I'm about to flip, I really don't understand why it won't come off.
https://youtu.be/RpL2gyEgo_s

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

If you drilled the head of the bolt, then you missed something else. Did you take off the EGR clamp underneath the manifold.

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Only diesels in this driveway.
2005 E320 CDI 243k Black/Black
2008 Chevy 3500HD Duramax 340k
2004 Chevy 2500HD Duramax 220k

I did. Hold up

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Agreed. There has to be something else holding the manifold on.

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


EGR block kit
http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

1985 CA emissions 617 owners- You Need This!
Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst.

Sanden Instalation Guide (post 11):
http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html

Color me stupid found the bolt, it was completely covered in dust.

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Well guess what it STRIPPED! So I drilled a hole and rammed an XZN bit into the hole.

Then the head broke clean off again!

So I had to drill out the nut with dull left hand bits. Now a stud remains.

Now I have to tap and die TWO holes and I have a canabalized intake manifold.
Goodd old times yeah? I'm done for tonight.

Attached Thumbnails

   

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

To remove a cruddy XZN, first clean every bit of dirt out of the socket. Then put your XZN bit in the socket and whack it with a hammer, like you were driving a nail. Then put the XZN bit in your wrench and turn it out. Whacking it sends a shockwave down the length of the fastener and disrupts rust and such.

I did and it sheared off again, check above. I smacked the hell out of it till brass was flaking of my brass hammer.

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Fyi, that's 2 sheared heads in total.

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

It can happen. Run it with 2 missing bolts. Not a big deal or gonna affect the seal much. Sometimes those manifolds are warped anyway especially when taken off hot. They’re aluminum, aluminum warps easy and cracks easy. It’s soft metal.

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Only diesels in this driveway.
2005 E320 CDI 243k Black/Black
2008 Chevy 3500HD Duramax 340k
2004 Chevy 2500HD Duramax 220k

The stud is still on, I tried vice grips didn't work. Is is it possible to rig a nut on and turn it off?

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1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Go buy yourself an external Irwin bolt extractor kit that will fit that stud. Hammer it on, then use an impact or breaker bar to turn it out. My kit has paid for itself many times over by saving my backside with broken fasteners and rounded heads.

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Current stable:
1995 E320 149K (Nancy)
1983 500SL 120K (SLoL)

Black Sheep:
1985 524TD 167K (TotalDumpster™)

Gone but not forgotten:
1986 300SDL (RIP)
1991 350SD
1991 560SEL
1990 560SEL
1986 500SEL Euro (Rusted to nothing at 47K!)

They're too big to fit

wow...

Drilling is the last resort. the correct method would be to remove manifold. Weld nut on to broken stud "put nut on stud and fill the inside of nut with weld". With heat it will back right out.

I actually keep one of those cheap $80 chincom flux core welders just for studs like this.
Sure I can use my big engine driven welder, but it's overkill.

OP it's easy to do it. Maybe a mobile welder will charge you 40 or so. will be maybe 5 mins of labor.