GVR-4 Broken middle injector rail bolt

[4gfun]

The middle fuel injector bolt snapped flush when I was tightening it. I did not overtighten it at all. The injector seals did not fit the head correctly and caused tension on the bolts.

I tried an easy out but the drill bit broke off inside. I have also ended up drilling holes on the side of the broken bolt unfortunately. I tried to slot the remainder of the bolt so that I could use a flat head screwdriver but that didn't work.

How much drilling around there can I do before I mess the head up? Any ideas. I have soaked the bolt in Kroil etc but to no avail. I obviously can't use a torch around it .

I have a built head that I'd like to throw on there and this gives me an excuse but even that is a bit extreme.

No local shop has left hand drill bits and I am not sure that even that will work. I am also concerned about getting too aggressive and messing up the space between the rail and the head.

Any ideas?

Thanks

 

[Mello]

My opinion is you're past the point of no return if I'm visualizing this correctly. I don't think this can be done by hand tools anymore. I recommend removing the head & taking it to a machine shop where they can clamp it down and get everything rigid & mill it out. May have to repair the thread with an appropriate threaded insert of some kind. Easiest would be Helicoil if you haven't gotten to far off center. Good luck.

 

[4gfun]

My opinion is you're past the point of no return if I'm visualizing this correctly. I don't think this can be done by hand tools anymore. I recommend removing the head & taking it to a machine shop where they can clamp it down and get everything rigid & mill it out. May have to repair the thread with an appropriate threaded insert of some kind. Easiest would be Helicoil if you haven't gotten to far off center. Good luck.

Maybe this will give me the kick in the behind that I need to replace the head with my built one. I'd bet the job would be easier to do with the head off the car. I'd still like any ideas on doing this with the head on while covering up the injector holes. I just don't want to be stuck trying to remove this for a few days.

I mean, it doesn't leak at all with the center bolt gone and the other two tightened, but I wouldn't want to drive around like that forever.