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[mick-1975]

hi guys i need your help big time ,,

  what should of been an easy job has turned into a pain ,,

  anyway had to take exhaust manifold off and found 2 bolts at the front snapped !!
 any ideas on how to get these out without takin the head of plz    
  ths mick

[Abiton]

What engine?

[mick-1975]

What engine?

 
  its 2.0l estate

[Abiton]

In that case it may be possible to sort out with the head on, but it'll not be easy if the studs have snapped flush, or sub-flush with the head alloy.

'Easy-out' type stud removers can work, but it is critical to drill the pilot hole really central.  They have been known to snap off compounding the problem.

I had just the very front one go on ours (immediately adjacent to the thermostat housing).  Eventually got it out with the aid of a very short electric drill and a special jig I made to ensure that the drill stayed on course.  T'was a struggle, but very satisfying to solve.
Tried easy-outs but gave up as I could 'feel' that I was about to snap one.  Re-tapping my newly opened hole was a delicate business too.

Jig available for loan, FOC; but IIRC it sits over the nearest other two studs, so you might have to remove/replace the other bust one before it could be of use.

[Matchless]

If you can get some round bar which is a tight fit in the manifold bolt hole you can drill a 2mm (say) hole through it and use it as a drill guide.
You will need a good light and a mirror to centre the manifold hole on the broken stud (quite a bit of slop in the holes) then nip up a couple of nuts to hold it still. Insert the drilled rod and use it to drill a pilot hole in the broken stud. Be very carefull not to drill too deep, just through the stud and no more, as there is a water jacket behind the front stud.
Biggest problem you will have is getting a drill in there, space is tight, a 90degree drive might be necessary.
If the studs were already snapped then check that someone hasnt already tried to drill them out....

[mick-1975]

   thanks everyone for the replys

   decided to take the head of last night around 8 , outside ,luckily in a car port and a light finished at around half 10,  
 
  i dont think thats bad at all ,  anyway waiting to get head back now to start putting it back together  

 not lookng forward to it at all        should be back on road good as new real soon ,  
 i shall keep you posted