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[Andy A]

For some reason I removed the EGR from the head. Here is its back. Both the gaskets in the gasket kit were wrong, so I bought one from Vx. I imagine the machined groove around the gas channel is for cooling purpose, and the two stumps in the centre are the temperature sensors.

machined slot between gas channel / temp sensor pocket is there so that if the gasket fails , coolant leaks out, down the engine and not sucked into inlet (causing hydrolock ) BANG !
yes to the brass stumps being the ECU CTS (coolant tempreture sensor) ,and the other being the dash cluster sender 
(hence why sometimes the ecu temp reading via scan live data is different to the temp the dash reports )

nice photos BTW Mr Paget 

Second that. 

[terry paget]

For some reason I removed the EGR from the head. Here is its back. Both the gaskets in the gasket kit were wrong, so I bought one from Vx. I imagine the machined groove around the gas channel is for cooling purpose, and the two stumps in the centre are the temperature sensors.

machined slot between gas channel / temp sensor pocket is there so that if the gasket fails , coolant leaks out, down the engine and not sucked into inlet (causing hydrolock ) BANG !
yes to the brass stumps being the ECU CTS (coolant tempreture sensor) ,and the other being the dash cluster sender 
(hence why sometimes the ecu temp reading via scan live data is different to the temp the dash reports )

nice photos BTW Mr Paget 

Thanks Dave; that makes more sense.

[terry paget]

EGR channel is built into the coolant bridge... Neat bit of packaging as it probably helps the engine warm up times

Well spotted, Doc, I see what you mean. 

[terry paget]

Fingers crossed chaps- ATP will send  another manifold set. Here is their note.
Hello,

we are very sorry for the inconvenience.

We will immediately arrange a replacement delivery.
 
Mit freundlichen Grüßen | Kind regards
 
Marina
Customer Contact Centre | Agent
ATP Auto-Teile-Pöllath Handels GmbH

[terry paget]

The good news is the 2.2 exhaust manifold kit arrived yesterday. My thanks to Nick W for thetip - it seems very cheap at 45 Euros.
The bad news is that I discovered there were 2 holding studs missing, and I broke off 1 more removing the manifold, despite wire brushing and applying heat.
Remaining studs are 2-3-4-5 upper row, and 1-3-5 lower row.
Should I:
a) scrap car
b) remove head and get it repaired
c) fit the new manifold on remaining 7 studs
d) something else.

My inclination is to fit the manifold on the remaining  studs, but I am open to advice. The car only cost me £190, so it owes me nothing.

[Nick W]

Option D


You don't need to remove the head to replace the missing or damaged studs. This is a straightforward job that is only complicated by access problems, and that isn't the case on a 2.2 Omega. M8 thread repair kits are cheap and relatively easy to use, the 'difficult' part especially for someone who hasn't done it before, is to extract the broken studs. There are numerous techniques, all of which have their place. Given your propensity to over think and over complicate things, it might be better if you pay someone else to do this part of the job.


As you have repeatedly discovered, a £190 car can cost much more than that to actually sort out.

[dave the builder]

I'd be drilling / removing the snapped studs and replacing ,
without all the studs ,clamping it flat , what stops it distorting / blowing /warping / cracking 
your not meant to use gum gum or similar pre cats ,
you have the parts now , studs drill easy with new good drill bits 
finding another car cheap, without other major issues , would be difficult

[Andy A]

The good news is the 2.2 exhaust manifold kit arrived yesterday. My thanks to Nick W for thetip - it seems very cheap at 45 Euros.
The bad news is that I discovered there were 2 holding studs missing, and I broke off 1 more removing the manifold, despite wire brushing and applying heat.
Remaining studs are 2-3-4-5 upper row, and 1-3-5 lower row.
Should I:
a) scrap car
b) remove head and get it repaired
c) fit the new manifold on remaining 7 studs
d) something else.

My inclination is to fit the manifold on the remaining  studs, but I am open to advice. The car only cost me £190, so it owes me nothing.

Glad you finally got the manifold delivered.

I would watch a few vids off the internet and try and centre punch and drill out the snapped off studs. After all what do you have to loose if you decide to scrap the car anyway.

Any chance you could put up some pics of what the new manifold looks like up close?

[terry paget]

Here are a couple of pics of the exhaust manifold kit.

[terry paget]

To improve access I can remove the dipstick. Also in the way is an aircon pipe; aircon has never worked and will never work again on this car, so I can get rid of that too. The studs have snapped off a little way inside the threads, making it tricky to centre punch them centrally. Is this easy work for a man who knows what he is doing?
I guess I must ask around for such a man. My son's friend Brummy the welder might know.

[terry paget]

Pics


Apologies to all, now using my laptop and strange things are happening.

[terry paget]

It  appears my desk top Windows XP is dying, am writing this on my laptop Windows 10. I can no longer see my earlier pics on my desk top, but I can see them on my laptop. Do let me know if you cannot see my recent pics of my new manifold. I see them on my laptop, but not on my desk top.

[TheBoy]

I can see the fanimold pics in the 2 posts above

[dave the builder]

I can see your latest pics 
your xp desktop could be not showing pics due to flash player /I.explorer not supported any more

later o/s desk top machines can be had cheaply if your xp machine hardware id to old to cope with windows 10 

[TheBoy]

could be not showing pics due to flash player /I.explorer not supported any more

OOF, by design, makes no use of Flash, for security reasons. Older IE's will work on the non-secure site (http), but might struggle with https - which TP's dropbox images are