Inlet Manifold Removal

[tonypy1]

Just been trying to remove my inlet manifold to deal with a leaking water pump and have sheared one of the long bolts on the front of the manifold. Anyone dealt with this problem before or any suggestions of how to deal with this? It's stuck solid so I can't see a stud extractor working.

Current thinking is to drill out some of the top of bolt to create a well to hold some diesel - may even try vinegar.... as a penetrating agent, doubt this will get me anyehere though...........

Many thanks

Tony

[DJT]

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Tony,

Sorry to hear this. Removal depends on where it has sheared. I take it the manifold is now off? Is there any of the bolt shaft protruding from the head, or has it sheared off flush? If there is any protruding it should make life easier. I would try heating the end of the bolt with a blowtorch, then as it cools spray it with WD40 or similar (be careful as it may flash due to the heat in the bolt). Get some good 'Mole' grips onto the bolt and carefully try and turn it back and forth until it eases free.

If, as I suspect. it has sheared flush, then the only way is carefully drill it out. You will need to accurately centre punch the remains and, using a small drill bit (3mm) drill a pilot hole. Then increase to a larger diameter until the bolt is almost gone. You could try an 'Easy-out', but these have a tendancy to snap off, leaving you with an even bigger problem.

Either way, I would Helicoil the thread before refitting the manifold. This applies to any of the manifold bolt holes that are in any way suspect. Another tip is to use a counter-sink drill bit and make sure that the bolt holes are not proud of the surface due to overtightening in the past.

Dave

[dogsnadgers]

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I would helicoil all the inlet manifold threads, as what happens is you do them all up then the last one strips as you give it 'the last quarter turn'! Then you have to take it all off and start again, then the last one strips again and you end up buying a helicoil kit anyway!
Dave

[tonypy1]

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Thanks for the replies so far - just to clarify the manifold is well and truly still in place thanks to this one bolt. The bolt sheraed just below the head - let's see how I get on with drilling etc!

Thanks again

Tony

[DJT]

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tonypy1 wrote:

Thanks for the replies so far - just to clarify the manifold is well and truly still in place thanks to this one bolt. The bolt sheraed just below the head - let's see how I get on with drilling etc!

Tony,

In this case, with all the other bolts out, you should be able to run WD40, or similar, down the hole, then there should be enough give to wobble the manifold around the stuck bolt. It should eventually rotate back and forth enough to loosen any corrosion between the bolt and the manifold casting. I have never studied the inlet manifold with a view to whether or not it will lift off with one bolt acting as a stud, but I would think it should. Certainly worth a try before picking up the drill.

Dave

[John]

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I agree with Dave. If there really is only this one bolt left, I'd definitely soak it and try rotating the whole manifold around this bolt as best you can first.

[alan_thomas]

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DJT wrote:

You could try an 'Easy-out', but these have a tendancy to snap off, leaving you with an even bigger problem.

I'll second that. I used an 'easyout' to try and remove a broken bolt from the inlet manifold and yes - it broke. No chance of drilling it out, far too hard. Quoted £50 to have it spark eroded out. ended up grinding the easyout out drilling the remaining part of the bolt (Which is what I should have done in the first place!) then building it back with weld and finally helicoiling it.

I think they were called 'Easyouts' by someone with a wicked sense of humour!

- Alan