Lost studs in intake manifold

MadBeez · Post by **MadBeez** » Fri Jul 11, 2014 12:15 pm

Ok, so there's a long colorful story before getting to this point but I'll spare you for now. Brought this 71 1608 DHSA 2 spider to NH from CA. Tried to drive it but gave up after about 500 miles and trailered it the rest of the way. Found the time this week to start working on it and found what is probably a game ender. 3 of the 4 studs from the top of the carb were missing. Looked into the carb throat and found one! Presumably the other two are in the intake manifold or worse.
I've got the carb off and 4 of the six intake nuts off but I don't seem to be able to get at the 2 remaining bottom nuts.
Does this require removing the fuel pump to gain access? Or can someone tell me what tool will get into that area?

Kevin1 · Post by **Kevin1** » Fri Jul 11, 2014 4:03 pm

What was happening with the car when you decided to trailer it? I think those studs would be too long to make the corner into the engine. Are you sure they were there when you started out?

I have found a 1/4" socket with a short extension leaves the most room to work under the intake. If you can't fit your hand in then you might need to remove the fuel pump to make room. Either way, you are almost there.

MadBeez · Post by **MadBeez** » Fri Jul 11, 2014 4:28 pm

I was experiencing my 15th breakdown - mostly overheating and exhaust system falling off. I looked at the air filter but I don't remember noticing whether or not all four studs were there. The last straw was when the front header pipe separated from the manifold but it seemed to run much worse at that moment too so may have sucked in one of the studs. I've managed to get the front lower nut off but that back one is really buried. I had planned to pull the drivetrain out and do a complete overhaul but if it sucked in those studs, I'm done.

seabeelt · Post by **seabeelt** » Fri Jul 11, 2014 4:52 pm

Pull the spark plugs. It will be pretty evident if anything made it into the cylinder. Don't give up the ship on the engine. Repair parts are available for everything.
R/

MadBeez · Post by **MadBeez** » Fri Jul 11, 2014 5:59 pm

Finally got the 6th nut off the intake manifold by pulling the fuel pump but it just barely jiggles. Are there more than 6 nuts? Is there some trick to getting this thing off or what?

131 · Post by **131** » Fri Jul 11, 2014 8:03 pm

Kevin1 wrote:I think those studs would be too long to make the corner into the engine.

Years ago I had to remove the head of a customers car to retrieve a stud, with nut still attached, that was embedded in the combustion chamber of one of the cylinders.

MadBeez · Post by **MadBeez** » Fri Jul 11, 2014 8:19 pm

Yeah, that's what I'm hoping I don't find. Is there something besides the 6 nuts holding the manifold to the block - like a set screw or something?

What I've found so far: 5 of the 6 intake manifold studs/nuts are accessible but the firewall-side, center bottom nut requires removing the fuel pump to reach. Then once you get all of them off and start backing off the manifold, you find that it bumps up against the brake booster before it's out enough to remove. Maybe I should've just pulled the whole motor.

seabeelt · Post by **seabeelt** » Mon Jul 14, 2014 5:11 pm

Double nut the center one and take the stud out. There are only six. It should come right off. You might have to give it a whack to break the gasket seal
R/

MadBeez · Post by **MadBeez** » Sun Jul 20, 2014 9:54 pm

I've been on a biz trip all week. Found a USB borescope on eBay and ordered it and will try it out on Wednesday when it comes in - $20 including shipping. If it works, I can think of all kinds of things to use it for. Also ordered a motor lift and decided to take the plunge.

Kevin1 · Post by **Kevin1** » Mon Jul 21, 2014 1:07 pm

Try disconnecting the motor mounts and then lifting the engine a little ways. It should give enough clearance without having to remove the whole engine.

"...a stud, with nut still attached, that was embedded in the combustion chamber…" Wow, I really didn't think it could make the turn past the valve. It will be interesting to see what the borescope reveals. Hopefully nothing got into the cylinder.

RoyBatty · Post by **RoyBatty** » Mon Jul 21, 2014 4:29 pm

Where in California?
Might be help close by if needed.

MadBeez · Post by **MadBeez** » Tue Jul 22, 2014 8:44 am

I re-mounted the intake manifold and am going to do some major engine bay cleanup today and wait for the borescope to arrive.

Kevin: I'll try that if I can't see anything with the scope.

Roy: I'm on the other side of the country in NH. Bought it in the Sacramento area and drove/trailered it here - but thanks.

Kevin1 · Post by **Kevin1** » Sun Jul 27, 2014 8:01 pm

Any news?

MadBeez · Post by **MadBeez** » Sun Jul 27, 2014 11:38 pm

Kevin1 wrote:Any news?

Yeah, I looked inside all cylinders with the borescope and didn't see any major damage. But I did see some unusual marks. Here's a link to one of them: http://i1282.photobucket.com/albums/a54 ... e99ad3.jpg

I can't decide if this is just build up on top of the piston or damage. But if a whole nut and stud had been sucked in, wouldn't there be more damage?

My plan for this car was to bring it back to looking and driving decently - not a back to original restore. This thing was "limoed" as in two good halves welded together - hence not a candidate for restoration.

The welding of the two halves seems to be good but I'll have to reinforce the bottom some due to floor rust on the rear passenger side floor. Please take a look and let me know what you (everyone possible) think.

All kinds of pictures can be found here: http://s1282.photobucket.com/user/7kRPM ... /2%20FIATs

MadBeez · Post by **MadBeez** » Wed Jul 30, 2014 2:17 pm

Taking the plunge. Getting ready to pull the engine but was hoping for some opinions on these pictures of two of the pistons.

Does this look like damage caused by a stud getting into combustion chamber or just buildup?

Thanks, Rich.