cylinder head removal
 

Hi all, we have had a boxter 2.7 2006 in for a snapped manifold stud at the head which we now discover has been attempted elsewhere and it is actually an 8mm tap that is snapped, we have not managed to extract the tap using all of the tried and tested methods, we are now looking at removing head, can we remove the head in place or is it engine out? thanks

You can remove the heads without removing the engine but it is very difficult to reinstall & you must buy special tools to set the camshaft timing.

I recommend you get this drill fixture made for the exhaust stud removal: BOXSTER/996/997 EXHAUST BOLT REPAIR KIT

In my project I had 2 bolts snap off on me (not exhaust manifold). I was able to remove the part and take it to the local welding shop. Very carefully they built up a bit of weld on the tip of the snapped off bolt then welded a new stud/bolt to the exposed end of the bolt then with a wrench turn out the snapped off stud/bolt (i think you have to let it cool a bit).
I've been told, the welding heat breaks free the snapped off stud then its just a matter of attaching something to turn out the snapped stud.

When I removed my exhaust manifold bolts the engine was out of the car. I read numerous horror stories about breaking off the studs soooo... I started carefully and even soaking the bolts with penetrating oil and trying to remove the bolts by wrench, still no luck. I finally reached a point where I tried all I could being nice and I had to remove the manifold sooo bring in the bigger equipement, air impact wrench! I chose the correct socket size and held my breath. I thought for sure I was going to be another statistic BUT it worked like a charm. It must have been the hammering action.

Can you grind it out with a Dremel tool and a carbide bit? Is plasma or EDM an option?