[rjSupra]

Well, after a few hours I was able to spin the crank by hand, and then I took out the #1 spark plug to have less compression to make it easier to spin to TDC on #1 cylinder. Finally removed CPS, was quite easy, No, do not remove all the air lines the TSRM tells you to, there's no need except for a small tiny one, not the 2 huge ones. And ditto on the PS reservoir, I removed the holding bracket, and then shoved it over to a side, and without too much wiggling got the CPS off the head. Hmm, it's interesting, with the water housing also now removed, there's a lot more clearance to root around. Still hard to tell but the metal cooling line that runs next to the block and heads to the back of the engine under the exhaust headers and heat shields looks ok, at least the small portion I can see, and after all that's the area where the leak is. The upper stud on the CPS mount has some built up gunk on it, looks like coolant that has been exposed to air, so could that be the smoking gun here? The gasket was sort of ok, I mean it split into two parts on removal like they all do, and I've certainly seen worse. So I can't figure if the 90 hose, the water housing outlet gasket was the source of evil.
So, so far so good. Except that with the water housing outlet now off, I benched it and drilled it in a wood vise to deal with that p.o.s. thermostat housing bolt that snapped off in it. I had to drill and drill and drill more and the stupid thing still won't let go, the hole I drilled actually went past the bolt end into the housing a little I think. Not all the way through wall I think. But it's a big mess, and I don't quite know what I am going to do. Can I helicoil this now? Should I just re-mount it with only the upper bolt holding in the thermostat to this housing? (don't really trust that and want to do that). The exit out the bottom of the water outlet housing is an oily mess. I have various small oil leaks and I assume it's oil and crud, but could that wet area be the leak where it starts to join that 90 angle small hose? If it's bad, do I replace it with some sort of like a plumber's thread with a new part? (not really experienced in this).
I also found it looks like a very small return coolant line from the turbo just underneath all this and I think I'll replace it as a precaution and the lower rad. hose since it's all very easy to get at now.
Any thoughts on how to deal with the broken bolt junk that won't come out?
And one more thing, the TSRM is confusing me. I have a replacement O ring gasket for the CPS. The diagram makes it look like it's the first thing to come off on the end of the CPS spline. Then on my CPS unit, there is no gasket ring at that spot or left in the head. There is a similar shaped thingee after the two gears in front of it, both of which then I'd have to remove. (meaning the TSRM diagram is wrong) And what??? Do I have to grind down something to get those two gears off to replace the o ring gasket like it says in Ignition chapter P 21-24? Anyone chime in on that one?
the pic shows the lower bolt housing that's all shot to hell from drilling and still lodged in there. There is white tape over the normal outlet opening to keep the shavings out above it.
Thanks