Boy, that is an odd thing to have happened!

As the other Member suggested bottemed out Bolt; I am not sure if a bottomed out Bolt would snap or not.

I believe the Bolt ought to be able to take what ever torque it is rated for. But, I not entirely sure that is true if the Bolt Bottomed out.

Was the Cylinder Head Resurfaced?

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84 300D, 82 Volvo 244Gl Diesel

Yes, that is possible. Hole #20 (and all of the holes in the top row of my picture) takes an M-10x102 mm bolt but the head bolt set also includes M-10x115 mm bolts for the middle row (next to the injectors). The bottom row (next to the glow plugs) takes the shortest bolts, M-10x80 mm.

If the OP accidentally put a 115 mm bolt in the #20 hole it would bottom out before the head of the bolt touched the aluminum casting. Because there is only a 13 mm (1/2 inch) difference, the error might go unnoticed until the bolt snapped.

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

If someone is following the rules...and taking these bolts down in increments BY HAND with a torque wrench... I do not understand how this would not be caught before it broke...
Only if it bottomed out at exactly the required torque.. THEN the 90 degree turn was added without the torque wrench ( which is the prescribed method )... that might break it..
Otherwise I am waiting to hear that this is not the procedure which was being used.....
Of course part of the rules involves using a tap before putting the bolts into the hole also... separate from the cleaning out the holes of junk...

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1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/diesel-discussion/10414-help-i-need-check-stretch.html

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

yeah well the good news was I got a new head bolt and gasket out of it and I was able to get the bolt out I've been work on the car for the last few days almost nonstoped other then a few hours of sleep and the few fire runs I went on. I need to find how to do the timeing for the chain and cam any advise?

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Rule of Thumb

so, you got a new 102mm bolt and a gasket. are you SURE you put in the 102mm bolt in that hole? can you compare the pieces and see the length. do you know why the bolt broke yet?

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

yeah same size the new bolt went in without a problem so I dont know why it broke

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Rule of Thumb

When you do not read and reply to the comments in your thread.... It allows people to jump to perhaps unwarranted conclusions... when I mentioned that this should have been caught way before breaking pressure got to the bolt IF standard hand torquing was being followed...and you skip right over that... many people will think you were using an air hammer for initial run down... because something caused it to break and nothing you have described yet has that potential...
Why don't you tell the whole story... it might be a good lesson to someone else down the line...

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1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

It is not impossible for the Bolt to have been defective. There could have been some internal defect or there could have been a problem with Heat treatment leaving the Bolt too hard.

You would not know without some sort of analysis on the Bolt.
Also, last night I read some info on counterfeit Garrett Turbocharger parts. I suppose it is possible for the Bolt to be a counterfeit part.

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84 300D, 82 Volvo 244Gl Diesel