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Sheared bolts....

Discussion in 'Z3 Roadster & Coupé' started by Fraser, Sep 10, 2019.

  1. Fraser

    Fraser Zorg Addict
    British Zeds The M44 Massive

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    I've finally got round to doing the whole thermostat/waterpump change today after running cool all day on Sunday, only to get to the point where all 4 bolts holding the thermostat in have all sheared off and stuck in the engine block!
    Looking at it I don't think the thermostat has been changed in the 22 years the car has been on the road and the thermostat came out in 4 pieces!
    Can anyone give me some pointers on how to get these bolts out without ruining the threads in the engine?? :nailbiting:
     
  2. andyglym

    andyglym Shiny Dust Caps Make Your Zed Go Faster.
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    @Jack Ratt may be able to advise.
     
  3. t-tony

    t-tony Zorg Expert (I)
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    How have they broken, flush with the surface or proud of the surface mate? Can you post a picture? Did you try to tighten them a little before loosening them?

    Tony.
     
  4. Fraser

    Fraser Zorg Addict
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    Cheers Tony. :)
    They're sitting proud of the block at the minute.
    The tops of the bolts were rusted quite badly and I had to hammer the socket onto the bolts initially to knock the rust off and gain the shape back again.
    They were WD40'd and I tried tightening and loosening them.
    I'll try and get an image so you can see what's going on......
     
  5. t-tony

    t-tony Zorg Expert (I)
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    OK.

    Tony.
     
  6. Stevo7682

    Stevo7682 Zorg Guru (IV)
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    Waiting to see the picture to see what's left before I suggest anything as at the moment you are potentially on the edge of a world of grief and your next move has to be carefully addressed.
    Stephen.
     
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  7. Fraser

    Fraser Zorg Addict
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    This is how it looks at the minute -

    IMG_20190910_223413.jpg

    Looks a bit tatty around the whole area tbh!
     
  8. Stevo7682

    Stevo7682 Zorg Guru (IV)
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    The lower right bolt is in a bad way
     
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  9. t-tony

    t-tony Zorg Expert (I)
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    Me, I would use heat. I would heat them up to cherry red, then give them a couple of sharp taps on the ends with a hammer and something flat at the end. Let them cool, heat again and then try some grips on them. I'll post pics of what I would use tomorrow.

    Tony.
     
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  10. Fraser

    Fraser Zorg Addict
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    I did try and get the bolts out nice and gently, but they just wouldn't have it. :(

    Knew I should have left the new parts in the garage for another 2 years!! :D
     
  11. Fraser

    Fraser Zorg Addict
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    Cheers for that Tony.

    Do I have to be careful around any other parts there? I don't want to catch a fuel line or injector and my headstone says "Here lies Fraser, he should have left the parts in the garage!!" ;)
     
  12. Stevo7682

    Stevo7682 Zorg Guru (IV)
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    But all may not be lost @t-tony are those bolts right through into the block or are they only into the front timing casings either way removal of the casing could be beneficial as if into head then allow more access and if in casing allows to work off car
     
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  13. Stevo7682

    Stevo7682 Zorg Guru (IV)
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    Bolt straight through casings and into cylinder head Screenshot_20190910-224801_Samsung Internet.jpg Screenshot_20190910-224727_Chrome.jpg 20190910_225111.jpg
     

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  14. Fraser

    Fraser Zorg Addict
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    Cheers for the input so far guys. :thumbsup:

    What's the worst that can happen.... I can start looking for a V8 that might fit instead!! ;)
     
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  15. Pingu

    Pingu Zorg Guru (I)

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    It looks like the ideal job for an induction heater and some Mole grips, but that ain't a DIY job as the tool costs around £600.

    Wait for @t-tony and see what he comes up with.
     
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  16. Fraser

    Fraser Zorg Addict
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    Oh, that doesn't sound good. :(
     
  17. Synclare

    Synclare Zorg Guru (III)
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    There are guys out there that do this stuff for a living, may be worth getting them in and saving yourself the aggro.
     
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  18. Nodzed

    Nodzed Zorg Guru (V)
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    I suggest hiring one of these if you can

    images.jpg
     
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  19. mrscalex

    mrscalex Zorg Guru (IV)
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    I broke a single bolt off on my M54. It was a frigging nightmare. I drilled it out but how I managed to do that without destroying the thread remains a great mystery.

    One of my mistakes was to try and keep grappling with what was still sticking out until I had nothing left to grip. I'd tend to agree the heat method is your surest best.
     
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  20. Stevo7682

    Stevo7682 Zorg Guru (IV)
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    I would agree with the heat that's also why I would attempt casings removed to gain access to where the bolt actually screws into cylinder head
     
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