[BioChemBro]

Hey Everyone

Since my vin (2009 335i) wasn't included in the HPFP recall i went ahead and planned to replace it myself since it's a fairly simple DIY

Everything was cake until i got to the last step before removing the pump itself, getting that dreaded 5mm Hex bolt on the rear side (towards the engine) out.



it must've been my aggression, but the hex bolt head is stripped (if that's the correct word for it, see pic below for example). the 5mm hex tool barely stays in place when force is applied, so i cannot break this last bolt loose



The bolt head is rounded leaving me with a few ideas on breaking it free but PLEASE chime in with any advice

**"Brave Me" is considering getting a dremel tool in there (with fuel lines re connected) and flattening two sides out to fit a Spanner tool and a wedge screw driver?

clearly the idea of sparks near a fuel pump sounds crazy, but I'm at a loss of what to do

[Brule]

Try and put a torx bit in there.
Line it up with the stripped part and tap it into the rounded off hole.

It should create tiny indents and create enough grip to loosen the bolt.

[JuniorB]

I run into this often when doing hex or torx. What happens is the grime and dirt make there way in there preventing the hex to fully seat in there, clean it out with a pick and shoot some brake clean in there to remove it, try the 5 again with a long extension and tap it till it seats, try a tight torx, or if it's tight, cut a long an men wrench and use a 1/4 drive ans 5 mm socket, it will come out. Looks like it didn't bit or seat all the way. Btw, that picture is of rounded Phillips head..

[BioChemBro]

Originally Posted by Brule

Try and put a torx bit in there.
Line it up with the stripped part and tap it into the rounded off hole.

It should create tiny indents and create enough grip to loosen the bolt.

Originally Posted by JuniorB

I run into this often when doing hex or torx. What happens is the grime and dirt make there way in there preventing the hex to fully seat in there, clean it out with a pick and shoot some brake clean in there to remove it, try the 5 again with a long extension and tap it till it seats, try a tight torx, or if it's tight, cut a long an men wrench and use a 1/4 drive ans 5 mm socket, it will come out. Looks like it didn't bit or seat all the way. Btw, that picture is of rounded Phillips head..

cleaned out the hex head, tapped the 5mm hex key and was able to get it to seat better than before. once pressure was added, the hex slipped out again, so now its torx time

thank you both for the torx bit suggestion, attempting this tonight of tomorrow

[pysical]

I plan to do this HPFP swap soon, I will keep an eye out for that one so I don't do the same.

[dyezak]

Calm down. The old saying, "use the right tool for the job and make your life easier" applies right now. Go buy a set of extractors, put it in the stripped hole, and relax as you watch the bolt come out:

http://c.shld.net/rpx/i/s/i/spin/ima...2&op_sharpen=1

[weehe126]

Originally Posted by dyezak

Calm down. The old saying, "use the right tool for the job and make your life easier" applies right now. Go buy a set of extractors, put it in the stripped hole, and relax as you watch the bolt come out:

http://c.shld.net/rpx/i/s/i/spin/ima...2&op_sharpen=1

Do you actually know what bolt he is talking about? If you did you would know just how hard it is to get to, let alone with an extractor.

[Chris@VargasTurboTech]

Pull out interferences (i.e. everything in the way to the best of your ability) tape off the lines to avoid any contamination and use an extractor like mentioned above. Just go slow and it'll go. You already lost the battle, so slow it all waaaayyyy down and take your time and it'll come out. You can still win the war.

Chris

[Makeuwunder]

These work pretty good for stripped hex and internal torx.
https://www.matcotools.com/catalog/p...RACTOR-SET-10/