How can I remove a broken airpump bolt and broken thermostat housing bolts from the aluminum waterpump housing without damaging it?

 

First off, and most important, repeat after me -

"I will go slow, and take my time".

That said, you need an EZ-Out. Use a centerpunch to make a divot in the center of the broken fastener. Drill into the fastener with a relatively small drill bit, and get in there pretty good - make sure you're in straight. Go with a bigger drill bit to widen the hole out.

Get an EZ-Out of appropriate size. Tap it into the hole. Twist it with a wrench. Might also help to apply penetrating oil to the broken bolt (PB Blaster) and maybe heat it up good with a torch.

The BIG gotcha - take your time with an EZ Out. They're very hard metal, but brittle - twist on it too much, and it will snap. If it snaps, you're out of luck.

If both broken bolts are in the water pump housing, might actually be worthwhile to find a good used one - they shouldn't be that hard to come by.

BTW, on the bolts that hold the water neck on (the ones you remove to change the thermostat) ALWAYS use anti-sieze on the bolts - helps keep this from happening. I also replace the bolts when doing a thermostat job - it's VERY common for the bolts to snap when you tighten them back in.

Push comes to shove, remove the broken parts and have a machine shop do the work.

Dale

 

Thanks for the info.