Help - Snapped Tensioner Arm Bolt

[mini-j]

After replacing alternator on 2003 Mini Cooper S I noticed that the bolt holding the tensioner arm snapped. Unfortunately there is not enough thread sticking out of plate behind to get a stud removal tool on.
I'm now looking at jacking engine, wondering what is behind there, if I can remove the plate behind? or better to drill and tap? Also, can I jack the engine enough to get to this plate without having to disconnect everything?
I now feel like I'm in over my head... Should I just put the wheels back on and tow it to a garage? Thanks for any feedback!

[Dave at Pelican Parts]

The preferred method is generally to weld a nut onto the remaining bit of the stud. Do it as a plug weld through the hole in the nut. Then you can use a wrench to spin the broken bolt out.

You can try drilling into the bolt and using an extractor, but those are somewhat risky--they are harder than most drill bits, and they are brittle. So they can break off in the stud, giving you an even worse problem.

You can very very very carefully drill in to the center of the bolt, then drill larger, then larger, and so on, until you finally use a dental pick to pull the remaining threads out.

Or you can tow it to a shop, who will probably do one of these things.

--DD

[mini-j]

THANK YOU!
That did the trick :-)

Well actually the bolt is so small (6mm) that the welder had a hard time getting a nut on, but was able to build it up enough to get a vice grip on it.

Thanks for the quick feedback!