Broken Fuel Rail Bolt

[spazkid1989]

Ok today has been a really bad day. First of all I went to start my car for the first time after rebuilding to motor. When I turned on the fuel pump to set the fuel pressure I had geysers of fuel coming from my line. When I went to tighten the bolts for the fuel rail I broke one of them. It was broken flush against the head so I went and grabbed my easy out kit and started drilling. Once I inserted the easy out and started to turn it, it snapped in half. Now I have a broken bolt with a broken easy out in it. I tried re-drilling the bolt out, but the broken easy out is making it impossible due to the harder metal. Does anyone have any input on how I can remove this bolt?

 

[92AWDHX40]

Drill it out, or get it out then retap it if you damage the threads.

 

[nightmares GS-T]

You can probably use a cobalt drill bit. Ace has them. I've used them to drill cast iron so give it a try. Be sure to use plenty of oil to keep the cut lubricated. Otherwise it will probably just overheat and round the bit off.

 

[junkyarddsm]

Ive tried to drill out easy outs before I have snapped a few and its pretty much not going to happen unless you can get it to a drill press. Ive used vise grips that have the lock bolt on the back to try and get a bit if its not in their crazy tight it might work for you or you can try the rounded nut easy off kits (got mine from craftsman for 20$) depending on how much is sticking out you try that as well if you can find one small enough.

 

[tonyseagle]

Same thing happened to me when I was upgrading my fuel system. I just use 2 bolts instead of 3 to hold the fuel rail down. No leaks.

 

[igotawdpsi]

That happened to me as well when I was upgrading my fuel injectors. I worked at a machine shop and would always take out broken bolts so for me it wasn't that bad. Depending on how tight you tightened it you should have been able to drill down the middle of the bolt and use the tap set tool to work the bolt back out.

 

[rza808]

take it to a machine shop, its worth the 20-40 bucks you'll spend and if they break there tools they get them replaced for free...I've seen many broken bolts with broken easy outs come in to the machine shop my friend owns, save the time,money, and trouble, call your local machine shop