Re: air induction bolt broken! help!

[jtrealty@xxxx]

Don't feel too bad as this is common. A steel bolt in aluminum with a 
little corrosion and this is the result. DO NOT REASSEMBLE WITHOUT 
FIXING!!! You will never get the engine to run smoothly as you will 
have a major vacuum leak. There are two avenues left to you. Don't try 
to muscle the bolt out with a stud remover or vise grips, you will 
just keep breaking off what's left. Either weld a nut onto what is 
left (if there is enough left) or drill it out. If you weld a nut on 
before trying to loosen it use a torch and heat it up as much as you 
can. If drilling it is critical to stay centered and straight. Start 
with a small drill and work up. If you totaly screw it up oversize it, 
thread some aluminum, screw it in and with the air intake plenum in 
place mark and redrill and tap a hole. If you manage to drill the bolt 
out but mess up the threads use a thread insert to fix it up but only 
if it is centered and straight. This is really a job for a machinist 
so be careful and go slowly. When reassembling use Never-Seize so this 
won't happen again.
David Teitelbaum
vin 10757