E30 Zone

Short version is as follows:

Trying to replace the existing rusty one the main securing bolt does not want to undo, used a whole can of penitrating fluid so far, along with socket set, breaker bar, adjustable spanner and mole grips, noting is shifting it.

Also tried tightening it to try and get the bolt to move... nothing.

also tried hammer and hammer and flat head screwdriver for some shock treatment and guess what?............didn't work either.

Just about out of idea's now so any help or advice you can give will be much appreciated.

Many thanks in advance.

Only thing left is to drill the little bugger out!

Or slice it's head off with a slitting disc and hope that the heat generated will loosen the remains.

Or cut the bracket off and fabricate a new one to weld in....

The filler pipe is scrap? Cut through the tab on the pipe so that you can remove it, block the pipe into the tank, and get some heat on it. Never failed to get one undone yet.

Hi mate any joy with the fuel pipe?

not yet, having to drill it out, nothing else has worked. going to fininsh it tonight after work hopefully, using Diamond Cut metal drill bits, small pilot hole, then increase the size with larger drill bits until it comes out. then just replace the 10mm nut.

I used 2.5 cans of penitrating fluid, coke, olive oil, even washing up liquid and bicarbonate of soda sprayed on it and nothing, sockets, adjustable spanner, spanner, breaker bar.

It got the point where i was putting so much pressure behind it i was risking snapping the bracket off the car, so safer just to drill it out and replace it.

Mine is the original pipe and bolt so no supprise its jammed as its been on the car for 24 years. lol. why did i think it was going to be easier than it has been.

Does anyone know the dimentions for the securing bolt???? I am drilling mine off and need to get hold of a replacement.

I know its a 10mm head, but what about the length, thread etc?

Just an ordinary M6 x 16mm bolt.

got the new one fitted last night, apart from the bolt, the new one needs adjusting so it sits right behind the fuel filler flap, that is the easy part. Those pipes for the fuel evap system etc are a pain to get off, replaced the original clips with jubilee clips, so much easier.

another 30 mins work and all should be done.................finally. If it actually goes that smoothly, which i doubt since everything else has been a total nightmare.

Well done mate. How many jubilee clips did you replace and what size so I know what ones to get before I start, cheers

erm i have no idea what size they were, i got a pack cheap in asda (£1.00 a pack and long with a pack of duzzit latex gloves for £1.00) green cardboard blister pack with 8 clips in it.

Finishing it off tomorrow night, not going to have time tonight. Mine was a pain, the securing bracket halfway along the pipe didn't want to come off, then didn't want to go pack on, the flexi pipe from the tank was quite stiff, penitrating fluid required and some gentle pulling and tiwisting worked ok.

The original clips and little clip ones, never seen then before, the larger one is a total pain (from metal pipe to the braided flexi one) to get off and back on again, the small rubber one wasn't too bad at all.

In total its taken probably 5 hours so far, still not managed to get the bolt out of the whole desipte drilling it, ended up cutting the pipe off. there is another bracket further down the system and i will cable tie the new pipe through the drilled hole with 2 or 3 cable ties to be on the safe side.

m8782538 wrote:still not managed to get the bolt out of the whole desipte drilling it, ended up cutting the pipe off. there is another bracket further down the system and i will cable tie the new pipe through the drilled hole with 2 or 3 cable ties to be on the safe side.

Drill it right out to 6.5mm if necessary, and use a longer bolt with a separate nut.

can't drill it out anymore, using an old black & Becker mains powered drill and you have to drill at an angle so i can drill anymore. Its being subborn, will be having another look tonight after work to try and get it all sorted out. its on the car, but needs adjusting as the filler cap sticks out too much and you can't close the flap correctly.

hopefully 30mins more and its all done. Then time to carry on with treating rust, applying filler and sanding, joy but new sanding flap wheels should be on their way meaning i am not totally sanding by hand