I think I got it fixed. As it turns out, the top two bolts were stripped. One of them had the threads from the head right with it. There also was evidence of some kind of J.B.Weld or something for thread repair.
A couple months, back maybe 6?, I had taken the housing off to replace the o ring and noticed there wasn't one in there. I suspect someone tried tightening the crap out of it to stop the leak. I could feel the threads stripped a bit then but hoped with a new o ring that it would stop the leak. It did temporarily but got worse over the months. I was losing a quart every two weeks I think.
Now back to the repair. If I could do it all over again, I would find 1/2 inch longer bolts then what was in there and try retapping and tightening down. If that didn't work, using the helicoil with a longer insert. say close to an inch. I believe the hole will accommodate it. Then I would take bolts that would run just short of the flange in the helicoil. Otherwise you bottom out and hit it. Then you strip the bolt out trying to tighten it up.
The problem I ran into with doing this job with the engine installed is:
1. I had to use the Kobalt air drill and lob off the drill bit and stick it deep inside of the drill chuck, then carefully sneak it behind the head.
2. I then had to pull the bit out of the chuck to drill a little deeper.
3. The tool they give you to install it didn't work right, I had to take the bit out of the guide and turn the coil in with a tight grip from both hands and finish with a small wrench.
4. There was no way that I could see to get a punch and knock out the flange inside the helicoil once it was installed.
The biggest obstacle I came across was the lack of clearance. It would have also helped to have a few long m6-1 bolts and nuts. I ground mine down to size until I could get them to work. All because I couldn't knock the flange out.
I think this will work for now. I may have jacked up the mount holes in the head though as I am afraid to ever take it off again. I'll be watching for a high performance head in the future. Next time it leaks, the whole heads coming off just to be safe.
I just had to make sure I had it back and running before the work week, and for a minute, I thought I was screwed.
Anyways, I think it will work for now.
Comments welcome.
-Adam
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