Date:         Thu, 12 Jun 1997 12:20:29 -0400 (EDT)
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         SyncroHead@aol.com
Subject:      Re: Help: Broken Cylinder Head bolt

In a message dated 97-06-11 03:42:11 EDT, JANPETRO@aol.com writes:

> While removing a very rusted exhaust pipe I have broken one of the bolts
with
>  only a very small part of it still sticking out. What are my prospects?
>  Drill?
>  Heat?
>  Removing the Head?

I doubt that a drill or heat will work.  I had this problem with an engine
out of the van and I was completely unable to remove the broken bolt with
normal tools.  I even broke off the (not so)easy-out inside the broken bolt.
 I took the whole engine to a machine shop that specializes in removing
broken bolts/taps/easy-outs and they used a laser to remove the remains of
the bolt and easy-out and installed a stainless steel "insert" with new
threads the same size as the original.

My advice is to call around and find a shop with this kind of tool and
experience and pay them to do it.  I wish I could get back all the
frustrating hours I spent on this myself.  Removing/installing the whole
engine might be easier for you than doing the same on a head if you're
talking about a Vanagon waterboxer engine.

Good luck,
Jim Davis
87 GL Syncro
88 GL Wolfsburg