I recently did a valve adjustment on my e30 and when I closed the cover back up, the valve cover stud stripped right out of the head. I barely had to turn the nut and in fact I was able to just lift it out of the hole.
After a bunch of research I decided I would drill it out, tap it, and insert a helicoil insert. After running around to parts store to get the inserts, drill bit, and drill guide block I got back to realize that the engine hoist bracket wouldn't allow me to get my drill in. I pulled the distributor and rotated the bracket out of the way to realize my drill guide block wouldn't fit with the intake manifold and rocker shaft caps in the way.
I cut down the guide block, chucked up my bit, and drilled as straight a hole as I could. I then tapped it and when I inserted the insert the tang wouldnt break off. Then the insert tool got stuck and completely mangled in the hole. I eventually got it out however, and the stud went in. Except it didn't really turn to that high torque - it still felt loose.
Not wanting to strip it again I called it a day, and went to put the cover on. But the stud was too angled to allow the cover on and I had to force it - completely improper way to do it but I was low on time and knackered. I got it on and torque as tight as I dared (can't really fit a torque wrench in there).
I am honestly at a loss of what to do. this is the most recent work I've done on the car and now I'm back at university but I want to find a solution before spring break so I can fix it.
The only solution I can think of is to drill it even bigger and the only way I can think of to keep the bit straight is machining my own L-shaped drill guide that clamps onto the other valve cover studs on either side of it. But I still would have to remove the insert, drill an even *bigger* hole with a bigger helicoil, and take all the risk of mucking it up again.
I could really use some advice because I'm completely out of my depth, and almost at the point of taking it to a mechanic.
