Hello, I broke the thin long bolt reinstalling a new water pump. I have searched the forum and I've found out it would be best to remove the front cover to get the bolt out. I don't really want to take the cover off. Has anyone just tapped in a short bolt into the cover. I believe the two short bolts just go into the cover and the long bolts go into the block.

I would also like to know if anyone has been sucessful using an easy out to get the bolt out with out taking the cover off. It's in about 2 1/2 inches so I'm sure it not too easy.

oh yeah the car is a 72 240z

I'd do it right the first time. I'd be willing to bet that if you did what you're talking about, you'd end up having to take off the cover anyway once the leaking starts. That is, if you could even get it to catch in the threads the second time.

All the bolts go into the block. Take the cover off. The broken bolt MAY come out if you get get some vice grips on it if there is enough of the bolt remaining that will be sticking out of the block. Easy outs don't work that good. I had one snap off in the block and had to drill it out , which wAS A MAJOR pita when I had to do the same thing you are going to do.. Be careful putting the cover back on so that you don't pinch the head gasket. Loosen up the front pan bolts which will make the job much easier reinstalling the cover. Search "water pump removal" and you will see what I am saying.

Ditto to EZ Out failure. They don't work on those small bolts. The bolts are too hard and it's impossible to drill the pilot hole dead center in the bolt.

If you have decent stick welding skills, you can "weld it out" by placing a nut over the broken bolt, and welding the nut to the bolt. You'll need to use a small diameter (1/16"), stainless-based electrode (like Eutectic 680CGS or MG 600 - - disclaimer---I used to sell those products and they work quite nicely). Others may work as well.

If the bolt is broken off inside the block, you'll need to have great stick-welding skills and recreate the missing portion of the bolt with the welding electrode. Don't weld to the block, though. That'll cost ya! That last scenario is very touchy and rquires excellent welding skills. Definitely NOT for amateurs like most of us.

Frank

Thanks guys I have read that it is difficult putting the cover back on with out damaging the head gasket. Hope I can do it.

One way to center drill a broken bolt (assuming that some portion of the bolt is above the surface) is to make a simple jig. On a drill press or lathe, take a piece of 1" long round stock and drill a hole through to the half the diameter as the bolt shank. Drill a hole, the same diameter as the bolt shank, halfway through the smaller original hole. Slide this over the broken bolt. Drill through using the smaller hole and bit. This will center the hole in the bolt. Try a small easy-out or drill using a larger bit leaving only the threads. Use a tap to clean out the remaining bits.