P Gasket Bolts

[Satancom]

Evning all.

I am in the middle of doing my P gasket on my 300tdi and have run into a snag. The three bolts that go through the waterpump were very stiff. I managed to work the bottom two out with a bit of wiggling but the top one is not interested. It rounded quite easily.

Any easy fixes? Mole grips didn't help much, only other thing I can think of is hammering a 3/8 socket onto it and trying again.. But then I have to remove the Fan and cowling, which means I have to get a viscous fan spanner.. Bugga!

Might just gut the head off.. actually no thats a silly idea as I won't get the casing off!

[flatmajor]

hi there, i recently done mine and what ****** it was. try banging a smaller socket on it or you can buy some bolt extractors off ebay or something simmilar. good luck

[Satancom]

Yeah I think im going to hammer a smaller socket on. Although its blinking cold today so may just do the fan belt on my scooby instead and stick it on Eblag.. Get some cash for it :D

[ComicalEngineer]

Shame you're in South Wales as I'd lend you my brand new (used once only) and still all sparkly viscous fan spanner. Take the fan off and leave it off!

There is a type of socket called a "surface drive" which grips on the flat of the bolt instead of the corners. These are much better than the standard square drive sockets as they don't round the bolt corners off.

Like these:

http://franklin-tools.co.uk/acatalog/Online_Catalogue_ENGINE_3.html

Hope this helps.

Tony

[rusty_wingnut]

for a cheap fan spanner, i ground out an old cheapo spanner to the right size across the jaws. then made the whole thing a hell of a lot thinneron one side (giving it some offset)

works perfect.

Interesting problem, never had any issues getting P gasket bolts out. sounds like a PO bodge....

[Satancom]

Interesting problem, never had any issues getting P gasket bolts out. sounds like a PO bodge....

Mmmm not a PO bodge know the history of the vehicle. Basically it started leaking water a while ago, but not a lot, so he just kept topping it up untill he took it off the road.. Basically its been rusting into the block for months and months!

[Satancom]

Shame you're in South Wales as I'd lend you my brand new (used once only) and still all sparkly viscous fan spanner. Take the fan off and leave it off!

Thanks for the thought :) My mate has one down his garage so will swing past there tonight!

[disco dude]

if no joy with smaller socket i recomend if you or a freind is any good at welding get a pice of bar on it.

or if you have the space grind the head off and remove what is holding it in then get a stud extractor or mole grips on it if no move ment try spreying penatrating oil over and leave for 24hrs and try again.

if its stuck i would recomend you take it steady with the abuse as you will be stuffed if you brake off the small bit of stud that is left out

when refitting new studs put a small amount of copper ease on the threads also if its a common size thread get a no3 tap with the correct thread pitch to clean it out 1st, use some brake and clutch to flush the rubish out.

best of luck
baz

[Satancom]

Cheers Baz.. Well I hammered a 3/8 socket on and it started to come, so worked it back and fro for about 10 mins taking it easy and then the head snapped off..

The cover was still stuck fast, it moved a little but is stuck on that bolt. I removed the waterpump too get access to the bolt and have soaked in WD40. I ground two flats into the side of the bolt and got a mole grips on it and wiggled it all over, no joy.

I then knocked my work lamp over and smashed the bulb so have left it for now, mates coming over to have a squint and will advise what to do next. I have no welding kit here so thats out of the question at the moment!

[Satancom]

Mate sideez came round last night and managed to move the cover away far enough so I could get a hacksaw against the block and finally got at the P gasket. The threaded end of the bolt came out of the engine with my fingers so happy days the blocks fine and cleaned up for the new gasket.. All I have to do is get the shaft of the bolt out of the aluminium casing.. Soaking in WD-40 at the moment hoping it will free up over night.. If not I'll chuck it in the car and pop it down to mates garage, see if he has a few moments to abuse it with his press.

[disco dude]

is the case threaded? i only ask as i never done one.

if it is try a blow lamp (slowly warm the surrrounding area as well) then heat the stud for a good few mins then use the grips might help it out.

take the plate in and warm it up over night then support it closeley either side and use a thiner bolt or a punch and tap it out, i say take the plate in as temp is in the minuses at the moment and a heavy impact and may cause the plate to fracture when hit.

i hope this may help and good luck.
cheers
baz

[Satancom]

Not threaded no.. but rusted in solid.. Have brought it into work and will pass it in the direction of the fitters as they have some biiig hammers :)

It stayed intoors last night to warm up to a more friendly temperature.

[Satancom]

I didn't know they had a Hydraulic press in work :D

May make some more use of that in the future, all out in 30 seconds! Back together tonight now :D

[Satancom]

P gasket is fine, water pumps pishing out though through the hole under the bearing. Will I get away with changing the water pump without changing the P gasket again ?