In a message dated 14/01/2004 1:47:00 PM Eastern Standard Time,
LISTSERV@GERRY.VANAGON.COM writes:

Can  anyone please tell me how this job can get done with out breaking the
bolts  and making the job more expensive etc.

No !  There are lots of tricks but NO  guarantees.  Welding a nut to the end
but the bolts at the rear would be  almost impossible to do that due to space
restrictions and that's the same  reason that if those ones break off, the
next best thing is to drop the  engine.  No way you can go there with a drill to
drill out the broken studs  & bolts.  Penetrating liquid can be tried but must
be continuously  applied and the area heated over a few days to have any
success and MOST times  the bolts & studs STILL break off so your just wasting
time.  Something  that most shops won't want to do unless you willing to pay for
this.  DO  NOT REMOVE THE HEADS.  Your just asking for more problems doing
that.   If the nuts and bolts break off the best way is drop the engine.  Then
remove the remaining bolts & studs the best way you can. Then drill out  the
broken bolts & studs, fit helicoil thread repair inserts to all eight  locations
then use stainless steel bolts of the proper length at ALL  locations.  Don't
forget abut flat washers, lock washers and the mounting  tabs of the push rod
tube covers when calculating the length of the bolts.   If the bolts are too
long you WILL crack the heads and if they are too  short you will not get a
good seal on the flange.  Clean up the exhaust  port gasket surface before
putting the engine back.  Good clean surface  here is IMPORTANT to having the
gaskets seal well.  ALSO, use Loctite  Ultra Copper High Temp Silicon Sealant on
both sides of the gaskets.
To make all this expensive work worthwhile and to  not have to visit this
scene again sometime in the future think about fitting a  stainless steel exhaust
system.  See my _STEBRO/Vanagon Stainless Steel  Exhaust System_
(http://members.aol.com/Fkc43/stebro.htm)  webpage for complete details on what I have to
offer.
Cheers,

Frank  Condelli
Almonte, Ontario, Canada
_BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm)  a VW Camper
camping event, Almonte, ON, June 10 ~ 13, 2004
'87 Westy & Lionel  Trains
Member: _Vanagon List_ (http://www.vanagon.com/) , _LiMBO_
(http://www.bcn.net/~limbo/) , _IWCCC_ (http://www.westfalia.qc.ca/)  & _CCVWC_
(http://www.ccvwc.ca/)
Vanagon/Vanagon Westfalia Service in  the Ottawa Valley
_STEBRO/Vanagon Stainless Steel  Mufflers_
(http://members.aol.com/Fkc43/stebro.htm)
_Frank Condelli &  Associates_ (http://members.aol.com/Fkc43/busindex.html)
or  http://frankcondelli.com