*Stripped Idler Sprocket* what to do now?

[verSat1l3]

Okay so I'm assembling this 96 ka24de I just sunk a ****eload of $ into and I realize now that the bolt that holds the idle sprocket pulley has 3/4 of the threads still wrapped around it. Its stripped for sure and now I am going to go freaking postal...

Okay so before I go downstairs and unbolt my head to take it back to the machine shop(while crying about how much money I've wasted on it). I want to know what you think I can do about it. Anyone think a Heli-coil will work? It needs to take 66-82 ft-lbs of torque according to the FSM, but keep in mind that this is going to be a turbo motor. My other option is to have the hole tapped one size larger and possibly have the bearing shaft of the idler pulley bored to match the new bolt size. I feel this would be the stronger option of the two but will cost more and also runs a danger of cutting into the water jacket. I also have a 93 head in my garage but was pretty sure that there were differences between the 93 and the 96 heads(maybe not?)...

Someone give me encouraging (and correct) news. Because right now I could lose it...

[verSat1l3]

Jeez 3 hours later and only 8 views... I know its a scary subject title right?

I took the head to the machine shop, and he told me to go watch tv and that he'd take care of it. I've been doing some reading since and it turns out that according to the technical data heli coils appear to be stronger than the original threading, especially in softer metals (aluminum head). Still not happy about it, but at least I'm calmer now.

[Vegascorbin]

... it turns out that according to the technical data heli coils appear to be stronger than the original threading, especially in softer metals (aluminum head).

I am no expert but that statement is consistant with what I have been told by people I trust.

If when you put it together it takes the torque with out problem it should hold like new.

[tramp_drift240]

i know the thread pitch of the bolt is M12 x 1.25

i just went to find a helicoil set for the idler gear bolt, only Carquest is able to get them here, and its 96 bucks for the set.

you wouldnt happen to have already bought this set, would you? 96 bucks is a little steep for fixing a single bolt hole.

[killernoodle]

Helicoil sets are only like $40 at my local auto parts stores... plus once you use a set you will end up heli-coiling all the other stripped bolts you have on your car

I helicoiled a friend's aftermarket Alcon caliper brackets on his WRX that corroded and stripped, then when my brother broke his frame slider bolt on his crashed bike I ended up drilling and heli coiling that too with the same set.

They're very useful, and once you get the master tool all you need is a tap and the corresponding inserts to do different sized holes.

[tramp_drift240]

true. but im trying to find someone who's got the kit for the idler sprocket bolt (M12 x 1.25) so i can borrow their stuff, throw them some money, so i dont have to spend so much for a single bolt hole.

y'know?

[killernoodle]

I might have that set. I'll let you know tomorrow when I'm around the shop. I think I probably have the M10 though.

[tramp_drift240]

definitely let me know.

im pretty sure the tap itself is supposed to be a m14x1.25, and a m12x1.25 insert will fit in. im not sure though.

i need this fixed asap so i can put my engine back together.