Stripped cylinder head bolt?!?!

Just got my head back on, torqued up all the bolts hunky dory in the right sequence from 40Nm to 60 and then a 1/4 turn. Got to bolt 10 and just as i put an 1/8th of a turn (after 60nM) it felt like the torque wrench went and made a bit of a clang. Though it was the wrench but the bolt went a bit loose then tight again. Soiled myself a bit.

I checked it on all the other bolts on 40 then 60 again and it was fine. Bolt 10 has maybe sheared some of its thread or ive not cleared all the oil etc out of the hole.

Is the block harder than the bolts so its less likely ive sheared the thread in the block?! New bolt??

Due to have it back on the road tomorrow. Just waiting for rocker cover back from painting

Just removed the bolt and some little bits of thread has come out with it from the block, but not a lot. Had a look down and theres no oil or water etc in it like its been blocking the bolt and stripped the thread.

Devastated. This corner is the same corner ive had a slight oil leave from since i got it and the reason i rebuilt it all. Probably the reason it was leaking because someone just nipped the bolt and didnt tighten it fully.

Needs some big help now. Gutted. Its practically built up ready to go

That’s horrible luck mate, sorry to hear that. The guys I work with build 911 race engines and quite regularly use these but you’re going to have to remove the head again to do it I’m afraid
++ TIME-SERT Official Threaded inserts for stripped threads, blown out sparkplugs,


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Thanks for the reply. Im gutted. Had the head all skimmed, new exhaust guides etc etc and all ready to roll!! Are they expensive kits? I can whip the head off, reluctantly, in no time really, new head gasket and bolts aint much as the cost.

I can do it with the block in the engine still?

Whereabouts are you ? I think we buy ours from wurth but I couldn’t swear to it. I don’t think they’re particularly expensive but  you do need the correct tool to use them and they require an odd sized tap to cut the new thread.


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Im from Morecambe in the north west, just up the coast from Blackpool.
The kit was like 400 dollors on the website. Not cheap like!! Have you seen it done before Jamie? Luckily i have an engine specialist 10 mins away from where i had my head done but if i can save a wedge and do a good job then ill try.

apologies if i'm wrong but is sounds like your bolts are not strong enough for the torque settings to be applied. perhaps they need to be a High Tensile for that particular application & setting… what size are you using? try www.belmey.co.uk 

I have heard nothing but good things on time-serts.
I would also suggest at this stage that you look into ARP Racing stud kits a tad pricier than new bolts, but they are re-usable.

ARP - The Official Site | Volkswagen Kits

Timeserts are more effective than helicoils imho, if yours is a decent machine shop, then they probably have heard of them.

When I had the mis-fortune to break 3 exhaust studs on my 90,  I had them timeserted, I think it was about 100 usd for the 3 of them, but it was worth it.   

The Machinest who did it has since retired and I haven't found a new one yet…..  

Awesome news. After a quick phone call, Lancaster engines, the firm that did my cylinder head last week not only said they can re tap my block but said they can come to my house this week and do it for next to nothing!!. Shocked how cheap they will do it for and they will use Timesert as you mentioned because they are better than a helicoil.
Im well happy. Even more when its done.
Deandubya the bolts are Victor Reinz bolts so they are good ones and they are all intact when i took them out.
After an inspection im adamant that the thread in the block was nakered before hand as only a fraction of the torn thread came out yet nearly all of the thread was stripped.

Hey that’s brilliant news I’m really glad you found an affordable fix, they sound like good chaps to know.
Not to sound stupid and state the obvious ( but I’m going to lol ) once you’ve stripped back down to the block make sure you cover the entire surface with a few layers of duct tape ( gafa tape ) and only leave the thread hole they will be working on exposed, as I’m sure you’re aware you can’t afford to take any chances with swarf and once they done make sure you blow out the repaired thread and the taped surface so it’s completely clean before removing the tape. If you haven’t got a compressor you can buy cans of compressed air, brake cleaner also helps  to get bits mobile in conjunction with air and so on. You get the idea. Good luck man and let us know how you get on


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Oh and just check the bolts, I don't know if they're stretch bolts but they haven't been through a heat cycle yet so will probably be ok but maybe do a bit of research just to make sure ?


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All I have ever heard was that the head bolts are one-use only.

I can tell you before I found out that they were one use only,,,,, I reused a set,  3 months later I was replacing the gasket again…..but using new bolts.

Thats funny Jamie because i had the exact same conversation with the guy on the phone about covering the block and he asked me if i had a compressor. I said no but i can get some compressed air cans from RS to clear out all the wholes haha. Funny you mention the exact same words. Not stating the obvious at all pal, its easy to get summit fever and miss the little obvious things that come back and bite you. Getting some good masking tape today and cover the block except the one hole.
Fingers crossed now for a repair asap then it will tie in nicely to get my rocker cover and fan shroud back from the bodyshop. Cheers for the tips advice and support guys. Update soon

Sounds like a good out come is likely. Good news.

I'd never heard of Timeserts! Every days  school day  

Ian

Apparently they are similar to helicoil but much better. Not cheap for a kit but fortunately i need just one, not the kit

I've used a 10x1 helicoil on the head for the coolant outlet, 6mm drill bit, liquid fill & then tapped… nervous times!!  used a cotton bud rimmed with wd40 to clean any debris out… 

Yeah theres no going back is there. Used similar at work before a few time but if i mes it up then im stumped. Still waiting for them to come do it. Getting annoyed now. Nearly a week

I suppose with all the weather related mayhem we've been experiencing you've slipped down the list a bit, very frustrating as you can't really moan at them for the fear they might change there minds altogether I suppose.
Hopefully now things are beginning to thaw you might get some progress ?


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All done and dusted. The guy that has a local engine machining and rebuilding service drove out to me, only 10 mins away like, and fitted a time sert for me. The size i needed he didnt have so he ordered a kit for £110 and then charged me 40!!! Absolute legend. He loves mk1s aswell and used to work for vw in the 80s when they released the cabs so we had a right old chat.
Head is on and set up and timing done. Feel chuffed to bits!!!!

WAAAAAAwhoooooooooooooooooooooo WTG just doesn't quite describe the joy.