Can anyone suggest how i could remove this. I've just noticed it was like this and has been since I bought the thing. It has snapped of flush with the engine block. Could I potential drill it out or is this fraught with danger? I think this may be cause of the rough sound exhaust note

Kelvin - Brisvegas

yes very likely the cause of noise. I tried to drill out a 340 water pump stud once and ruined the head, so yes quite difficult to drill into steel surrounded by aluminium. Getting the drill centered is the hardest bit, try a dremel ball grinder first and start with a small bit. Then you need a removal tool to screw into it. Once you have the removal tool in, get the engine nice and hot as the Al will expand more than the steel. Still may not work though, may need drilled on a jig with a pillar drill.

i made this a while ago, it's written in Dutch.
http://forum.volvo300club.nl/showthread.php?t=6570

i hope google translate will work for you. if you have any questions in translating or something, you're free to ask offcourse!

as Tony says though, centering perfectly onto the stud is the most important bit.

Love your work boys.... is it best to remove the engine block?

FWIW, if I was going to fix it I would take the head off and get it to an engineering shop.

Thats easiest to clock in on a mill and that way you won't take the head out. Trying to do this with a pistol drill is pretty much impossible.

Then again, I'd likely leave it unless it really is leaking lots.