1. Gather the Necessary Tools:
- Drill: A drill with various drill bits, including a cobalt or carbide drill bit specifically designed for metal.
- Easy-Out Bolt Extractor: An extractor tool designed to remove broken bolts.
- Vice Grips: A pair of locking pliers or vice grips to hold the broken bolt.
- Hammer: A small hammer or mallet.
- Penetrating Oil: A spray can of penetrating oil to help loosen the bolt.
2. Prepare the Engine:
- Disconnect the battery to avoid any electrical hazards while working on the engine.
- Remove the valve covers and intake manifold to access the camshaft bolts.
3. Apply Penetrating Oil:
- Spray the broken camshaft bolt with penetrating oil and let it sit for several hours or overnight to help loosen the bolt.
4. Use the Drill:
- With the drill, carefully center a small drill bit (such as a 1/8-inch bit) on the broken camshaft bolt. Drill a hole into the bolt without going too deep, just enough to create a starting point for the extractor.
5. Insert the Extractor:
- Choose an extractor that is slightly smaller than the diameter of the broken bolt. Insert the extractor into the hole you drilled and turn it clockwise until it is firmly engaged.
6. Apply Pressure:
- Use the hammer to gently tap the extractor with consistent force. This helps to break the bond between the bolt and the threads. Continue tapping until the extractor starts to turn.
7. Rotate the Extractor:
- Once the extractor starts turning, continue to turn it clockwise using a wrench or pliers. Apply steady pressure and turn slowly to avoid breaking the extractor.
8. Pull out the Bolt:
- As the extractor loosens the bolt, continue turning until the broken camshaft bolt is completely removed from the engine block.
9. Clean the Threads:
- Use a thread cleaning tool or a tap to clean the threads in the engine block where the broken bolt was located. This ensures that the new bolt will fit smoothly.
10. Install a New Bolt:
- Apply a thread sealant to the threads of the new camshaft bolt to prevent leaks and ensure a tight fit.
- Screw in the new bolt by hand until it is snug, and then use a torque wrench to tighten it to the manufacturer's specified torque value.
11. Reassemble the Engine:
- Reinstall the intake manifold and valve covers.
- Reconnect the battery.
By following these steps carefully, you should be able to successfully remove the broken camshaft bolt from your Chevy 350 small block engine. Remember to take your time, use the right tools, and be patient during the process. If you encounter any challenges or have any doubts, it's best to consult with a qualified mechanic for assistance.
