Broken 4" Water pump Bolt...help!

[Dway540]

I have a 1994 540I. While removing the water pump I broke one of the long upper bolts in the left side of the water pump. Approximately 1/2 inch of the threaded end of the bolt is in the engine block. What should I do? I tried to
remove it with an easy out drill bit but it's not long enough to reach the stud.

[Rory]

I have a 1994 540I. While removing the water pump I broke one of the long upper bolts in the left side of the water pump. Approximately 1/2 inch of the threaded end of the bolt is in the engine block. What should I do? I tried to
remove it with an easy out drill bit but it's not long enough to reach the stud.
Check the following link for some good tips:

http://www.asashop.org/autoinc/may2003/techtotech.cfm

1/2" should be enough space for an easy out, if not you may want to check for a different sized easy out.

Good Luck,
Rory

[Dway540]

Thanks Rory! I really appreciate the info.

[drice]

I tried for months to remove the broken piece without any success. With careful application of the "uprated" gasket from the dealer (not the paper one that comes with the pump) and careful torquing of the other bolts, it has held just fine for over a year now. Just so you know in case....
Dan Rice

[Dway540]

Thanks D Rice! I will try that if I can not remove the broken piece.

[Dway540]

I could not remove the broken bolt so I replaced water pump gasket and reinstalled the water pump. The water pump is leaking. What should I do now?

[632 Regal]

whats the story about removing the broken part? Is it accessable? I think your going to have go back in doctor.

[Tiger]

You have to soak that broken bolt with WD40 to break the corrosion that made it break... then you use easy out if there is no stub to grab. Otherwise you have to heat up the bolt and area with heat to get it out.

[Dway540]

The broken bolt is approximately 3 1/2" deep in the engine block. The easy out drill bit was approximately 3 1/2" long. I welded the easy out bit and made it longer but I could not remove the broken bolt. I drilled the broken bolt down so I could cut some new threads in with a tap. When I started cutting the new threads in with the tap.The tap broke and I cannot get it out. So now I have a broken bolt and a broken tap stuck down in the the block. The tap broke off approximately one inch deep from the opening. Approximately 2 1/2" of the tap is stuck down in the block. Can I leave the bloken bolt and the tap down in block and seal them in and cut some new threads in and use a shorter bolt to connect the water pump?

[Tiger]

Whoa! That's even worse... Waterpump will never seal without that bolt as you know... Have you tried easy out on the tap? Tap is such a hard metal. Last resort is to use heli-coil for the size of the opening and use the right short bolt to go with the heli-coil.

[Dway540]

I tried easy out the on tap but I could not remove it. I guess I will use heli-coil with a shorter bolt. Thanks Tiger & Regal!

[632 Regal]

Okay...I believe we NEED to see some pictures here. I did my waterpump and just cant remember that hidden length bolt, its not really obvious on the real OEM site either.

Edit: the long bolt might be also holding the timing cover tight, you dont really want to eliminate this one!

PICS!
PICS!
PICS!

Them easy outs and crap suck to get out.

[wingman]

Sounds like you need to get it to a fitter and turner. They'll drill it all out and insert a helicoil. I broke an easy out (useless article) off doing the same thing with my E12. I was able to drill and tap though. Good Luck.

[632 Regal]

unfortunately I think this bolt goes through the timing cover into the block.

[Dway540]

Initially the water pump had 2 bolts approximately 4'' long and 4 bolts approximately 1 1/2'' long holding it to the block. I think the two 4" bolts support the water pump and hold the timing chain cover.Today I inserted a heli coil and used a 1 3/4" bolt to replace the 4" broken bolt and reinstalled the water pump.The water pump is no longer leaking and my vehicle running good at the present time. I really appreciate you guys for helping me!

[632 Regal]

mint original!

lol