Balls TD...
I had exactly the same probs on the Elite - one of the deciding factors to take the heads off, and make a proper job of the manifolds.
Access it not going to be great, to drill and tap in situ
On a plus point, being a 4 pot, it won't be any hardship to get the head off if needed
Having said that, I guess the bigger concern for you, is being without the car - as no car = no work!
If the manifold were to be removed, do you reckon there would be enough stud to extract?
I seem to remember when the vx muppets snapped some of them last time.....the vx dealer gave me a choice.....take head off and send it away, but will take longer.....or get someone in to do the job without taking the head off, but will cost more......i went for the later option....and didnt pay either.....i used the argument then of....you broke it....you fix it!.....think the dealer claimed for the expense on the warranty.
Dont know about how much stud is left in the hole.....both of them have snapped with about 3/4 inch of thread attached to the nut.
Not really bothered about how long it takes....as my VectraC comes back to me on Monday.....so I can use that for work if i need to.
I just need to find someone local to do the job really....
Presumably its not going to do any damage if i continue to use the Omega as it is.....just ticking noise get worse i assume.
I understand that the manifold obviously expands as it gets hot.....but are the snapped studs due to overtightening in the first place?
ie did the vx muppets overtighten them when they refitted the manifold 50k miles ago?