TheSamba.com :: View topic - Newbie Help

Fri Apr 09, 2021 9:00 am

The broken bolt is a problem. Not sure how you got it out and back in once and then managed to snap it off taking it back out. That might indicate it was cross threaded.

Someone skilled can likely address it with the intake installed, but won't be stoked to deal with it. That requires someone coming to you are towing it to someone.

The other option which is not that big a deal is to remove the intake runners from that side and bring the runner to someone to deal with the bolt.

Sorry that happened. As far as the injectors, There are other considerations besides fit. Injectors are sized and have flow rates made into them. Also you need to compare the resistance. There are low resistance injectors and high resistance injectors. You need to match the resistance to the VW injectors by verifying with an ohm meter.

Fri Apr 09, 2021 9:06 am

By all means, if you feel out of your element, seek professional help. Ask here for a recommended shop in your area if you go that route.

I have successfully used a screw extractor set to solve this problem. If you decide to do that, I recommend that you start with a drill bit that is smaller than the extractor size you choose. Then, move up to the next drill bit size, etc. until you can insert the extractor. Give the extractor a few taps into the screw to ensure it's biting before you try to turn it out.

Fri Apr 09, 2021 9:08 am

If you do attempt to drill out the broken bolt, remember to stuff paper towels in the injector holes so you don't get metal shavings down into your motor.

Fri Apr 09, 2021 9:16 am

If you've never drilled a broken stud/bolt, and used an extractor, which if the bolt is cross threaded, won't work well, I'd pass it on to someone experienced. You can easily "F" this up exponentially for the person that will end up having to fix it. Snapped drill bit, broken extractor or if you are unlucky. both.

I'm not saying don't attempt it, but if you are a virgin, I'm saying don't attempt it. So, I guess I am saying, don't attempt it.

Fri Apr 09, 2021 9:33 am

I'll chime in saying that you should really assess your skill level for extracting the broken fastener.

To someone experienced and who has the tools, it is an easy task...... half hour even if everything goes wrong.

To an inexperienced hand? It can be daunting and result in an bigger headache.

Dave

Fri Apr 09, 2021 9:53 am

i'm sure you can find an intake runner pretty easily... i know Dave has several lying around ;)

remove the two 13mm bolts holding the runner, put paper towels in the intakes, take the runner to a shop and they can remove it if it's beyond your ability.

bravo for tackling the job, welcome to the learning curve.

Fri Apr 09, 2021 10:30 am

https://www.thesamba.com/vw/classifieds/detail.php?id=2314038

$13 shipped. Not even worth messing with drilling out the bolt.

Fri Apr 09, 2021 10:33 am

Stupid question and I could look it up. Is there a left and right?

Edit: looked it up and there is a left and right. Different part numbers.

Fri Apr 09, 2021 12:18 pm

The runner length is different. I wonder if this is to offset the clamps?

Fri Apr 09, 2021 12:59 pm

my holding bolt broke. got it out with the usual arsenal of patience and tools. was cleaning up the threads with a tap and i knocked the manifold off the bench, hit on the tap and broke the tap off below the surface. i cried and used a different manifold. need to get the tap out someday.

Fri Apr 09, 2021 2:03 pm

dabaron wrote: i'm sure you can find an intake runner pretty easily... i know Dave has several lying around ;)

remove the two 13mm bolts holding the runner, put paper towels in the intakes, take the runner to a shop and they can remove it if it's beyond your ability.

bravo for tackling the job, welcome to the learning curve.

I didn't think that section could be removed. I was going to say, getting access to that fastener would have been extremely difficult to keep straight line access.

If I can take it out and put it on a bench, I'm confident I can remove it.

Fri Apr 09, 2021 2:04 pm

DanHoug wrote: my holding bolt broke. got it out with the usual arsenal of patience and tools. was cleaning up the threads with a tap and i knocked the manifold off the bench, hit on the tap and broke the tap off below the surface. i cried and used a different manifold. need to get the tap out someday.

That's the perfect example of the exponential problems that can arise. You don't have a tap extractor? :wink:

edit: Quote:
If I can take it out and put it on a bench, I'm confident I can remove it.

That's the right attitude. Good luck.

Fri Apr 09, 2021 2:31 pm

Besides length, the right manifold has a stud to hold the TPS plug in place.

Pull those two 8mm (13mm head ) bolts and the manifold is yours!

Do check the two intake hoses on the manifold, they dry out and crack, you may need new ones along with a new manifold to head gasket, most often a thick spacer.

Dave

Fri Apr 09, 2021 2:52 pm

Intake gasket fits 2 ways. Only one way is correct.

Fri Apr 09, 2021 3:52 pm

DanHoug wrote: my holding bolt broke. got it out with the usual arsenal of patience and tools. was cleaning up the threads with a tap and i knocked the manifold off the bench, hit on the tap and broke the tap off below the surface. i cried and used a different manifold. need to get the tap out someday.

Chuck Norris could scare that bolt stub out with a sideways glance. Considering how hard taps are, the broken tap would require a roundhouse kick.

Fri Apr 09, 2021 3:53 pm

4Gears4Tires wrote:

The runner length is different. I wonder if this is to offset the clamps?

It may not be obvious to you folks raised in North America, but to me, it is obvious that runner is for the left hand drive (LHD) Vanagons. The UK export RHD vans, not including Syncros, which used Syncro-specific (higher ground clearance) runners, had the short/long sides reversed, which allowed for the higher compression on the DJ engines. Operating these UK-designated vehicles on the right hand side of the road could lead to lean misfires.

Okay, back to work now . . .

Fri Apr 09, 2021 4:58 pm

Really? Syncro specific runners? I have a 2wd engine/intake in my syncro and no problems with the intake runners hitting.

Fri Apr 09, 2021 5:07 pm

If you drive on the left side of the road, they will hit the tarmac.

Seriously, though, I was joking in my two posts above, which I think you were aware of.

Fri Apr 09, 2021 7:17 pm

This is a headless thread.

Fri Apr 09, 2021 8:44 pm

Howesight wrote: If you drive on the left side of the road, they will hit the tarmac.

Seriously, though, I was joking in my two posts above, which I think you were aware of.

I 100% thought you were serious. After finding enough Syncro specific parts that my van was and is still missing, intake runners were totally in the realm of plausibility.