removing exhaust manifold today to replace headgasket, all bolts came of no problem, the last bolt was coming off fine, then the stud twisted right off into the ground. What do I need to do it get it out. Not sure if there are threads exposed once manifold is removed.



Darryl
1993 940 non-turbo wagon 280k
1993 240 classic non-turbo 170k

If you are pulling the head anyway, no big deal. Just keep going and you will soon have it in your lap to look at /check, you can try easy-out, or drill out and re-tap or let local head shop do it because you will have to have it in there to be re-surfaced even if you don't do a valve job.

The FAQ has extensive discussions of ways of repairing broken exhaust manifold studs.

if you are pulling the head, give it to the machine shop and pay them the check the head for warps, cracks, etc. and to remove the stud. it may not be cheaper, but it should be faster. good luck, chuck.

Chuck, today I removed the headbolts, all came out with some force, but in good shape. Questions I have. In the FAQ, it didn't mention about removing the cam sprocket or how to remove, since the timing back cover is a one piece and the only way to remove the head is remove the cam sprocket. Does the belt tensioner and spring have to come off since it is attached to the head. Those things are holding me up. Thanks in advance.


Darryl

the tensioner has to come off. spin it real good and don't clean it with any solvent. if it's noisy or it's been on for more than 2 belts, replace it. the cam sprocket can stay with the cam when you unbolt that from the head. or, it's just a 14mm head bolt, just lock the cam somehow and unbolt it. good luck, chuck.

Yep, and if they bugger it, it's their baby. If the threads have to be redone, opt for a timesert instead of a helicoil if given the option. I think those may well last longer than the aluminum head.

Thanks Chuck, you always give great advice.