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i had some strange noise like that.. the hose was off the smog pump connection at the check valve. also make sure your manifold bolts/studs are not bottoming out. if they are, manifold well not seal even if the bolts/nuts are tight,
depends on how much metal was removed. my favorite repair for that would be useing keyserts. they're used for aircraft as well, so they have to work. i've found that helicoils are mostly good for a one shot repair, one that you never plan to remove again.
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