Tool Block
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How do you remove a broken bolt from an engine block?
The head of a bolt broke off of the bolt shaft on my engine block while I was replacing my water pump. What is the procedure to remove it? Do I need to retread the block? What tools do I use and is it worth trying to do it myself (I have no experience doing this)? Also, how much would it cost to have it fixed professionally? The bolt is very easy to access.
Thanks
1990 XJ 4.0 engine
John, the pump only has 4 bolts. That probably won't be an option for me as the pump might easily leak or distort.
tough one to answer without seeing the offending item.
However...
I'm assuming that it is just the head that has broken off, and the shaft of the bolt is still intact and sticking out of the block.
firstly give it a good dowsing in with a penetrating oil (something like WD40) because there is a reason why it broke in the first place, it's probably seized in the hole.
Now get a pair of Mole/Vice grips on it, locked on tight to the exposed shaft. Give it a bit of backwards and forwards wiggle as you are trying to "break" the seizure. Once it "cracks" it should come out with some gentle persuasion.
If the bolt has broken flush to the surface then you will have to drill down the centre and use a stud removal tool (it look a bit like an over sized drill bit with a reverse spiral on it to get it out.
If this fails then you wil have to gradually drill out the old bolt using slightly bigger drill bits each time until the old bolt collapses and falls out, then run a blind tap down the hole to clean the thread out.
Good luck!
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