How to Repair Broken Exhaust Manifold Bolts

an Exhaust Manifold
  • 2-10 hours
  • Intermediate
  • 50-100
What You'll Need
Penetrating oil
Wrench kit
Torque wrench
Propane torch
Vise grips
Power drill, bits and taps
Replacement bolts
New manifold gasket
Fire extinguisher
Safety goggles

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 six 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 one 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 it with your fingers. With a torque wrench, tighten the bolts to the correct tolerance as specified in your service manual.