84 1.6D stripped head for injector

[Paul773car]

Afternoon all, im having a very bad day.

I few weeks back i noticed i was getting blow by past one of my injectors. I ordered a new seal and the 27mm injector socket assuming it just needed a new seal.

Unfortunately some as**ole has previously stripped most of the threads in the head and used sealant instead of torqueing the injector down. I have cleaned out what i can and it doesnt look good.

So i think im looking at a new head? Hoping someones going to tell me thats not the case and i can somehow heicoil or threaded insert fix it?

Any advice appreciated

Paul

[Paul773car]

So ive ordered an M24 2.0 helicoil kit and a 24.5mm drill bit. Will try to do it in situ if possible.

I might as well try i suppose

Paul

[davidoft1]

Have you tried cleaning the injector threads and the head and torquing down the injector?

[Paul773car]

Theres literally one thread left. It isnt going to take 50ft lb

Thanks

Paul

[davidoft1]

So ive ordered an M24 2.0 helicoil kit and a 24.5mm drill bit. Will try to do it in situ if possible.

I might as well try i suppose

Paul

You may have better success with an adjustable reamer , have you got anything to drive the drill bit ?

[Paul773car]

Yes, i have a good few drills. Was thinking of trying to clamp a bracket and use a threaded bar to drive it

Ive never used a reamer before will google it.

Will it repair the threads?

Paul

[Paul773car]

Looked it up, so you mean for sizing the hole before using the tap and helicoil

Thanks for the suggestion, i think id prefer to try it than to drill it as it more likely to end up with a hole that centres properly. Will see if i can get one

[davidoft1]

Looked it up, so you mean for sizing the hole before using the tap and helicoil

Thanks for the suggestion, i think id prefer to try it than to drill it as it more likely to end up with a hole that centres properly. Will see if i can get one

Yeah for the hole, i would say you have a pretty good chance of getting it spot on with a reamer , or an adjustable one may be better as you can creep up slowly in size, nothing to lose

[Paul773car]

This is more difficult than i hoped.

The tap is tapered so its really difficult to tap the bottom threads. Then if you install the helicoil but install too deep the coil doesnt slot into the thread and then you cant get the injector in. I have used 5 helicoils trying to get it at the right depth but to no avail so far. I have drilled deeper and tapped further but now have had to order some new inserts as ive used the 5 in the kit. . Thinking about cutting the taper off the tap so i can get proper threads further down. I still think it might work but it certainly isnt as simple as it sounds

[Oldiebut goodie]

You are using the wrong tap, use one without a taper to get to the bottom for the last few turns.Gently as you don't have the reamer action of the tapered tap.

[Paul773car]

Ok any ideas where i would get one?

And what size it should be, the one i got came in the kit so its marked m24 kit, but i assume the tap size is bigger as the m24 refers to the inserts thread?

Im a bit new to this

Paul

[davidoft1]

Ok any ideas where i would get one?

And what size it should be, the one i got came in the kit so its marked m24 kit, but i assume the tap size is bigger as the m24 refers to the inserts thread?

Im a bit new to this

Paul

You can regrind the tap to make it a plug tap , it’s probably 26mm or maybe 27mm depending on the thread pitch , you can measure the tap diameter

[Paul773car]

So I've taken the tap down to our local blacksmith (so lucky we have one still) he's going to take the tapered end off the tap for me. I didnt fancy trying to do it myself as it would take forever and get hot.

Will be done by tomorrow for the pricely sum of £12

My new inserts arrive tomorrow too so hopefully it'll work

Paul

[Rascal]

You need a Tap for a blind Hole but glad you have a smithy.. I wonder how he will take the taper off, out of curiosity seems more like a machinists job

[Paul773car]

He has allsorts of stuff down there, they do fabrication and general engineering projects too.I didnt ask too many questions but he did say i would have probably ruined it if I'd took a grinder to it as it would get too hot. Will ask what he did when i collect it tomorrow.