Worst Job Ever Broken Bolts Runaway Diesel

[@bodgitandleggitgarage]

I know if I don't mention this. I will get all the armchair mechanics. Telling me how to fix it And what I did wrong.😂 I have released this video 1 year ago on my patron. This vehicle has been fixed. Would be interesting to hear how you would go about fixing this As always there is more than one way to skin a cat In my opinion there was a few ways of doing this 1 Just bodgit it and hope for the best 2 Do it "properly" and replace every single part.= Would not be worth fixing 3 Replace the engine 4 Or do it the way I did. Over a year later still running with absolutely no problems = A good bodge.😉😁🙃

[@Jonodrew1286]

These are a problem on all the VW/ Audi stuff I get 4-5 calls a week for these bolts - people seem to freehand them and I see broken drill bits and easy-outs - have done plenty - mostly the bolts even the V6 has issues - Also the bolt design is identical to the Ford Transit

[@davyarthurs]

This is how I’d fix it: Ship it in your direction 😂

[@kib2675]

drill out hole, 5,5mm down to bolt, then drill out bolt with relevant drill for 6mm heli coils

[@Jonodrew1286]

@@kib2675 yep that works - prefer to unscrew them in 5mins, only have to drill them out totally if someones broken a drill bit or an easy out 👍

[@BensWorkshop]

Not a lot you could do with a cross threaded bolt or a broken rocker cover. However I have dealt with stuck injectors and one that would not move for love nor money. On a Jaguar X Type diesel, same as the Mondeo. First stuck injector was split leaving part in the engine, got that out fairly easily. Other one not moving. I asked around and the suggestion was try removing from a hot engine. Much much easier! Not nice working on a hot engine but much easier to get out.

[@PJ-om2wq]

Years ago I pulled a stud out of the head on a 2.0 HDI (stud that held down an injector). This was because the Haynes manual had the wrong torque wrench spec. I did exactly the same thing, helicoiled it and a new stud. A helicoil is stronger than the original aluminium thread so it's a really good solution. That engine went another 200,000 miles and was still going strong when the body rusted out.

[@isaacplaysbass8568]

Excellent work. I know that sinking sensation that you get when you realise that you're working with a failed a fastener. But your determination, resilience, and delicate (ahem) hand with the right toolset won-out. Nice work. I'm looking forward to the next instalment.

[@Choober65]

I replaced a bunch of injectors and before i put them in, i polished them with Autosol, then applied a thin skim of copperslip. They come out very easily next time.

[@dharradi]

Well done Leon, I've been there with the slide hammer. It hurts.

[@kirilakmadjov8307]

The reason you broke this bolt is because its been reused and its a tty one time use only and the garage that has worked on it previously have not replaced with new bolts, didnt seem to me that it was cross threaded but glad uve fixed it now

[@bartoszk4812]

Leon's favourite phrase: "an absolute nightmare!" 😂

[@Tikkawrap]

BUT

[@bodgitandleggitgarage]

Boom sorted lol

[@kevinrobertfrasier1309]

Place a hollow sleeve into the bolt hole to use as a guide for centering a drill bit. The bigger diameter drill you can after piloting the first hole the pressure will reduce against the threads. 5.0 or 5.5

[@ast1527]

It's jobs like these that makes you question your life choices😂 . I know the feeling mate🙂

[@bodgitandleggitgarage]

😅😅😅😅 Definitely mate, definitely if I wasn't so stupid. I wouldn't be doing this job, stay in school kids.

[@lolorick5885]

I have drilled a small hole in the intercooler and screwed a self tapping bolt with a tight fitting into it. So each time I do an engine oil change, I can drain any build up of oil in the intercooler.Even so when I have checked the intercooler for oil, none has ever drained from the intercooler. All of this was done to prevent a diesel runaway engine, as a precaution to be safer than sorry as diesel runaway can wreck the engine.

My dad always taught me that when things are not going right, walk away have a cuppa then go back chilled and ready again. Never keep bashing away.

[@peterdavies5749]

I've literally just done this job on Friday on caddy 😂

[@michaelmcdermott1877]

What a nightmare of a job. You have the patience of a Saint. I think I would've pushed the piece of junk out of the garage and burned the bloody thing. 😂

[@darkwaterblue]

Great video, nothing is ideal when working on other peoples cars. Intrested to see how you remedy that, if you can get enough bite with a helicoil then guess thats easier than taking the head off on a work hack.

