[cxmplex]

Well, I followed Kern, and I had thought I installed the new HPFP perfectly. I was enjoying the MDH Stg2+ Map, it's a beast.

However, I noticed an issue. The bottom of the HPFP was slowly leaking oil onto the little metal tray below it, which in turn was dripping oil onto the catalytic converter of the downpipe, causing smoke.

Just reseat the HPFP right? Well I tried that, and managed to shear the head off the bolt:









I really did think I did it correctly, I walked each bolt 1/4 turn alternating between the two of them. I didn't tighten fully either since the spec is 12nm I believe, however I still had that leak, which then led to this bolt shearing.

Any idea on how to fix this? I called a shop near me and they refused to work on it and said my best bet is the dealership. They didnt' want to drill in it for fear of either sparks flying and hitting oil and gasoline, or destroying the part the bolt goes into (I can't remember the name).


Interesting enough, the car still drives. I know how sketchy it is, I had to drive home though (I noticed the smoke while 40 minutes away). It seems like the HPFP is staying depressed and secured, but obviously its dripping oil.

[T_H_O_M_A_S]

i wouldnt drive it anymore like this .

take of the pump in whole and see if you have any bolt left to clamp on to.
or you might use a dremel and make a small slit in piece of thread , use a normal flat screwdriver to take it out .

[njdangelo]

If you installed it to the proper 12nm you should have no issues getting a bolt extractor bit set and carefully backing it out. If it's significantly tighter than that you might have some issues. That being said, weird that the pump was leaking and weird that the bolt sheared. Did it somehow get cross threaded on install?

[cxmplex]

Originally Posted by njdangelo

If you installed it to the proper 12nm you should have no issues getting a bolt extractor bit set and carefully backing it out. If it's significantly tighter than that you might have some issues. That being said, weird that the pump was leaking and weird that the bolt sheared. Did it somehow get cross threaded on install?

I don't think so. I walked both bolts in about a quarter turn at a time, somehow they didn't compress the pump enough I guess (or perhaps the pump is slightly off center?) which was enough to cause the oil leak. I have no idea how this bolt sheared all being said, I was REMOVING it when it happened and it had vibrated a bit looser.

To describe where it was leaking, its around the erm bottom of the pump, I'll draw on a photo to show you:

Imagine the red line as the middle portion of the bottom lip of the HPFP or I guess the "left" side of it. That's where it wasn't making full contact.

[cxmplex]

Originally Posted by njdangelo

no issues getting a bolt extractor bit set

Don't have a drill, but I could get one.


I want an honest answer though. Given that I fucked up the HPFP install, and I don't claim to be an expert mechanic (I'm quite new to be honest), do you think I will make this worse by trying to fix it myself? Can a noobie reliably remove a sheared bolt from that section without causing anything terrible to happen? Am I going to create a spark that ignites that oil somehow lol?

[Pussiwillow]

Originally Posted by cxmplex

Don't have a drill, but I could get one.


I want an honest answer though. Given that I fucked up the HPFP install, and I don't claim to be an expert mechanic (I'm quite new to be honest), do you think I will make this worse by trying to fix it myself? Can a noobie reliably remove a sheared bolt from that section without causing anything terrible to happen? Am I going to create a spark that ignites that oil somehow lol?

Remove the pump, use a welding blanket to cover the area, cut out a small hole where the sheered bolt is. This way, only that is exposed, still be careful of vapor, that's what's flammable, contain any open fuel lines and seal those off, I don't see a problem with you taking your time, watch videos, get an idea, it's absolutely doable and easier than you think, take your time.

[jackstrath]

Bolt extractors are harder to remove than the stud material left. If your doubting your self dont make it worse for someone else. Your going to want to remove the pump completely to get tools in about there. Id personally quit while your ahead.

Any decent mechanic should be able to get that out one of 2 ways, ether bolt extractor or weld a washer/nut onto the bolt and back it out. Order up some new bolts and a new gasket and you should be good to go.

Dont drive it any more ether, the cam puts a decent amount of force onto the fuel pump and you risk the pump shearing the other bolt and doing more damage!

