I recently learned of the problem these vans (1998 Pontiac Transport – Montana Edition) have with their intake gaskets. The van was starting to weep coolant (~185 000km). As such, I was replacing my lower intake manifold gaskets over the weekend. Everything was going quite smoothly (despite the obviously ridiculous disassembly routine). The lower intake gaskets definitely needed replacement, but were not as bad as some people have had. The gaskets were replaced and reassembly was starting. Then wham. One of the rocker arm bolts broke on me. Actually it was a family mechanic who was using a torque wrench and tightening them to 168 inch-pounds. He clearly screwed up and now has me seriously questioning his qualifications (nope, I’ve just thrown them out … I’m tightening every bolt from now on). I won’t rehash the my rant any further. To the crux of the matter then …
The bolt broke such that no part of protrudes from the head … its essentially flush with the surrounding surface. I’m not quite sure how to proceed from here … there are some options:
1. Take out the bolt using a broken bolt/screw remover drill bit - with the head in place on the vehicle.
2. Take out the head and then remove the broken bolt.
3. Take out the head and give the work to a machine shop.
I have taken broken bolts out before and know the routine fairly well; but in this case I am concerned about the fact that the bolt (steel?) is broken in an aluminum head. Are there any special steps I should take or issues I should be concerned about. I don’t want to exacerbate the problem any more.
Any thoughts?