You turn on your engine and suddenly hear all sorts of noise coming from the inside of it. First, you hear a loud rumbling sound coming from your exhaust. Next, you hear a strange ticking noise from under the hood. Later, you start to notice your exhaust system has also started to leak. Don't wait a minute longer. Fix your exhaust manifold bolts before it's too late.
Difficulty level: Moderate
Tools that you'll need:
- Propane torch
- Penetrating oil
- Socket wrench
- Vice grips
- Drill and drill bits
- Gasket scraper
Step 1: Cool down your engine before you start to work. You may also wear protective glasses and gloves for safety. Make sure you have enough space to work around your car.
Step 2: Let penetrating fluid work on all of the exhaust manifold bolts, including the broken one. Leave this for a few hours. Unfasten the exhaust manifold bolts and again pour penetrating fluid on the bolts if some of them still don't move.
Step 3: While waiting for the fluid to set, heat a propane torch if bolts are still stuck. Once a stubborn bolt turns red due to hotness, let the bolt cool. After this, the bolt will be easier to detach.
Step 4: Reach the broken bolt by detaching the exhaust manifold. It helps to use vise grips to coil the bolt out. Next, drill the bolt out. A drill bit the same diameter as one of the exhaust manifold bolts without the threads should be used.
Step 5: Clean out any remnants of the broken piece by running a tap into the hole that is the same size as the exhaust manifold bolts. Tap the remaining manifold bolt holes so that the bolts will thread back in easily.
Step 6: Attach a new bolt in replace of the broken one and clean up the rust on the threads of the original bolts using a wire brush or a wire wheel.
Step 7: Use a gasket scraper to remove the gasket material from the engine block and the exhaust manifold mounting surfaces. Next, fix a new exhaust manifold gasket between the exhaust manifold and the engine block. Make sure bolts are tightened.
Step 8: Finally, run your vehicle to check if the exhaust still leaks. If it does, you not have done the steps correctly. You can start again making sure all the new bolts are secured properly.
Replacing your car's exhaust manifold bolts can be a bit challenging. However, with the right tools and correctly followed procedure, it will take you less than an hour to finish the whole process.