[T_H_O_M_A_S]

you prolly has misalignment of your gasket while tightning down the bolts .
the hdp5 has different surface compared to hdp6

why the bolts stripped no idea

[Jnat]

Sorry to hear, some of the ideas above are your options, good luck!

[cxmplex]

Originally Posted by Jnat

Sorry to hear, some of the ideas above are your options, good luck!

Yep, I think I'm going to take it in and not try doing this myself. Appointment monday at the dealership, seems like the best option, especially if they need to replace the gasket after drilling, they'll likely have a gasket on hand.


Does anyone envision any issues at the dealership since it's not the "official" pump for the car?

[Jnat]

I'd personally be thinking a BMW tune type shop, fwiw... any in your area?

[kern417]

Originally Posted by T_H_O_M_A_S

you prolly has misalignment of your gasket while tightning down the bolts .
the hdp5 has different surface compared to hdp6

why the bolts stripped no idea

This is my thought as well. Misalignment or damage to the gasket causing the leak.

The bolts are aluminum and soft. That's why the torque spec is so low. It's really the best case vs chewing and stripping out the hpfp mount in the cylinder head.

I've seen this happen to 2 other people. Just have to be careful with torquing. It needs to be seated, not super tight/cranked down. Same goes for all of the bolts in the cylinder head if you ever have to remove and reinstall them.

[cxmplex]

Originally Posted by kern417

This is my thought as well. Misalignment or damage to the gasket causing the leak.

The bolts are aluminum and soft. That's why the torque spec is so low. It's really the best case vs chewing and stripping out the hpfp mount in the cylinder head.

I've seen this happen to 2 other people. Just have to be careful with torquing. It needs to be seated, not super tight/cranked down. Same goes for all of the bolts in the cylinder head if you ever have to remove and reinstall them.

Hey, to update this thread, I took it to the dealership in Peabody, MA and had a good experience. They did it in 3 hours labor, $340 out the door. About the same labor cost as even the independent places.

They replaced the other bolt too just incase. It wasn't overtorque'd or cross-threaded, he was able to tap it out.

He thinks likely since I was using an extension on my torque wrench to be able to reach the bolt that I accidentally put too much pressure outwards from the center of the bolt (since the extension wasnt perfectly vertically aligned) and sheared it that way. Not that I tightened it too much. Basically just poor use of the tool is what did it.

The leak was misalignment, he said that the way I had the fuel lines installed was forcing the HPFP slightly up off the bottom lip of it. I basically had the same issue as you Kern in your video with getting them all to install. I thought I had gotten it, but it appears not.

[jackstrath]

Good to hear you had a positive experiance with your dealer, and glad to read its fixed!

[weehe126]

Did you attach the hard line to the pump before tightening it down? Might have caused the issue.

[cxmplex]

Originally Posted by weehe126

Did you attach the hard line to the pump before tightening it down? Might have caused the issue.

Yep, you guessed it! Tightened half way and then attached the hard line because I couldn't get it on any other way. But it's what caused the issue, so yeah haha.

Overall a positive experience even though I biffed it. Learned how to access that area of the car (removing strut bar and covers) and nearly learned how to install a HPFP. I know how to remove one at least haha. Learned some valuable lessons on what not to do as well.

[paul e]

Sometimes you are happy to spend the money to have someone else do it. This is one of those times, IMHO.

I think you made a wise decision, I’m happy to read it has been sussed out.

[rlaugo]

You should be able to back it out carefully using a bolt extractor bit if you tightened it to the specified 12nm. There could be concerns if it's much tighter than that. However, it seems strange that the pump was leaking and the bolt sheared. Did it get installed backwards or something?

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[G.Newt]

Originally Posted by rlaugo

You should be able to back it out carefully using a bolt extractor bit if you tightened it to the specified 12nm. There could be concerns if it's much tighter than that. However, it seems strange that the pump was leaking and the bolt sheared. Did it get installed backwards or something?

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Holy reviving a 2.5 year old thread lol.

[B58togo]

Lol, I would hope this is resolved by now.

[morritse]

Just wanna say, whish we had dealerships like that in CA. All the ones here would either refuse to do it, or charge $1000+