Argh!!! Head removal nigtmare

[montez]

Started stripping down the engine to replace my head gasket, was pleasantly surprised how easy it was going. Head bolts off, down pipe off all good. I was planning to take the head off with the turbo and exhaust manifold still attached as a previous owner/garage had decided to rounded off 4 of the nuts (as with most jobs i start with this car I find someone has previously bodged it).

Problems:

I cannot remove the water line from the bottom of the turbo, it is really badly corroded and I cant seem to get anything to fit it. I am guessing it is a 5mm hex bolt but there is so much rust and corrosion nothing fits.

The water line on the block also has completely fudged bolts, I can’t understand why people replace things with old bolts especially when they are damaged. I think this may be my best option of splitting as I have more room to drive a torx bit in if I have to.

I cannot split the turbo to the manifold either; I have managed to get one bolt loose out of the four. I have a good fitting ring spanner on another of the bolts but no matter how much force I put on it with a bar, it will not move.




Any Ideas or tips on removing these bolts as I am starting to lose my patience?

[driftin jo]

You mean the oil line to the block, the water line is just a hose clip on to
a special core plug, easy to remove even when rusted.

Drill, cut or file the heads off the bolts on the oil return line to the block and you can just remove the threads left in the block with a pair of pliers.

[Knight Rider S4]

I used a socket and hammered it over the bolt so it cut into the outside of it , and came off no problem

[montez]

Yeah meant the oil line, drill off at the block should be easier to remove than bottom of the turbo. Might be able to get a stud extractor on it then.

[montez]

I will try hammering Torx, then a socket, then file a slot for screw driver and as a last resort drill out.

[s2_wot]

Sometimes a 12 sided socket is better than a 6 sided and vise versa when you're hammering them on.

I have also used a die grinder to cut away the end of a rounded nut, might help.

[SteveH]

If you can, use heat or weld a nut onto the offending bolt head.