Repairing broken exhaust manifold bolts is time-consuming, but necessary for your car's safety and efficiency. Follow these steps to fix broken manifold bolts.
Step 1 - Remove the Exhaust Manifold Bolts
Loosen and remove all the exhaust manifold bolts including the broken one. Soak the bolts in penetrating oil for 6 hours. Heat bolts with a propane torch as needed.
Step 2 - Remove the Exhaust Manifold
Pull off the exhaust manifold with vise grips.
Step 3 - Drill Out the Broken Bolt
Drill out the broken bolt from the hole or engine block.
Step 4 - Clean all the Bolt Holes
Chase all manifold bolt holes with a tap to clean out gunk and metal shavings.
Step 5 - Reuse or Replace Manifold Bolts
Clean intact manifold bolts with a wire brush and reuse them. Take 1 bolt to the auto shop for correct replacement bolts.
Step 6 - Replace the Exhaust Manifold Gasket
Clean gasket residue from manifold and engine. Put a new exhaust manifold gasket between the manifold and the engine block.
Step 7 - Reinstall the Exhaust Manifold
Insert the manifold bolts and tighten with your fingers. With a torque wrench, tighten the bolts to the correct tolerance as specified in your service manual.