[@JariRantasalmi-dj9gk]

Injectors are sometimes really stuck.its litlebit easier if get engine really hot.near of boilingpoint.its not nice burn hands and fingers.but really stucked can come out guite easily,but but buuuut.many times car wont start to get engine hot.

[@larkehoe6716]

intrested to see the bodge leon, as said before im at a movano at the minute having terrible time with injectors, first was black death, then was some monkey had been in before and drilled one clamp bolt and just stuck in a bolt in with no spacer , now we have on re assembly 2 that are still leaking gas and diesel... looking at the bigger version of helicoil, so awaiting your results egerly..

[@garywinterbottom6073]

Last year the seals had gone on my 1.3 cdti motor my mechanic said he would remove and replace somehow in the process he must have damaged an injector but kept it quiet and when i picked up the car it sounded like an old Ferguson tractor i complained he said it might be a hydraulic tappet that had gone after much argument and the wife getting involved she is great at getting workmen to make good things he said he would get them pressure tested ie the spray patterns this he said proves that the injectors were all ok but i wasn't convinced and it still sounded awful so got a 2nd opinion from a friends mechanic he straight away said faulty injector or more than one he instructed me to a local long standing trusted diesel specialist who diagnosed no3 cylinder faulty 1 new injector and new washers on the others and it has run super smooth my advice get someone who knows what they are doing prefererably a injection specialist. 😊

[@gezski]

febi ceramic grease on the injectors when you reassemble :)

[@eddieMurphy11111]

on my old freelander i had a stuck injector but it was the diesel around it had gone hard i wondered why i kept smelling tar like smell i did get it out in end and clean all the injector bore and no more leaks so i must have done a good job but i would not like to do you job but i know you will sort it one way or another good luck, and i would bring it to you as i am getting to do it thanks for the video

[@dodgydruid]

More likely someone went at that bolt with a windy impact, I had last year to take off a cross threaded wheel nut that had been put on by a tyre shop with a windy gun and it was a bloody mess requiring a new drum as the studs were integral (old classic) and I was not amused. In the end I had to use a nut splitter it was that awful :(

[@Diagnosedan]

Victory tastes sweet Leon! Great video my "friend" 😉

[@antonoudenhoven7573]

I recently helped a guy push his vw van to the side of the road,all the injector bolts where torn out of the engine. The engine literally spitid out the injector rail 😂

[@bharatbenz8278]

Same problem in my VW 1.2 polo car

[@LondonCarnaval]

So this video is year old and it was fixed then and still going 💪 qudos to you 💪👌👍💯🏆 I'm not mechanic yet but it's very interesting to watch the masters at work 👌👍💯🏆 ✌❤☘

[@mercedeslove4291]

Torture, as the saying goes you are only one broken bolt away from a 10min job turning into a 3hr job. Most customers will never understand this.

[@spawntohell]

I think helicoil is the right thing to do to fix it, regardeless what some people might say as is real world stuff, otherwise what? bolt extractor will not work on stretched and crosthreded bolts (do not ask how i know....). my gues is of what happened there is someone tried to get in there and failled to get injector out and reused the old bolt (that should be renewed anyway after removal as has a torque and a 180 degree further i believe so onced torqued to spec is streched) and it crossed it in the same time and ... the result...

[@Wonlongpong]

I had this situation on a friend's Audi A1 1.6 diesel. The broken part was loose in the head, and I was able to remove it by rotating/wobbling it clockwise using a finely ground long centre punch. The result was that it wound itself out. It took a little while but worked well. I was prepared to drill it and use an extractor, but that would have created swarf and required the cover to come off. The bolts are stretch bolts designed to be loaded to almost their elastic limit (like sll stretch bolts). They should never be reused as reloading them will increase 'necking' then failure of the shank or thread section.

[@MrGrtx]

you are an awsome mechanic.

[@markmawson1]

I took on a job exactly like that where the oil seals and valve cover were leaking so i stripped it down and snapped one of the injector hold down clamp then did the job drilled out the broken hold down clamp bolt helicoiled it (what i did do was pack around where i wanted to drill with cloths using a screwdriver then lather it in general purpose grease then once i had got it helicoiled i lather over the top of the grease with more grease to encapsulate the swarf) then put all the injectors back in with 2 new clamp bolts then the bastard was only running on 3 cylinders so one of the injectors had failed so i had to remove the clamp bolt, the owner got a new injector and i said you need a new bolt and he said that is a new bolt so i said there is no way i am putting that bolt back in because they are torque to yield bolts and if i put that back in and torque it up it will snap and we will be back to square one, so under duress he bought a new bolt for it, i will never ever do another VW 1.6TDi injector job ever again.

