Broken Bolts

[Cody D]

I was recently installing new injectors into my 1993 Talon TSI AWD (which has a 6 bolt engine from a 1990 Laser RS Turbo) when I was taking the fuel rail off of my car two of the three bolts broke off in the head.

This was bad so we decided to try to use an easy out in the first of the two broken off bolts, we drilled it out perfect and started turning the easy out, and snap the easy out broke off inside the bolt, very bad. So we decided we'd worry about that one later and go after the second bolt this time we bought a different brand of easy out and used a larger one, we drilled it out again started turning the easy out and snap, very very bad.

So today we tried welding nuts onto the bolt in the head and then extracting them that way, well no matter what we tried the weld would not hold. There was nothing wrong with the welds, but those bolts are just in there too good.

I have an extra head from my 7 bolt engine that I've got down at an engine rebuilder shop and they are going to check it out for being warped and check out the valves.

I've got two questions the first is will this 7 bolt head that was originally in my 93 Talon TSI AWD be a direct swap with the 6 bolt head from my 90 Turbo Laser engine that is in my Talon currently?

The second question is whether or not there is another way to get those bolts out that I haven't tried, we don't think we can drill them out because of the easy outs broken off inside the bolts.

Any help would be greatly appreciated.

 

[GSX92AWD]

The head should fit with no problem. As for the bolts, the only thing I can think of is to try to drill them out and us heli coils but like you said it would be hard with the easy out stuck in there. It can be done though.

 

[Travis Dailey]

Just take the head to a machine shop and have them remove it for you. A buddy of mine broke off 2 turbo to manifold bolts and i spent 4 hours trying to back them out with and extractor kit and eventually ended up taking it to a local shop. Took the guy 15 minutes and they were both out. But if you are still determined to try yourself try a ton of heat and pb blaster if you haven't all ready.

 

[Cody D]

Thanks for the responses.

I'll find out what kind of condition the 7 bolt head is in on Monday, and if the valves are bad then I'll get them to fix the 6 bolt head. What a pain in the butt. It'll all be worth it when I get it back together and have the fuel system done.

Off topic. My 14b felt like it was pulling hard after I got the 255 pump in, I can't wait to get the t04b on there.

 

[tsi_daggie]

when i was extracting exhaust manny broken bolts i used a mig welder. tried normal steel setting and let it cool and just snapped the weld. finally all said and done i had the welder cranked almost all the way up, you have to make sure to get good penetration. also make sure you let it cool completely that way the bolt expands and contracts from the heat and allowing it to cool (will help break it free)

good luck

 

[Cody D]

Well trying to get it we pretty much wrecked the head, so I'm getting the 7 bolt head fixed up right now. One question though, I've got a 60 trim T3/T4 a little bigger than I wanted but I found a great deal, and I'm worried the OEM head gasket won't hold up, should I order one of those Cometic ones while the head is off?