Removing Cam Cover Bolts the Hard Way

[Dynomite]

Removing Cam Covers for Camshaft Timing Inspection, replacement of PCV filters, checking top Timing Chain Guide for wear

Removing Torx 40 bolts Not so easy......but then turned out very easy.

1. Cam Covers were removed by first removing Bolts from C-Frame, Loosening Engine Mount Bolts and then dropping Transmission a bit so cam covers could clear Brake Booster (two Torx-40 bolts near brake booster were removed with cam cover). On the Passenger side the Temperature sensor for Evaporator was removed easily and set aside (plenty room to then remove cam cover bolts and then cam cover on passenger side). The Transmission was lowered to remove Torx-40s on passenger side and then raised to remove Cam Cover on passenger side clearing Fire Wall bolts.

2. Now the Hard Part......as can be seen five Torx-40 Cam Cover Bolts failed in the Torx receiver on the bolt head even though considerable downward pressure was applied to the Torx-40 socket/wrench. Several types of Torx 40s wrenches had to be used because of the clearance. Considerably more torque than the 19 ft-lbs for Torx-40 Cam Cover bolt installation was applied trying to remove them (a cheater on a 1/2 inch socket wrench)

3. Now the Easy Part........What to do.....Drill, Heat....Torch...
a. I tried drilling and ruined three drill bits.
b. I did not want to try heat (A little heat works great on Injector Housing for removal of Coolant Manifold Bolts) as there is no way to get heat where it is needed.
c. Chisel...........well wouldn't you know it.....Using a chisel to first notch one side of the bolt and then pounding that side counter clockwise with the chisels about 10 times without touching the Aluminum Cam Cover surface popped the bolt loose (all five). I would never have guessed it but ran out of options as I was just going to use a chisel to knock the Torx-40 bolt heads off (a poor concept in itself)




Removing Cam Cover and Camshaft Timing Inspection