This is my first posting in the DII section.... I have owned a 98' DI for a little over a year now, and LOVE it. I replaced the head gaskets on her right after I acquired it, and found the process pretty easy.
On my most recent purchase, a 2003 SE7 with 98,xxx miles also had a blown head gasket. I was able to pick it up for a cool 2500 bucks in prestine condition with a full service record. The trouble began when I went to put the passenger cylinder head back on, 2 head bolts stripped their threads right out of the block. I read all around the forum until I found enough info to act. I drilled the hole, tapped it, and inserted a helicoil in both holes. I then left the head off and procedded to put on the other head. On this head, 6!!!!! Head bolts stripped those threads. I put helicoils in them as we'll, and returned to the other head to begin reinstalling it. As I was tightening the first helicoil, I could feel it give. I immediately removed the head and found that the helicoil was already pulling out of the block!!!!

What should I do????

P.s
Yes, I cleaned/chased the threads,
Yes, I lightly oiled the head bolts,
Yes, I used new stretch bolts from Atlantic British,
Yes, I used the proper torquing sequence and method, 15ft/lb, 90,90.

 

You may want to use those motor builder ones which do not have all the stretch needed. Meaning bolts with no stretch.

Or can you get stock rod that will fit just a tad oversize in those holes?
Have the rod come out - like on an MG motor.
And then just put nuts on the top to hold the head down?
You are in a pickle.
Sorry.
Did you put a stripe on the bolt? Maybe you are going 100 degrees and 100 degrees and just blowing it out??

Maybe put in the helicores and go 90 degrees, then 60 degrees and the hell with it.
Try it out that way.

 

Meant a paint stripe.

 

order a ARP head stud kit about $150.00 redo the helicoils and buy a new torque wrench.

 

Thanks for the responses.
I have a newish Snap-on torque wrench, so I doubt it is bad. I have a head stud kit on order since the POS TTY bolts are spent already. I also have a homage gauge to tell if I am turning 90 degrees. Most bolts stripped on the first 90 degrees.
What about the helicoil that ripped out. Just redrill and tap with a 1/2" kit?

 

you need to go to the next large size if the hole has pulled out. But weight until the ARP stud set come before you tackle that one. You may have to put a coil inside a coil.

Installing helicoils in alumium is very tricky and need to be done slowly and with care.

As far as you snapon wrench being fairly new (that meens nothing) you should check it before each use.
When 8 out of 16 head bolts strip you have to step back and ask yourself what am I doing.

The ARP studs do not use that 90 degree/90 degree, they give you a torque spec to tighten them too so

 

I will check my torque wrench tonight on my vise, and see if that is calibrated.

Also, what about boring out the hole too much, are there water jackets or anything that I might destroy? I considered ordering the half inch ARP kit and just drilling out every hole then retapping with the half inch helicoil.

Could this be an issue of a bad casting on the block?

 

I wont drill any more than absolutley nessasary, the waterjacket is right next to the head bolt hole within MM.
Personally i would have my eye out for a 4.0 BLOCK

 

Where is a good place to find a 4.0 block?

 

where are you located