I just did a coolant change on my 2017 Fit. It all went fine except that when I undid the overflow reservoir bolt it was turning but with difficulty, then it sheared off just proud of the fan shroud where it mounts.

There isn't room to try to drill it out because the engine is there, and there isn't enough thread to get some locking pliers on to get it out. Any ideas?
For now I've used a couple of zip ties to secure the top of the reservoir to the fan shrouds. It's not going to go anywhere, but I don't love that.

 

Your other alternative is to weld a nut onto the exposed bolt. Then you really juice it up with your favorite rust penetrating fluid and slowly work it back and forth a bit at a time to try to loosen and remove it. You're basically trying to clean the threads as you loosen and remove the bolt, so a tiny bit out, a tiny bit in, a hair further out, then back in, and so on.

 

Remove the fan and shroud, work on it out of the car.
A left-hand drill bit set can be helpful. Left-hand meaning the bit cuts when turning counter-clockwise, the opposite of a regular drill bit. They're great for removing stuck bolts, as the bit rotation is trying to remove the bolt rather than drive it in further. Also get an M6 x 1.0 tap to clean the threads, and a tube of anti-seize to keep it from happening again.

The bolt appears to thread into a metal insert in the plastic fan shroud. I guess pulse resistance welding might work, but any traditional welding techniques will just melt and/or ignite the fan shroud.

 

Looks like removing the fan involves taking off a lot of the front end! I've got it pretty secure right now. I'll leave it until I have reason to take more drastic action.

 

Removing the radiator does, as it's trapped between the cross-bar (part with the hood latch) and the lower radiator support (similar cross-bar structure). The headlights also bolt down to that cross-bar, so the headlights need to come out to remove it. Bumper needs to come off to remove the headlights, and so on.

I haven't looked at just the fan - are the bolts holding it to the radiator also trapped under the cross-bar? Guess I'll go take a look.

Edit: Yup. I can get my fingers on the bolt heads, but I don't think a ratchet would fit. Even with the bolts out, there's not enough space to wrangle the fan out from under the cross-bar with the alternator and intake manifold in the way.

 

Yeah, it's pretty annoying, but not surprising given the lack of space in there. I'll get around to it at some point, until then I'll just keep an eye on my zip ties.

 

Yes!

 

I actually have one of those. I'm not sure there's enough room for that with a drill bit in it though. Might be worth a try before taking the whole front end off!

 

Here you go - simple solution. 😉