*urgent Help Please* Head Bolt Issues

[James Cornell 10]

Hello

 

I have just had a blown head gasket on my 1.9 GTI 8V 205 and I thought I would use it as an opportunity to change the cam belt, water pump, tensioner, relap valves etc however I have hit a big problem...

 

I have replaced the water pump and cam belt tensioner and I have rebuilt the head, when I came to put the head back on last night all 9 (new) head bolts were finger tight all the way down to the top of the head except for one (number 8 in the picture below).

 

 

and so I took the bolt out, swapped it for another one and it was the same issue again. I then I removed the head (again) and put a screw driver into the hole and it was very apparent that there was something in there...

 

I have just about (given this was 11 last night in the rain) managed to get my head in there with a torch and I can see something metlallic in the thread at the bottom.

 

I have checked all of the old head bolts and they all measure the same so nothing has snapped off when I removed them and I can't shift whatever this is with a long screw driver.

 

I am at a total loss, the car is ready to be put back together (this is my main vehicle) and I can't seem to do anything with conventional tools.

 

I think my option are

 

1). By a new block (I really, really, really, really don't want to!)

 

2). Some how get a massive drill bit into the hole and drill out whatever is there and then use an old head bolt as a donor to recut the thread and remove the swarf

 

3). Possibly drop the sump off and gain access to the foreign object and then drill/re-tap from the bottom (maybe???)

 

I will be honest I am totally gutted, I was hoping to have the head torqued on last night and to just be re-fitting bit tonight and this problem seems to be delving into the world of machining and specialist tools that I don't have...

 

Any help would be greatly appreciated.

[Pugleyrich 37 1 Cars]

Youre aware that you need a spacer on that one aren't you, due to the water pump? Sometimes people forget and punch a hole in the block..

[Kane 34]

I would say you have misplaced the extra spacer that goes on that head bolt. The one on that particular bolt is double the size of the other head bolt spacers. Whatever you do DO NOT drill or attempt to torque up the bolt and all you will do is drive the head bolts through the water pump housing leaving a lovely hole in your block.

 

Believe me it's a PITA, this is what happened to me and it was only when I had rebuilt everything and was putting the coolant back on I noticed what had happened.

 

If you can't find the misplaced spacer you could always stack up several thick washers to provide enough clearance for the head bolt.

 

Hope this helps

[welshpug 1,622]

Yup, there is an extra 22mm spacer for that bolt

[James Cornell 10]

Oh you guys are are total heros! I know what that is now, when I took the head off I noticed a spacer drop onto the floor but I just assumed it was from the alternator or something and I was going to worry about it later.

 

I think I have saved it in a bag of bits somewhere...

 

so just to confirm the spacer will fit above the normal spacer for the head bolt

 

i.e.

 

Bolt head

Big spacer

Normal little spacer

Thread

[welshpug 1,622]

yep

[James Cornell 10]

I really hope I have not fooked the block with my screwdriver stabbing last night!

[welshpug 1,622]

depends how hard you were stabbing!

 

on the left you can see the standard height hole, on the right you can see the raised bit above the water pump.

 

[James Cornell 10]

Ahh I see, it all seems so much clearer when it is not 11pm and raining

 

Hopefully I will get it on tonight!