In a message dated 7/30/2002 10:09:59 PM Eastern Daylight Time, 
LISTSERV@GERRY.VANAGON.COM writes:

> Can the head to exhaust gasket be replaced without removing the rest of =
> the exhaust system? (2.1)
> 
       Yes & No !  It's a trick question.  If there are studs in the head and 
they do not come out when you remove the nuts then you have two choices.  Try 
to remove the studs or remove the header pipe which will entail breaking the 
connection at the collector.  Actually, you should remove the header pipe 
anyways to clean up the surface of the exhaust port gasket surface.  If it 
has been leaking for a while the surface will be not acceptable to a new 
gasket therefore it won't last long.  The other thing that's going to happen 
is more than likely one or more of the studs will break off and you will be 
obliged to drill the remainder out and tap new threads.  I highly recommend 
you install helicoils or time-serts at this point so you will have nice new 
good strong threads to hold new stainless steel bolts or studs, your choice, 
just make sure the bolts you use will not be too long but long enough to get 
a good hold on the threads in the head.  All of this is easy to do at the 
front of the motor, relatively speaking of course.  BUT, at the rear of the 
motor you run into a bit of a problem due to the crap in the way.  If you 
need to renew the threads at this end you will need to drop the motor enough 
to get clearance for the drill to operate.  Good luck !  All this is why I do 
not give quotes on installing a new exhaust system on a Vanagon engine.  
Could be easy could be a major PITA.  Last one I did all four of the exhaust 
studs at the front broke off and I had to drill, tap and helicoil four new 
holes.  The rear had only one, lower LH side one screw up, and I was able to 
run a tap in and out and clean up the threads well enough to get a new stud 
in.  Whew !  That was luck that time around,

Cheers��

Frank Condelli
Almonte, Ontario, Canada
<A HREF="http://members.aol.com/BusFusion/bfhome.htm">BusFusion</A> a VW Camper camping event, Almonte, ON, June 2003
'87 Westy & Lionel Trains
Member: <A HREF="http://www.vanagon.com/">Vanagon List</A>, <A HREF="http://www.bcn.net/~limbo/">LiMBO</A>, <A HREF="http://www.westfalia.qc.ca/CIW_English.asp">IWCCC</A> & Capital City VW Club 
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
<A HREF="http://members.aol.com/Fkc43/stebro.htm">STEBRO/Vanagon Stainless Steel Mufflers</A> �
<A HREF="http://members.aol.com/Fkc43/busindex.html">Frank Condelli & Associates</A> or http://frankcondelli.com