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86 6.2 Injection Pump Bolts

86Chevyboy86

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Well i finally decided to turn my fuel up. I read around and decided to adjust the fuel screw from the top. I was taking the top cover off of the injection pump and two of the three bolts/screws broke off in the pump housing. What do i do?

Chris
 
After your done crying,cussing,and feel like junking it ?..
I know that feeling all too well..:doah:

I busted one pump cover screw off in the IP on a 6.2 parts engine I have--I have not tried removing the remains yet,there is just a 1/8" nub sticking up above the casting it threads into,I am hoping I can braze or weld a nut to that stub and be able to extract it successfully..

If your bolts have sheared off flush,you probably will have no choice but to try and drill them out,which will prove very difficult no doubt--any time a steel bolts breaks in an aluminum or die cast part,the drill will always want to wander off the steel and bore into the soft aluminum...the IP hasn't much "meat" around the bolt holes either,so there isn't much room for error--if you can get a hole drilled you can use nuts and machine screws ,I would not attempt to tap new threads,most likely the "ear" will break off..

If this fails,perhaps a jerry rigged method might work to hold the top cover on,like a worm gear hose clamp,but you'll always fear it will leak, if it did work,everywhere you drive it..

I hate "fragile" expensive parts like these--:angry1:..
 
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I have successfully welded to those to extract them, but lots of different risks involved. Probably be best to remove it and get all fuel drained, then figure out a way to keep stuff out of the top of the pump while working.
 
Well I drilled and tapped new threads on one of the holes. The only problem with using a bolt, washer and nut is that the bottom of the ear is angled...
 
You could bend the new bolt head a tad and insert it with the head at the bottom,nut on top..or use a wedge shaped washer...the cover doesn't need to be torqued down too tight,so it would likely work OK..

You must have better luck than I do drilling out a steel bolt in aluminum...and tapping that ear,that would be instant "snap" if I attempted it,no matter how careful I am..
 
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