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Mon Dec 01, 2003 8:49 am

I'm trying to find the source of my exhaust leak (pop-pop-pop) and I discover that there's no stud on the front left exhaust port (front means front). So I get a stud and am trying to get it in there...twist-twist-twist and around it goes without ever getting tighter.

So it appears that the hole in the head is stripped. I guess my plan is to try to tap the hole to the next bigger size and fit a new stud in there. My question is: Is this possible to do with the engine in the car? It's definitely tough going lying under the car and messing around up there, but I'd like to try it without dropping the engine if at all possible.

So do folks think this is do-able? Or does anyone know of any other tricks to deal with this problem?

Mon Dec 01, 2003 9:16 am

It would be nice to know if your talking about an upright 68-71 engine or a type2/4 72 and later.... sounds like you may be referring to the later model but I can't tell for sure.

there is a recent thread pertaining to this, shouldn't be too hard to find.

oh here it is I found it a page or 2 back....http://www.thesamba.com/vw/forum/viewtopic.php?t=56633

if you look around you will probably find more old threads.

and I'm sure you'll get some fresh advice. I personally do not like helicoils... I prefer adn oversized " adapter" type step stud. or a "time sert" type insert.

yes the job is do-able engine in, but it is sometimes easier to go ahead and drop the engine depending on the working conditons/ tools you have

Mon Dec 01, 2003 9:23 am

Sorry...it's an upright 1600 engine.

I searched some previous posts on this, but most seemed concerned with getting the old stud out. Mine's already out, but it appears that the threads in the hole are buggered. So is it feasible to tap the sucker with the engine in place?

Mon Dec 01, 2003 9:34 am

OK .. gee I was just modifying the other post and you posted again... okay that thread was for the type2/4 so disreguard that one.

upright... easier than the type2/4 engine.

get a 10mm x 1.5mm tap and an " adapter step stud" like I spoke of.
it is 10mm on one end and the 8mmx1.25 like the stock stud is on the other. Most VW shops or parts suppliers should have them. If you have trouble finding them I can mail you one tomorrow or Wed for sure.