Rusty screw, intercooler, can't remove

tadaska · 07-27-2016, 01:03 PM

I had a guy come to remove the turbo off my E90 320D and I asked him to remove the intercooler. But the screws are very rusty and he he only got one out. The other one won't budge. We left it there for now as he was worried he will break the plastic that the crew goes into.

Have any of you been in that situation and come up with a clever way of removing it?

Any suggestions will be welcome.

BlindWolf187 · 07-27-2016, 01:29 PM

Worse comes to worst, you can drill it out, remove the intercooler, then drill out a bigger hole in the part that the screw is threaded into and install a threaded insert.

feuer · 07-27-2016, 02:01 PM

As far as I remember is screwed in directly in the bolt, no? So I would apply little heat directly on the bolt. Either heat gun on torch. That should loosen it up.

tadaska · 07-27-2016, 02:43 PM

Thx guys for the suggestions, both spot on.

But I'm now thinking if there is a need to remove the intercooler at all. If I remember correctly I only wanted to remove it because I read that when turbos fail oil gets into them. But my turbo looked clean. There was some play when wiggling the propeller but nothing nasty. Does that mean the intercooler will be clean?

07-27-2016, 01:03 PM	#1
tadaska Major 114 Rep 1,002 Posts Drives: 2006 E90 320D ES Join Date: May 2016 Location: Eastbourne iTrader: (0)	Rusty screw, intercooler, can't remove I had a guy come to remove the turbo off my E90 320D and I asked him to remove the intercooler. But the screws are very rusty and he he only got one out. The other one won't budge. We left it there for now as he was worried he will break the plastic that the crew goes into. Have any of you been in that situation and come up with a clever way of removing it? Any suggestions will be welcome.
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07-27-2016, 01:29 PM	#2
BlindWolf187 Private First Class 48 Rep 134 Posts Drives: 2008 E92 335xi 6MT Join Date: May 2016 Location: Denver, CO iTrader: (0)	Worse comes to worst, you can drill it out, remove the intercooler, then drill out a bigger hole in the part that the screw is threaded into and install a threaded insert. __________________ 2008 335xi 6MT Coupe - Monaco Blue on Saddle Brown \| fully optioned
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07-27-2016, 02:01 PM	#3
feuer Major General 4276 Rep 9,206 Posts Drives: wife crazy! Join Date: Apr 2015 Location: Chicago, IL iTrader: (5)	As far as I remember is screwed in directly in the bolt, no? So I would apply little heat directly on the bolt. Either heat gun on torch. That should loosen it up.
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07-27-2016, 02:43 PM	#4
tadaska Major 114 Rep 1,002 Posts Drives: 2006 E90 320D ES Join Date: May 2016 Location: Eastbourne iTrader: (0)	Thx guys for the suggestions, both spot on. But I'm now thinking if there is a need to remove the intercooler at all. If I remember correctly I only wanted to remove it because I read that when turbos fail oil gets into them. But my turbo looked clean. There was some play when wiggling the propeller but nothing nasty. Does that mean the intercooler will be clean?
	Appreciate 0 Quote