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Old 01-07-2019, 08:35 PM
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Join Date: Jun 2018
Location: SF
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johngrefe is on a distinguished road
N62 Broken Valve cover bolt in Rear

Tools:
  • Harbor Freight 3/8 Drive air drill (reversable)
  • Small hammer
  • Auto Punch (spring loaded)
  • WD40
  • Wratchet
  • Extensions
  • Telescoping magnet (stronger the better)
  • T10 & T15 Tox bit
  • *or*
  • Fastenal left handed drill bit


This is a quick note if anyone else runs into this.

Remove plastic sub assembly that keeps cabin air filter slid up. I'd actually recommend this for anytime you service the valve covers, really opens space up, makes clearance on cam sensor much better.

Harbor Freight has an excellent 3/8 drive air reversable 90d drill. It's just small enough to give you two fingers behind it and hit the stud at a straight.

Get an auto punch tool to divet the center of the stud.

Pack area with rags, leaving no gaps, cover cams / cam towers / valves and oil gullies

Spray area with WD40 or equiv to catch shavings in oil while drilling / soak your bad stud.

Drill using cobalt bits, work from smallest up.

Drill slowly, in small bursts, try to keep bit centered, or work the hole towards the center. Don't touch the sides.

Working slowly, pull the bit every drill, and use a magnet to clean up shavings. The bolt is steel and the heads aluminum so this works easy.

Two directions here:

A) Use a high quality reverse (left handed) drill bit on the above drill to spin it out. You have to be dead nuts centered with your above pilot hole, and high confidence in your angle of attack.

B) (my choice) In the small hole you've made hammer in a Torx 15 socket into the hole until firm, use extensions and wratchet to get a very good angle and slowly apply pressure until it comes free. I prefer this, because the head is at an askew angle, the work space is tight, and the larger you make the hold, the higher your chances of hitting the cylinder head sleeve / threads, which is an 'engine out'.

I know there is a 1000 write ups across the web for tackling sheered valve cover bolts, but I'd figure I'd make this note as it is X53/N62 specific process, and you are working with tight clearances and odd angles.
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