[2008E92335XI]

Hey guys. As I was changing out my valve cover gasket I noticed that one of the bolts had snapped off at the head. It’s the bolt located at the 10 o’clock position if you are standing at the front of the car. It’s in a tight spot so there’s not much room to work back there. The vcg was replaced not to long ago but was leaking again.

So far I have tried squirting a little WD-40 around the bolt, an easy out and a left hand drill bit with no luck. My question is what are my options at this point? I really don’t want to tow the car to the Indy.

Can I use some gasket sealer around that one broken bolt and close everything up? Or do you have any other advice on how to get that bolt out?

Thanks in advance.

[PichaDis11]

Yikes man. If it's one of the corner bolts it sounds hard reach and cramped area. Though, I've had a few successes with my approach on doing it, the bolts were broken at a shallow depth in the head. Since you've already tried a few things, it seems it got a little more difficult. My first steps are to try using a punch to create a notch and then tap at a 90° angle going counter-clockwise of course. If you should drill, use a punch to create an indent center of the bolt. Use a smaller left handed bit and start the drill off slowly. I should note I apply some PB Blaster overnight.

[smass]

Most of the VC bolt threads are open ended. Feel the underside of the area and you probably will find open threads. Remove cowl for better access. Get a 12" 1/8" drill bit from Home Depot. Drill into what is left of the broken bolt. Once the bit bites into the metal a little, the broken bolt may just spin out the bottom side. That is how I got 4 of mine out.

[robthewrench]

Originally Posted by 2008E92335XI

Hey guys. As I was changing out my valve cover gasket I noticed that one of the bolts had snapped off at the head. It’s the bolt located at the 10 o’clock position if you are standing at the front of the car. It’s in a tight spot so there’s not much room to work back there. The vcg was replaced not to long ago but was leaking again.

So far I have tried squirting a little WD-40 around the bolt, an easy out and a left hand drill bit with no luck. My question is what are my options at this point? I really don’t want to tow the car to the Indy.

Can I use some gasket sealer around that one broken bolt and close everything up? Or do you have any other advice on how to get that bolt out?

Thanks in advance.

You'll need to get it out. Did you snap the easy out? Try another easy out or two. Use PB-blaster or another true penetrating oil (kroil, others). Is any of the bolt sticking out above the surface, or is it all recessed into the bolt hole?

[2008E92335XI]

Thank you for all the replies! I truly appreciate all the advice.

I haven’t tried a true penetrating oil but will give that a whirl. Rob, it’s funny that you ask about the easy out. As a matter of fact, it did snap off. I got most of it out of the bolt but there is a small piece of the easy out still sticking out. I will try to take a picture for you guys and upload it later so you can see. In hindsight, my center punch mark was also off center. The center punch must have moved as I went to hit it given the tight space.

About drilling it out...if I drill from the top, I’m worried that the bolt or the metal shavings will fall into the engine from the bottom. It’s really hard to get my fingers under there given the location of the bolt. If I drill from the top, where will the bolt go from the bottom as it gets pushed out?

Thanks again everyone

[smass]

Here is a pic of the underside of an N54 head on the exhaust side. Note how the valve cover bolt threads are visible along the edge.

[robthewrench]

It it pretty easy to snap an easy out and I've snapped a lot of them. Are you using a T-handle wrench for the easy-out? I am less likely to snap them when using a t-handle vs. a box wrench.

Try putting needle nosed vise grips on the part of the easy out still there. If that comes loose, try more oil and another easy out. Sometimes I've snapped 2 or 3.

If you are worried about drill shavings, put heavy grease (like wheel bearing grease) on the top of the bolt. The grease will collect the metal shavings.

[2008E92335XI]

Thank you guys!

I have some pictures to help understand whats going on.


You can sort of see the small wedge of easy out left in there. and it is such a tight area that my center punch kept sliding away and put some scratches on the head.

I will definitely try the penetrating oil and grease to prevent metal shavings from flying everywhere. Rob, I have been using a T-wrench for the Easy out but that bolt is stuck that it does not spin the easy out (the easy out just got stuck in the bolt)

Just so I'm clear, I would take a 12" 1/8" drill bit and drill from the top of the head to push the bolt out from the bottom of the head? i tried to get my hand under there and couldn't. the bolt is located towards the upper left corner of the head, where it slopes downwards. so where would that bolt fall?

also, if i can't get that easy out removed, what other options do I have at this point?

Thanks everyone!

[PichaDis11]

Originally Posted by 2008E92335XI

Thank you guys!

I have some pictures to help understand whats going on.


You can sort of see the small wedge of easy out left in there. and it is such a tight area that my center punch kept sliding away and put some scratches on the head.

I will definitely try the penetrating oil and grease to prevent metal shavings from flying everywhere.

Just so I'm clear, I would take a 12" 1/8" drill bit and drill from the top of the head to push the bolt out from the bottom of the head? i tried to get my hand under there and couldn't. the bolt is located towards the upper left corner of the head, where it slopes downwards. so where would that bolt fall?

also, if i can't get that easy out removed, what other options do I have at this point?

Thanks everyone!

Need a more hardened bit to drill into that easy out. Carbide bits. Start with smaller bits though.

[Monster900]

Left hand drill bit

[smass]

The 12" 1/8" drill bit trick is for bolts that are not frozen like yours seems to be. In your case, just drill the old bolt out and tap in new threads. It does not need to be exact as the hole in the valve cover has some wiggle room.

[2008E92335XI]

Originally Posted by PichaDis11

Need a more hardened bit to drill into that easy out. Carbide bits. Start with smaller bits though.

Just to make sure, do you mean to get a regular carbide drill bit set and drill down into the bolt, hopefully pushing it out the other side? will any debris come out the other end? i can't access that area and don't want any metal shavings or shards that I can't clean up.


Smassey, if i drill out the bolt, is there any danger of any debris falling out the other end? I looked at the picture you posted (thank you for that) but just wanted to make sure with you since you have the experience. I tried to get my hand in there but i couldn't get in far enough to feel the other end of the bolt.

i called a few automotive machine shops in the area and they are telling me the cylinder head has to be removed. very discouraging to hear that.

[smass]

I have only fixed these on N52 but I doubt N54 is much different. Can you get a small mirror under there to check? This is just to give you piece of mind since you are being extra careful.

[PichaDis11]

Originally Posted by 2008E92335XI

Just to make sure, do you mean to get a regular carbide drill bit set and drill down into the bolt, hopefully pushing it out the other side? will any debris come out the other end? i can't access that area and don't want any metal shavings or shards that I can't clean up.

I meant drilling into the broken easy out may require a more hardened bit if you can't get your regular bits to drill into it. Use a mechanics mirror to check the underside to see where the bolt will come out. doesn't seem anything will get into the head from there.