Replaced rear valve cover and gasket to fix one leaking spark plug chamber seal. This is what my engine looks at 44,100 miles. Clean... I did an autoX treatment at around 28K miles and have been using synthetic oil ever since (mostly M1 10w30).

Rear Bank Pictures

One issue I encountered was the wrong torque spec listed in the FSM for the cover screws. This cause the screw/bolt where the arrows point to in the picture to break. The correct torque spec seems to be at around 15lbs, way below what is listed in the FSM (65-82lbs). Couldn't get the broken piece out, so I would like any suggestions to get this resolved. I put everything back together and no leaks from the valve cover, but would like to get the broken screw one resolved soon. Thanks.

Pedro

Can you drill a small hole into it and then find something to fit snug into the hole and back it out?

From what I read in the FSM, those fasteners are torqued in inch pounds instead of foot pounds. Though it may be hard to get to the broken one to remove it, you might get lucky and turn it out with a small pointed awl or something. If the hole was clean before it broke, it may not be that tight since the head of it is gone. If you decide to try drilling it out, be very careful to ensure you don't make the hole unusable by drilling into the threads. Being that it's aluminum, it's much softer thanthe broken bolt and easier to drill into by mistake. Good luck.

Pedro,

Do you have any pictures with the valve cover on but the intake removed? I have a webpage with the spark plug replacement write up, but have no pictures for the rear.

To answer your question, you can get a tap at home depot. They are drill bits that go the opposite way when drilling into a bolt that has snapped. You'll have to drill a small hole in the broken bolt to start, then put the tap on and keep drilling. It will expand in the hole of the bolt and turn the broken bolt the opposite way. Good luck. Oh, the name of the product is Black & Decker Screw Extractor Set (16270-03).

You are talking about 2 different things here. A tap is for threading or repairing a hole and a screw/bolt extractor is used to remove a broken bolt.

He would need something like this to get it out.

Didn't take any pics beside the ones I posted. Will take some pics the next time I remove it to get the broken screw out. Will pay a visit to Home Depot for the extractors. Will tackle the issue next weekend.

Pedro

Sorry, I meant tap the screw with the extractor.