Broken Ex Manifold Studs

[DBF]

All,

Further to my original post, I eventually removed the head and my buddy
brought it to a very good engine repair/rebuild place in town.  They spent 3
hours on the 3 ex manifold studs.  They were drilled out and helicoils
placed in.  As well the water neck bolts broke off as well.  They took and
hour to do.  Incidentally, the shop said there were eezy-outs in all three
ex man studs!!

I put it all back together last night.  Funny thing happened though.  After
realizing I was 2 teeth off on the cam timing, I finally got her to fire and
settle into a stumbling idle.  I let it run enough to heat up a bit and I
shut it off to check for leaks and investigate the stumbling.  I figured I
forgot a vacuum line or such.  I had no leaks so I tried to start it up to
replace the coolant.  It wouldn't fire.  I tried moving the distributor.
Still nothing.  So I'm checking the cam timing and the old man says 'what
kind of shape is the dizzy cap in"?  Well, I popped it off and the center
contact that rides on the button was gone.  Non-existent!!  So I fumble
through the shed, find an old one (remembering of course it is 11:30 PM)
swap the wires over and she fires right up. I never turned in until 12:30
this morning!!

So, the car is running fine, starts right up and settles into a good idle at
950.  Not bad for a car with 398 000 kms eh?  Thanks again for all the
responses,

Dan
----- Original Message -----
From: "DBF" <dbf288 at eastlink.ca>
To: <quattro at audifans.com>
Sent: Tuesday, December 28, 2004 5:41 PM
Subject: Broken Ex Manifold Studs


> Good Day:
>
> I'm doing a favor for a buddy of mine, that is replacing the ex manifold
gaskets on his '87 5k avant. As well, I would very much like to keep the
head on the car.
>
> I knew what I was getting myself into, as #1 cylinder was missing both
studs (broken) and #2 bottom was missing/broken as well. After I got the
manifold off today, I discovered #2 bottom had something peculiar sticking
out from the broken piece in the head. I've seen it before, an easy out that
was broken off! Man they are hard. Good thing I can sharpen bits.
>
> Anyway, do any of you have pointers in removing the broken studs? I've
done it many times before on 'merican iron, and I suspect the method is the
same. I'm just a little leery about the aluminum head. I have a good VSR
DeWalt 6 amp corded drill, but what I lack are right (or is it left,
whatever the opposite twist bits are) twist bits. I have used these many
times before and you can get lucky and remove the broken piece while
drilling the hole for an easy out. Any pointers/thoughts would be greatly
appreciated. Thanks all,
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