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Old 11-07-2001, 08:06 PM   #1
scooby5
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Member#: 1998
Join Date: Jul 2000
Location: Toronto, Ontario, Canada
Vehicle:
1999 Impreza STi v5
Silver Mica

Angry Cap bolt just won't come off!! Need help!

Arrrrgh!

I was fixing the valve clearance on my EJ20K and took off the rocker cover and proceeded to remove the camshafts.

Intake camshaft came off with no problems, all 6 cap bolts came off. Now turn to the exhaust camshaft, all but 1 bolts come off.

The problem bolt is actually on the cap near Cyl 1, where I had the clearance problem; in hindsight, looks like some front end damage and a hit might've caused the clearance problem and that bolt not wanting to come off.

Anyways, on with my problem! The damn bolt won't come off (spec'd at 7ft/lb) . I go for a 1/2" drive 10mm socket and apply gobs of force and shear the bolt head off! At this point I'm thinking Holy Sheit, this is a tough bolt.

So I get a bolt extractor, drill out the bolt with a 3/32 bit and insert a #2 extractor, as I'm torquing the extractor, the damn thing breaks off under the load! Luckily, I'm able to make a groove in the head of the bolt with my Dremel and remove the broken extractor with some pliers.

So I try another extractor, this time a #3 and drill out the existing hole with a 5/32 bit. Put extractor in, torque it and *break* . By this time I'm swearing so loud the neighbours are covering their kids ears! Again, I'm able to pull out the extractor.

I've tried applying heat, release oil, tapping, used a flat head screwdriver in the groove I made but to no avail!!! The damn thing's stuck!! And I can't really afford to mess up the cap, since it's machined to the head! losing the cap would mean a new head, no?

Anyways, I can see the hole in the bolt is squared in the bolt and not touching the cap. And that's how it's sitting right now.

Anyone have any idea on how to get that damn bolt out?!
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Old 11-07-2001, 08:31 PM   #2
D_REX
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Member#: 8945
Join Date: Aug 2001
Chapter/Region: TXIC
Location: Houston, TX
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MY02 WRX
Blue

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It looks like you drilled the hole in the bolt considerably off center. I know you were using a hand held drill but this reduces the efectiveness of the extractor significantly. You should definitely pu the bolt on the other side of the cap back in. The cap could be canted a little putting the bolt in a bind. Let me know if this helps.

Later,
Dustin
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Old 11-07-2001, 11:20 PM   #3
scooby5
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Member#: 1998
Join Date: Jul 2000
Location: Toronto, Ontario, Canada
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1999 Impreza STi v5
Silver Mica

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D Rex, that helped somewhat!!

When putting in the other cap bolt, I noticed the part that's in the cap isn't threaded! So I carefully wore down the head of the stuck bolt with my Dremel until I could peel off what was left of the "head".

At that point, all I had left was a stud, and the cap slid out! And now since there was no longer any 'pressure' from the head of the bolt onto the cylinder head, a good pair of vise grips did the trick!
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Old 11-08-2001, 12:34 AM   #4
djerickd
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02 WRX WFC#040
Clean on 19's

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Good Kill!!! I hate it when stuff like this happens!
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Old 11-08-2001, 01:25 AM   #5
D_REX
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Glad I was able to inadvertently lead you to a solution.

Later,
Dustin
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