Isuzu SUV Forum banner
1 - 3 of 3 Posts

·
Registered
Joined
·
15 Posts
Discussion Starter · #1 ·
2001 Rodeo 3.2 V6

In removing and replacing the passenger side cylinder head I broke the bottom left head bolt.

The bolt broke 1 3/4 inches below the surface.

http://www5.snapfish.com/snapfish/s...otsc=SHR/otsi=SPIClink/COBRAND_NAME=snapfish/

I tried to drill it out and failed.

I discovered a Mercedes head bolt that was 12mm thick (1 mm thicker than OE bolt) and short enough (about 40 mm shorter) to allow me to use the 1 3/4 inches available in the block.

I ordered a Big-Sert thread repair kit.

Discovering it would be near impossible to drill the block straight so I created a jig out of square tube.

http://www5.snapfish.com/snapfish/s...otsc=SHR/otsi=SPIClink/COBRAND_NAME=snapfish/

The area was too tight to get any of my drill motors into so I welded the Big-Sert drill bit to a 13mm deep socket.

http://www5.snapfish.com/snapfish/s...otsc=SHR/otsi=SPIClink/COBRAND_NAME=snapfish/

Here is a look at the jig installed.

http://www5.snapfish.com/snapfish/slide ... =snapfish/

Here is a look at the successfully drilled hole. It looks egg shaped but it was not.

http://www5.snapfish.com/snapfish/s...otsc=SHR/otsi=SPIClink/COBRAND_NAME=snapfish/

Here you can see the tapping of the block for the Big-Sert.

http://www5.snapfish.com/snapfish/s...otsc=SHR/otsi=SPIClink/COBRAND_NAME=snapfish/

The tapped block.

http://www5.snapfish.com/snapfish/slide ... =snapfish/

Reaming the hole for the Big-Sert.

http://www5.snapfish.com/snapfish/slide ... =snapfish/

The hole tapped and reamed.

http://www5.snapfish.com/snapfish/slide ... =snapfish/

The Big-Sert installed.

http://www5.snapfish.com/snapfish/s...otsc=SHR/otsi=SPIClink/COBRAND_NAME=snapfish/

I cannot take all the credit for this fix. I heard about the idea from another member on a thread that I cannot find at the moment.

The head bolted up perfectly.

Once I get some miles on it I will report back to let you all know how it's holding up.

Also thanks to Jerry Lemond for selling me the head and some other parts. He's a good man to know.
 

·
Registered
Joined
·
166 Posts
I wish I had known this when I was doing mine, by I'm still glad that I had a EDM machine shop get mine out. I did use a Time-Sert though. The later model V8 Cadillac's almost the same bolt too and are famous for having headbolts breaking so I found someone around here that has experience with them put an insert in mine.

PM me if you're having problems with photos & etc. I can help out with that. It sounds like you're already making headway on this, but a GOOD machine shop should be able to drill out the bolt and put a bushing or insert in for you. Other people like Med!c and Sassee have had it done before and all three of us have torn down these engines. Some of their posts may be worth a search and look.
 

·
Registered
Joined
·
3,934 Posts
For future searchers sake, your head bolt broke because you didn't follow the removal sequence. Lot's of people make this mistake including myself. I'd bet money that the broken bolt was the last one or second to last one to be cracked loose.
 
1 - 3 of 3 Posts
Top