How to remove a broken Cam chain cover stud ?
 

Hi folks,
Long time since I posted here :D

I've had a weep of oil from a broken stud at the top of my left cam-chain cover, forever, and it now remains the only oil leak there is.

I don't really want to do an engine drop to fix it, so was wondering what methods would work to remove & replace the stud with the engne in-situ. I guess the limited access is the main problem, but I did read very recently here on pelican about installing the carrera chain tensioners without removing engine & that got me thinking it may be possible.

Any suggestions, or ideally has anyone actually done this ?

Very old pic, but shows the broken stud
http://i24.photobucket.com/albums/c2...ned_cables.jpg

Thanks,
Declan

cant see much in that photo

but you should be able to get that out as it passes right through and should be easy

is there any of it exposed ?

take rear tinwork off and timing cover and see if you have anything youcan grab with vice grips. a little heat and unscrew it.

Yeah, I will try & get a better pic this evening.

Is there anything special about removing the timing chain cover ?

thanks.

I have used left hand drill bits for this. Over the years I have been amazed at how many times the drill "bit" into the stud and backed it right out. I have shortened them for use in tight places. Good Luck!

no secret to timing cover at all. better get a new gasket at the ready though so you are not down for too long. Many people time cams with the engine in the car and this is exactly how they do it. I think it might be tough getting a drill in there square though. Actually if you cant get the stud out a new gasket with a thin smearing allmost glaze of sealant and I bet it stops leaking.

Which one......
 

Declan,

Which of the four (4) upper chain housing cover stud is broken? Depending on the location of the stud and the drill you are using, you might encounter space limitation without a partial engine drop. A small angle drill could do the trick. Keep us posted.

Tony

Well I had another look this evening and I actually have 2 broken studs at the top of the chain cover.
On the plus side, it seems there will be something to get hold of when I remove the cover :)

http://i24.photobucket.com/albums/c2...s/image_3.jpeg

http://i24.photobucket.com/albums/c2...ads/image.jpeg

http://i24.photobucket.com/albums/c2...s/image_2.jpeg

http://i24.photobucket.com/albums/c2...s/image_1.jpeg

I assume I should drop the oil before removing the chain cover ?


Thanks again for the help :)

Declan

You dont have broken stud.The chain case are old style and somebody forgot to take off the two short stud when he put the carrera covert these require longer stud.

So Warren was right, all those years ago !

Early S man, aka Warren, advised me the same may moons ago and I had totally forgotten until I was looking back through the old threads I had subscribed to on here !

http://forums.pelicanparts.com/3414831-post46.html

Did you run your car 10 years like that.

Well I haven't run it for 3 years, but yes it has always been missing those 2 studs.

I went the other way .. I have an SC and super long studs at that point to hold the smog pump.
They came out easy and I put shorter ones in when I deleted the pump.

In my wisdom I bought 2 M8 studs as per the Porsche diagrams, but then realised the old ones are M6. Searching this forum yielded another wise post from Early_S_Man suggesting just to use longer M6 Studs instead, so thats what I did.

Now if I hadn't torn the new gasket, it would all be back together again.

Is that the Euro 2.7 with MFI and 210 HP?

Yep, it's the only one I've ever had :)

Best to double nut the studs. Using vise grips screws up the thread and makes it difficult if need heat and to double nut anymore.

I’d spend the $20 on a stud removal tool from Amazon. YouTube has tonsbo vids on the topic.
It keeps the torque concentric to the stud centerline so it reduces chance of breakage.

Yes, double-nut is how I got the old studs out. They were very tight to get moving, but once they started moving they came out easily enough.