Ouch.
I would keep your eyes out for an 04 you can afford.
And maybe use that 03 as a parts truck.
May be heart ache on the way fixing that engine...

If the shop would not fix it.
Then the owner had no money.
And never did anything to it but run it into the ground.

Saw one like that here in Cali.
Guy bought it and I am not sure how he made out.
He found a melted piston and had to buy a new piston.

 

I would atleast try the thread inserts. be careful drilling into aluminum because it is a very soft metal. what size bolt is the head bolt? 90 degrees seems like alot for the second torque sequence but i have not done heads on my disco. I know Caterpillar sells an excellent thread insert kit and they stand up to just about anything. might call your local dealer and order up a kit.

 

Not sure of the head bolt size and pitch, but as has been mentioned, GM makes the timesert, and Bigsert for stripped holes on the Cadillac Northstar engines. I had several stripped holes on my Caddy block and went with Norms inserts with the Audi/Volkswagon ARP stud kit at the time. Norms inserts are engineered to be much stronger than the GM inserts. There is considerably more surface area engagement with Norms inserts. It would be worth your time to investigate the inserts for your block.

http://www.huhnsolutions.com/INFOPACKNS300LIS.pdf

MAK

P.S. I just torqued my stretch bolts to 75 ft lbs and called it the day on the rebuild. No problems after 1500 miles and I beat the **** out of it after the break-in.

 

Did you resolve you bolt issue? I'm going through it right more and would like to know what happened with yours. What did you use and did it work?

 

What torque wrench are you using? I would be thinking if my wrench was to blame. Has it been calibrated recently?

 

Never got it to work, ended up ordering a 2004 engine online installing it myself.

 

I have used Helicoils in alu and magnesium castings many, many times. If done correctly they are as strong as orginal threads. Best to use a hi performance lube when screwing into alu or even steel though or the risk of thread stripping is enhanced.

https://www.google.fr/search?q=helic...mgUKCg&dpr=0.9

 

Wow I am really rooting for you, OP. I'd like to know how that resolves.

 

Old old thread. Revived.

Nice to get the update from the OP though.

 

Whoa, I missed the dates...