aldo56 0 Posted August 3, 2006 I recently had a cracked exhaust manifold, and so i bought another and attempted to fit it. The problem i now have is that 2 of the studs snapped inside the head!! Its the 2 outside bottem studs and ive tired sealing it without them, with new gaskets, bolts, and exhaust putty to no avail. I just cant shake the ticking sound!"!! Ive now narrowed my options down to either, taking the head off and having it retapped, or buying another a 1.9 engine and therefore upgrading from my 1.6. Money is however a problem with this as ive been quoted £200 for a J reg 62,000mile engine delivered but im not really sure of the condition. I do want to upgrade the power anyways but there is nothing really wrong with my engine and i have just done a timing belt on it!!! Basicaly im wondering if anyone has any advice on the situation or possible other solutions to the problem (or even a 1.9 engine for a more reasonable price! ) cheers allan Share this post Link to post Share on other sites
Miles 331 1 Cars Posted August 3, 2006 You can get a angle drill, normally compressed Air thou to get in and drill the studs out and then either use a stud extractor of tap depending on how far you go. It will never seal without all the studs present. With the engine you'll need the ECU, AFM, Dizzy if you do change it Share this post Link to post Share on other sites
steve@cornwall 100 Posted August 3, 2006 You can get a angle drill, normally compressed Air thou to get in and drill the studs out and then either use a stud extractor of tap depending on how far you go.It will never seal without all the studs present. With the engine you'll need the ECU, AFM, Dizzy if you do change it My local garage attempted the angled-drill extraction for me- no guarantees could be given- and it c*cked up big time! (no charge). If budget is a concern it's probably cheaper to drop the engine out complete and drill/extract the studs yourself- or oversize and re-tap, modifying the manifold to suit- no head gasket costs.... I just replaced the engine, leaving the broken stud one for another day... Share this post Link to post Share on other sites
sorr 0 Posted August 4, 2006 You can get electric angle drills in most hire shops, I hired an angle drill the other week and it was £14 for the weekend.. As Miles says there is plenty room down the back to get at it. Just buy decent drill bits and start with a small diameter drill as a pilot hole then move up to the size required for the extractor. It is not hard as long as you take your time and plug the exhaust ports to stop any swarf getting in there. The critical part is getting a punch mark in the middle of the bold and holding the drill at the same angle as the bolt so it goes in straight. Also if money is tight an engine swap will cost more than you imagine when you factor in the tasks you should do when the engine is out (timing belt and water pump) and the consumibles you will need to buy gearbox oil, coolant etc. Share this post Link to post Share on other sites
GLPoomobile 958 Posted August 4, 2006 Oh dear, I feel your pain! When I got my first 1.6 I decided to fit a full Magnex on it. It was only when I removed the standard manifold that I found that one of the end studs had been snapped off previously. I never got the bloody 4-1 manifold to seal at that end! Ticking? Try sounding like a bloody tractor! I used to regulalry seal it with exhaust putty which would last a week or so and then the tractor sound would start to creep in as the putty cracked off. If there is something I have learned, it is that you inevitably end up pissing around far longer and maybe screw soemting up if you try and take a shortcut to the solution. If it were me I'd be taking the head off or dropping the engine out to tackle those studs properly, with no space restictions. Share this post Link to post Share on other sites
Grim.Badger 15 Posted August 4, 2006 The previous owner left me with a snapped lower outside bolt . The best I can manage is to tighten the other seven studs really well and use silicone sealant. It's not perfect and it's getting slowly louder I think. Alex is selling a reconditioned engine that I was going to get, but my finances are worse than Enron's at the moment so it might be worth asking him about it. Share this post Link to post Share on other sites
aldo56 0 Posted August 4, 2006 Just ordered a low millage engine today. I feel your pain with the exhaust putty cracking off and it getting louder and louder. more and more tractor like! hopefully my new 1.9 engine wont have the same problem althought ill ahve a look at it when its out and so drilling wouldnt be so hard. I do work in a garage part time so the consumables ie oil and coolant come pretty much free. I dont really have to worry about that however im thinking it might be a good idea to stick a clutch in while its out and obv a timing belt! All the costs are adding up but hopefully ill have a stronger, more realiable (due to the low millage) and NOT TRACTOR like engine!!!!! thanks for the help anyway. Allan Share this post Link to post Share on other sites
Guest Fangoria Posted August 4, 2006 have a look on the for sale on here, jonnie205 is selling 3 1.9 engines for £60 each Share this post Link to post Share on other sites
