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57 Volvo Penta

A

agitator

Contributing Member
"Guys, Both starter bolts brok

"Guys, Both starter bolts broke off on my 5.7. The broke about three threads deep. No way I can drill and use an easy-out. Any body got another idea? I bought this boat new in 1999. They had to replace the flywheel after two years and now the starter. Its not used that much and is well cared for. Are there known issues with volvo starters/flywheel? Do I pull the engine?????????"
 
"Billy, some of the older AQ m

"Billy, some of the older AQ models with the 5.7 used to have the starter bracketed to the block at the free end cover. The idea was to prevent cases like yours. However, it seems the do not use that system in newer 5.7 engines.

Not sure of how easy is to access in your engine the area of the broken bolts, but perhaps you could reach them with a 90º pneumatic drill. Also, you could try reaching them with a small screwdriver or punch ant try to remove them with a counterclockwise motion, as the threaded bits left in the block cannot (I'd rather say "should not") be too tight. You may need the help of a mirror."
 
Thanks EP..
I tried the right

Thanks EP..
I tried the right angle drill and just can't seem to get to it squarely. I tried to tap it with a hammer/punch/screwdriver but there is just no room to swing! I may grab a case of cool drinks and try it one more time today.. maybe two cases!
 
"I do all types of engine/driv

"I do all types of engine/drive repairs, and with great success........ but I'd not even attempt this while the engine is still in the boat.
Assuming that these broke while attempting to turn them out, they are being held in by corroded or rusty threads.... correct?
IMO, it is not worth the risk of thread damage should you or someone try to do this while working upside down, etc.

These are amoung the easiest engines to disconnect and remove.
Once out, have a person with machinist type skills center punch the broken bolt and go from there.
Bolts are maybe a grade 5, but the female threads are soft cast iron thread!

The layout of these two threaded holes precisely position and locate the starter motor.
Don't let someone screw these up for you. They are just too important.


This time around, use some Automotive "Never-Sieze" on the bolt threads. (do not use this below the water line on anything else).

Also, consider one of the PMGR or HTGR starter motors w/ bolts of correct length."
 
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