Snapped bolt when changing alternator, HELP!!!

[dgrand]

Hi Folks,

one thing after another, when changing a busted alternator, I snapped bolt 11 exactly as shown on the picture. Put the new alternator back, and I am unable to put the serpentine belt on now. What to do? Ideas? Drill it out? 2 - look like the engine block, I am f.k.ng scared now...

DG

=================
01 RIBBED V-BELT 6PK X 1538 1 11281706545 $51.48
02 Base plate 1 11281726774 $84.70
03 Bush 1 11281748718 $11.16
04 Pitman arm 1 11281726773 $76.41
05 NEEDLE SLEEVE 2 12311713153 $23.06
06 ADJUSTING PULLEY 1 11281748131 $57.46
07 Fillister-head screw M10X25 1 07/2007 07119920150 ENDED
07 Fillister-head screw M10X25 1 07129905534 $2.17
08 Hydraulic belt tensioner 1 11281717188 $140.19
09 Hex bolt M8X40 1 07119901161 ENDED
09 Hex bolt M8X40-ZNNIV SI 1 07119905549 $1.52
10 Hex bolt M8X50 1 07119912652 ENDED
10 Hex bolt M8X50 1 07119904533 $4.12
11 Hex bolt M8X105 1 07119901785 ENDED
11 Hex bolt M8X105 1 07119904532 $2.58
12 Flat washer 3 11281440369 ENDED
13 Hex bolt M8X35-8.8-ZNS 1 07119913111 ENDED
14 WAVE WASHER B8 1 07119932121 ENDED
15 Deflection pulley 1 07/2007 11281748130 ENDED
15 Deflection pulley 1 11287841228 $58.51
16 Hex bolt M10X150 1 07119904677 $5.54
17 PROTECTION CAP 1 11281730349 $3.44
18 PROTECTION CAP ADJUSTING PULLEY 1 11281727159 $3.44
19 PROTECTION CAP 1 12311713143 $0.61
20 Mudguard 1 11281730532 $3.44
21 Complete hydraulic belt tensioner

[petener999]

Is the bolt broke from the inside?

[dgrand]

Yes, the piece of about 15 millimeters is inside the plate numbered #2 on the right site of the picture. The rest of the bolt is out, no means to tighten it as there is not enough thread.

[petener999]

I think you need to tap and dice the rest of the bolt out.

[dgrand]

Tap and dice. Easy to say. Ok the bolt is 8mm in diameter, you drill with 4 mm? Has anybody seen bolt extraction kits with bits long enough for that thing? It has to be 10cm or longer, I can find none so far. Has anybody seen drill bits 4-3mm longer than 5cm. I need 10 at least. Looks like I am completely f.cked.

[ARTRIGA]

Can you remove the plate#2 and then get to it w/extractor that will reach? I don't know what else you would have to take off to do this.....just a thought.

[dgrand]

Ok , I got it out this morning. I took off the lower support pulley, hydrolic tensioner ( basically bolts 10, 13 and 7 ) hex bolt on a pulley is a bitch. Part 4 - the holding arm does not have any threads in it. I checked on this at the dealership prior to start working. The whole thing (right side of the picture) just came off. Then the broken bolt is just at the level of the base plate. Started drilling and a saw it getting loose. Screwed it our with my fingers then, new bolt - six bucks - got it at a dealer. Thanks everyone!

Now I gotta move that stupid nut on the lower bolt of the alternator that sticks in the alternator housing, can not put it back at all now, too tight.

This is not my car, but the guy got the same problem on his X5. See the pic. He must have followed the same stupid advice to loosen tensioner by going clockwise, I think somebody mentioned that this was written in Bentley manual

http://i603.photobucket.com/albums/t...100_0255-1.jpg

[petener999]

Glad you got that fix dgrand. Now clean your engine.

[dgrand]

>> Now clean your engine
>> This is not my car, but the guy got the same problem on his X5...

mine is squeeky clean like a maxi pad

[dgrand]

Ok boys, I got it all running just fine. 9 hours of work and 3 hours driving to the alternator shop, BMW dealership and various tools stores. I would not say this is 3 out of 10 on a scale of difficulty. It's more like 5 out of 10. I mean it, I took engines apart on other cars.

So a couple of remarks for the next guy down the road:
1) When placing alternator back, pull out that washer on the lower bolt. It is getting pulled inside alternator bracket when you tighten lower bolt. You will not be able to place alternator back unless you move it. I filed it a little as it did not move, used WD-40 and a vice.
2) When tightening the belt, make sure hydraulic tensioner bolt (the one that snapped for me) is released and just pull serp belt really hard towards the alternator pulley. Alternator is the last pulley you want to get it on.

oh yea, last thing the price of the job: about $150 for the failed voltage regulator, bolt #11, and other tools like TORX T50, really long hard screedriver for the "fan clutch" release tool etc. F..K the dealership - they will charge you a thousand or more, they charged a buddy of mine $1400 for the full job.