shank enough for the easy out to grab otherwise youíll weaken the bolt and itíll break more.


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Old 09-09-2019, 05:25 PM
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My 4mm sticking out has broken off now. I bought a #1 Easy Out and a GrabIt Drill-Out (2507P). It's an M6 bolt so either should work, but it's an aluminum bolt. So I'm guessing that the Easy Out is a better choice because it requires a smaller hole. I suspect that the GrabIt is made more for steel.
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Old 09-09-2019, 10:37 PM
audiophool audiophool is offline
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I still say a left-hand drill bit makes more sense, but the GrabIt is similar. If you drill the bolt and put in an extractor, the bolt remnant will expand when you apply torque, possibly making it even more stuck than it is. Thing about left-hand drills is they warm the bolt and will start turning it out as they drill. Make well sure the drill is centered and plumb.
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Old 09-10-2019, 12:59 AM
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your gonna want to make some sort of barrier to stop the chips from falling in the head,

then your gonna want to center punch,

come in with a number 42 (3/32) or so drill

then step up to a left hand number #32ish somewhere around ( 1/8)

the point is you need the center punch so it doesnt walk, then you want to open a small diameter hole center thru (not in to the head) about half way thur the bolt

then when you come in with the left hand it should feed pretty quickly and about half way in it will bite and back out.. Its pretty easy

thats like a 8 min job... good luck
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Old 09-10-2019, 01:35 AM
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Ok Iíll go get a left hand drill bit instead, that sounds like a good plan.

Any suggestions on how to keep the drill plumb with the head while drilling the pilot hole?


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Old 09-10-2019, 02:27 AM
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Iím surprised we so quickly got away from the Dremel disc idea.


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Old 09-10-2019, 07:52 AM
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Quote:
Originally Posted by BabyUnicornTaco View Post
Iím surprised we so quickly got away from the Dremel disc idea.


I did notch the top to try a screwdriver, didnít work. I was able to get a good grip using a Vice Grips, but the bolt sheared off without any movement in the threads. Itís stuck in there tightly. So moving on now to the left hand drill bit.


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Old 09-10-2019, 09:42 AM
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Originally Posted by away_one View Post
Ok Iíll go get a left hand drill bit instead, that sounds like a good plan.

Any suggestions on how to keep the drill plumb with the head while drilling the pilot hole?


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I use a small machinist's square to get it perpendicular on one axis, and a helper to check 90 degrees away.
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Old 09-10-2019, 11:39 AM
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Something like this might be of help in centering the drill bit for the pilot hole. In theory, if you could fit a left hand bit in the housing, drilling the bolt out might just take one step.

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
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Old 09-10-2019, 05:47 PM
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The only left hand bits that I could find in town today are some cheap ones at Menard's. As soon as the bit started to go into the pilot hole it bit into the bolt and then broke. I was going slow with it. Luckily I was able to get the end out with my pliers.

I'm about at the point now of having it towed to a shop. Since I've already drilled the bolt I'm nervous that I'll just destroy things more trying to get it out.

Not even sure how I would use an Easy Out, as my tap handle hits the camshaft bracket.

Any ideas would be greatly appreciated!
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Old 09-10-2019, 06:51 PM
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Broken Valve Cover Bolt!

It sounds like you ďnotched the topĒ but didnít try the Dremel disc? This was such a surprisingly easy fix with the Dremel when I had even less bolt to work with.


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Old 09-10-2019, 07:07 PM
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Originally Posted by BabyUnicornTaco View Post
It sounds like you ďnotched the topĒ but didnít try the Dremel disc? This was such a surprisingly easy fix with the Dremel when I had even less bolt to work with.
See post #19 in this thread
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Old 09-10-2019, 07:14 PM
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See post #19 in this thread


Thatís what Iím referring to. You said you notched it.


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