Re: Broken bolt, need advice..

[AUDIDUDI@delphi.com]

> While replacing the timing belt tensioner in my '87 5Kcst, I broke the
> bolt that holds the tensioner in place. (Still can't figure out how, as
> I didn't put much pressure on it.) Other than pulling the engine to drill
> out the old bolt and replace it, what options do I have? Locktite? JB
> Weld?  The bolt broke off in the casting, no stub protruding to get a grip
> with anything. Due to position, I can't get a drill lined up to drill and
> use an easy-out.

The same thing happened to me when I did my timing belt three weeks ago ...
the "casting" you refer to is actually the oil pump and you'll need to pull
it.  If you're lucky, as I was, there will be 1/4" of the bolt sticking out
of the block and you can spin it out with vice-grips.  If not, well ... you
will either need to lift or drop the motor to get a shot at it with a drill
and/or ez-out.  You can unbolt the nose panel but I doubt that would be the
quickest way to gain access but I could be wrong.
 
To get the oil pump off, you've got to drop the subframe (but not remove it)
and pull the oil pan ... replace all the gaskets and seals while you are in
there and it's not that big of a deal other than somewhat inconvenient.  As
I recall, the only difficulty I had was getting the accessory belts back on
... I replaced these as well and they were a bit tight.  BTW, your best bet
is to press the idler pulley in or hammer it using a proper-sized socket as
a drift.  The 6mm bolt just isn't strong enough to pull the pulley in (even
though it looks like the obvious method) and my particular one was corroded
badly enough that it broke just trying to tighten it up to 15 lbs/ft...

Good luck!

     _             _             
    / l       l o l  \       l o   Jeffrey Goggin
   /__l l l / l l l  l l l / l l   * * * * * * *
  /   l l_l \_l l l__/ l_l \_l l   AudiDudi@delphi.com