2 injector clamp bolts snapped in hole, 2010 Mercedes E350 3.0 V6 . What should I try ?

[KennyN]

He altered the bolt and it's fine only thing to do now is bleed air out and then get it started up

Tried tightening down one of the 2 today and the bolt span in threads some of the threads came off from the hole onto the bolt.

If everything was fine yesterday why were you tightening the bolts today ??

Looks like the repair to the head has now passed the DIY stage and professional help is now required , more than ever.

To do the job properly the broken bolts will need to be removed , an insert welded into the oversized hole and an extended threaded insert used so the head may need to come off and be set up on a boring machine to do the job correctly and to prevent anything penetrating the water jacket.

K

 

[ALFAitalia]

Did you modify the clamps before trying to tighten the bigger bolts as i said above?...if you did not modify the clamps the bigger bolts will not be able to pivot enough in the clamps for them ever to tighten down. I had to attack the clamps with a rats-tail file to give the extra tilt room...then they sealed up a treat.

The holes give plenty of tilt room for the standard size bolt....but not the bigger M8 thread I used....so all that happens is the clamp goes straight down onto the head rather than tilting to hold the injector in place.
Also the underneath of the bolts head needs to be rounded to move correctly in the clamp hole.

 

[Petrol Pete]

Post 58# OP showed us the 'fatter' bolt being used . As we can see it is a 'flat' bolt and by boring the holder out all of the 'dwell' or chamfer will probably have been removed from it making any kind of 'pivoting' of the injector retainer impossible.

 

[ALFAitalia]

Exactly.....

 

[KramEkard]

He felt it leaking today when he put his hand over and did a different bolt but it just span took bolt out and it had threads on the bolt from the hole, he said tomorrow he's going to come and drill deeper into the hole because he didn't drill deep the 1st time I think he's going to try make the bolt catch the threads nearer the bottom

 

[KramEkard]

Did you modify the clamps before trying to tighten the bigger bolts as i said above?...if you did not modify the clamps the bigger bolts will not be able to pivot enough in the clamps for them ever to tighten down. I had to attack the clamps with a rats-tail file to give the extra tilt room...then they sealed up a treat.

The holes give plenty of tilt room for the standard size bolt....but not the bigger M8 thread I used....so all that happens is the clamp goes straight down onto the head rather than tilting to hold the injector in place.
Also the underneath of the bolts head needs to be rounded to move correctly in the clamp hole.
View attachment 156531

He drilled a bigger hole in the clamp for the new bolt to drop down into

 

[KramEkard]

Post 58# OP showed us the 'fatter' bolt being used . As we can see it is a 'flat' bolt and by boring the holder out all of the 'dwell' or chamfer will probably have been removed from it making any kind of 'pivoting' of the injector retainer impossible

 

[KramEkard]

Post 58# OP showed us the 'fatter' bolt being used . As we can see it is a 'flat' bolt and by boring the holder out all of the 'dwell' or chamfer will probably have been removed from it making any kind of 'pivoting' of the injector retainer impossible.

By hilder do you mean clamp , should get a new injector clamp ??

 

[KennyN]

By hilder do you mean clamp , should get a new injector clamp ??

If the head has a damaged thread then fitting a new clamp wont make any difference , plus you will need to drill the new one out to accept the larger bolt.

K

 

[E55BOF]

OP, I'm sorry to have top say this, but I think it's time to stop digging in the hole and get somebody who knows what they're doing in to try to repair the damage already done.

 

[philnewmerc]

This thread is addictive, can't wait for the next installment

 

[ALFAitalia]

He drilled a bigger hole in the clamp for the new bolt to drop down into

That won't help.... you need a bolt head with countersunk style, rounded underneath and a counter countersunk top to he clamp to match.... otherwise the clamp won't be able to tilt and put pressure on the clamp. You need to go to someone who knows what they are doing. Took me less than a day to figure out what was required and engineer a solution for bigger bolts when i had a similar problem (damaged threads rather than snapped bolt though)... and I'm an amateur these days!

 

[Trickythemerc]

This will not end well............................. The potential cost of sorting this out is increasing with every attempt at fixing the problem. Thus far it is nothing less than a total bodge and hope job.

 

[KramEkard]

If the head has a damaged thread then fitting a new clamp wont make any difference , plus you will need to drill the new one out to accept the larger bolt.

K

Told me mate I'm getting it recovered to a garage.
Situation now is it has 2 snapped bolts half still inside which above he has widened the hole and put 2 shorter but thicker bolts in on top of the snapped ones. One of them is tightened down fine and not leaking but the other was leaking so when I took bolt out some of the threads from inside the recut hole came out as well.

He's insisting to come tomorrow and drill deeper and saying he can fix it but I am hesitant so I want to take it to a garage and have them try and repair this.

Do you think it's salvageable,?

Thanks

 

[KramEkard]

This will not end well............................. The potential cost of sorting this out is increasing with every attempt at fixing the problem. Thus far it is nothing less than a total bodge and hope job.

Told me mate I'm getting it recovered to a garage.
Situation now is it has 2 snapped bolts half still inside which above he has widened the hole and put 2 shorter but thicker bolts in on top of the snapped ones. One of them is tightened down fine and not leaking but the other was leaking so when I took bolt out some of the threads from inside the recut hole came out as well.

He's insisting to come tomorrow and drill deeper and saying he can fix it but I am hesitant so I want to take it to a garage and have them try and repair this.

Do you think it's salvageable,?

Thanks

Quote

 

[KramEkard]

OP, I'm sorry to have top say this, but I think it's time to stop digging in the hole and get somebody who knows what they're doing in to try to repair the damage already done.

Told me mate I'm getting it recovered to a garage.
Situation now is it has 2 snapped bolts half still inside which above he has widened the hole and put 2 shorter but thicker bolts in on top of the snapped ones. One of them is tightened down fine and not leaking but the other was leaking so when I took bolt out some of the threads from inside the recut hole came out as well.

He's insisting to come tomorrow and drill deeper and saying he can fix it but I am hesitant so I want to take it to a garage and have them try and repair this.

Do you think it's salvageable,?

Thanks

Quote

 

[KennyN]

Do you think it's salvageable,?

What , your friendship with your mate ,or the car

Most things are repairable with the right skillset + tools , oh and money. So providing the repair attempt hasn`t gone too close to the water jacket then it should be fine.

Good decision to have the vehicle removed to a garage for repair

K

 

[Stratman]

Out of interest, how much would a used cylinder head cost?

 

[Petrol Pete]

Something similar looks to be about £100 . BUT , is it any good. ? are the cams line bored ? if so best have them included in the sale , new head gasket , labour costs........

2009-2012 MERCEDES E CLASS W212 3.0 E350 CDI ENGINE CYLINDER HEAD A6420109720 | eBay

We not take any responsibility for fitting, exchanging, replacing or repairing parts and delays happen.

www.ebay.co.uk

 

[KramEkard]

What , your friendship with your mate ,or the car

Most things are repairable with the right skillset + tools , oh and money. So providing the repair attempt hasn`t gone too close to the water jacket then it should be fine.

Good decision to have the vehicle removed to a garage for repair

K

I meant The car lol

I've booked it in with a reputable engine repair shop in Burscough for May 22nd.

It hasn't gone to close to the water jackets because he didn't drill too far at all on one of them and probably half a bolt on the other . I was getting worried about the width of the hole as he's already recut it at the top above where the snapped piece is stuck , so that's why I decided it's time to take it to the pros

Are they likely to drill the entire bolt out or will they botch it up like my mate did with short oversized bolts etc

How much approximately do you think I would be charged to have them do this ?

Thanks again