[@TheOriginalDaveJ]

Course you can fix it. Hardest part is drilling the bolt parallel to the hole.

[@colinhamer6506]

All I'd do different is instead of using coil's switch the bolt's for the biggest stud's it can accept if they fitted them with decent stud's from new and put injector seal's on the service schedule we wouldn't have to deal with this sort of thing as often

[@Badgertronix]

You're a legend mate

[@evanjones2539]

Not cross threaded... bolts were over tightened, stretched and snapped..

[@Jw20000]

These unlike other vw's are one time use injector stretch bolts. Seen mechanics change injectors twice on these and a week later injector comes out as bolt snapped. lol. Every time that bolt is undone it needs a new part and torqued to spec. If they tried to get injector out and it came out abit. Using the bolt to pull it back down would have likely over stretched it. The new injector has to be spotless. Mechanics aren't given enough time to get them. This leads to them getting this reputation. If they never failed we wouldn't have this problem but these injectors on cr vw's fail all the time.

[@andrewlaw]

Its not a CAYC engine by any chance? I had exactly the same job a couple of months ago. Right hand bracket bolt sheared off in the head. Started taking the left hand bracket off and that bolt broke as well. Took the cam cover off and the metal surround underneath to get to the remains of the bolts. New bolts, injector seals and leak off pipe clips and 3 hours later the job was done. A week later the owner rang me to say no.3 injector had blown out. Car recovered and the new bracket bolt had broken! F**k my luck, had to do the job all over again for a 2 quid bolt. Why VW use a stupid 6mm bolt is beyond me, a 10mm bolt at the minimum is needed to hold two injectors down.

[@morganreyman7929]

beware, mayby the helicoil is to short , should should be the same lenght like the bolt, it doesnt work with helicol in the old PD engines

[@Choober65]

Moral of this story? Run injector cleaner every 5k or so, and change oil about the same. I NEVER have problems with my engines and i drive them HARD.

[@kie185]

I have a job the very same injector weren't seated carbon in oil pick up got blocked

[@robertwilson8365]

Madness, 6mm, from 8mm down to 6mm, what happened to german engineering, 8 or 10mm all the way.

[@leefurniss]

I had a peugeot boxer on a 20 plate that was leased for the company i work for that went into a dealer for a new engine only doing 74K, broke down after less than 100 miles after it was fitted, the local scrap man round the corner would have made a better job. I have video's to prove this if any peugeot dealerships care to object to my comment

[@kstacey3063]

I would do exactly what you are doing but I’d use a guide tube with a smaller bit to make the initial hole

[@johnhutchings8658]

In other words then; you destroyed the thing trying to get it out, then when it was totally FUBAR you blamed the dealer - bad form chap

[@andrewthompsonuk1]

Flat.rate at the dealership? I really do not know how someone trained as a mechanic would cross thread that. I guess after rushing that one out the door there would been a cash cow job or two to finish the day.

[@galeus1000]

well impressed and great entertainment.

[@matthewhaddon599]

It may not be stretched all the way down, but difficult to drill straight to try to remove it...may be worth trying before going the helicoil route. Ideally it's a head off job.

[@ionutgeambasu6491]

helicoil route we use at dealership.. the best!

[@matthewhaddon599]

@@ionutgeambasu6491 You have to weigh up cost I suppose and helicoils would be cost effective if appropriate for this situation...not sure I'd trust a helicoil here, but it would not be worthwhile or cost-effective removing the head, so may be the only way to go.

[@julianpalmer4674]

I feel your pain

[@razvanturcu9871]

I can't find the diagnose video for this car :(

[@bodgitandleggitgarage]

kzbin.info/www/bejne/r5TCfYWri8t-l7M 😊

[@sats7819]

You can get new injectors lol

[@bodgitandleggitgarage]

I never said you couldn't get new injectors.. Cause when I originally filmed this video. It was during the height of COVID. And parts We're very difficult to get And there was a huge backlog Especially in the country I am in. I originally posted this on my. Patriot Over a year and a half ago So before making stupid comments and looking very silly. Make sure you know all the facts.

[@theadventuresofjavier8698]

Crikey…😮 STUKAS 😢😢😢 Mustangs to the rescue..😂

[@jasonbainbridge7610]

Probably main dealer but still some kid with 2 months experience working on your car😅

[@ARES-ed9fn]

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