Timing belt cover bolt snapped inside head

[damounh]

I was placing back the timing belt cover when I accidentally forgot the triangle curved triangle piece (shown by yellow arrow) that goes in between the timing belt cover and cylinder head. Since I forgot this, there was a small gap between timing belt cover and the cylinder head. I kept tightening the bolt (shown in red arrow) until it snapped :(

Theres now a small piece of the bolt stuck inside the head, nothing sticking out so only way to get it out is to try to extract it (I think). I tried extracting it, but its so stuck that the extractor broke too. I'm considering drilling a hole big enough to try to get to the threads and then try to get whatever thats in there out.

I'm wondering if anyone has any other suggestion. Can I keep installing the cover without that one bolt? If I do, then i can't install that triangle piece since it'll only be held by the other bolt on the top right. Any suggestions?

I just took out the cylinder head to replace a head gasket and everything else is pretty much hooked up so I'm trying to avoid taking the cylinder head out again.

[ahlem]

So you were able to get some sort of hole drilled into the bolt, I assume. First thing would be to get a left hand drill bit and drill the hole just a bit bigger with that. Don't break it off but you may get lucky and it will back the remaining bolt section out as you drill. If that doesn't work, you can get a carbide burr about 1/8" diameter for a Dremel from your local Home Depot for under $10. You can carefully and surgically grind the hole larger with the burr. and hopefully about the time the size hits the threads, you will be able to use a new EZ out to get it to spin out. It helps to use a bit of crayon on the bolt once it warms up like penetrating oil.

[Som]

https://www.amazon.com/dp/B0002KKPXK

I bought the helicoil above for rethreading that exact hole. Worked great. I didn't have a stuck bolt in there, though. 1/4 inch drill to make room, so if you can drill that out, you should be good to go. I ended up just using 1 coil, but I imagine if you can go deep enough you could do 2. Not sure it's necessary, though. I just didn't crank down on the bolt when I put the new one in.

Som

[jeffnhiscars]

I'm thinking helicoil too since that broken bolt snapped cause it bottomed out in the head. That means it's jammed in there pretty good and is unlikely to back out.

Because you are using this bolt to hoist your engine you really want to do it right.

[e30crazie]

On that note, I should install the hook bracket back on your head. If your bolt down without the bracket, your timing belt will rub on one of the ridges inside of the timing belt cover. This happened to me today and I ended up taking it apart to place that piece back inside. The other thing it damages is the inside of the distributor cap, it pulls it too far inside and the rotor scrapes inside and you get all of the dust from the cap and rotor. Make sure you get this back in place.

[BMW B3N]

I snapped that same exact bolt taking it out. Then I put the cover back on with one bolt on the unbroken side and since its held in place with the bolt guide thing on the other side it wont move. Ive had only one bolt in it for a couple months now with no problems. Not saying you should do this but it worked for me.

[e30onBBSs]

Heli coil is really good stuff, you need a tap and die set though