Head bolt wouldn't torque to stage 2 and broke - Saab 900 Bulletin Board - Saabnet.com
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Head bolt wouldn't torque to stage 2 and broke
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Posted by BOS_saab [Email] (#3188) [Profile/Gallery] (more from BOS_saab) on Sun, 7 Apr 2024 17:06:31 Share Post by Email
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Hi all-

I was reinstalling the head on my 1994 900T convertible and I broke the new head bolt on the exhaust side between cylinders 1 and 2 during the second stage of torquing the bolts. The bolts were new Victor Reinz head bolts from eSaab.

All bolts torqued down successfully to 44 Ft. Lbs. during stage 1. Bolts 1 and 2 successfully torqued down to 65 Ft. Lbs. during stage 2.

When I got to bolt 3, the bolt would not torque to 65 Ft. Lbs. and just kept turning until it broke. I knew something was not right when the bolt turned more than the bolts 1 and 2. Thinking something was wrong with the torque wrench, I put the wrench on bolts 1 and 2 and the wrench immediately clicked. I don't think it's an issue with the wrench.

I have since removed the head and broken bolt. The bolt was broken about 1/2" below the unthreaded area and is about 1/4" longer than the other bolts. It was clearly stretched around the break.

Any ideas? I was diligent in cleaning the bolt holes with brake cleaner and compressed air. I also lubed the threads with WD-40 as per the Townsend Imports instructions. The head was sitting flat and was not wobbly before torquing to stage 1. The only thing that was not per the procedure was that the dowel pin on the intake side of the head stayed in the head during disassembly and was stuck in the head. The dowel pin on the exhaust side was in the block as per the procedure.

Any thoughts on what the issue could have been?

I have ordered new head gaskets and bolts and will try again this coming weekend.

Chris

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