Exhaust Manifold GSX

[TDC GSX]

I bought a 1991 Eclipse GSX. The left side bolt has broke off, leaving half a bolt in the block. When cold the exhaust manifold leaks. When hot the metal seals the leak, so I have some time before all hell breaks loose. My question is what is the best way for me to fix this problem before by block gets damaged by the exhaust. My dad and I were thinking of pulling the head and having it machined out so new bolts can go in to seal the manifold. Is this the best way to fix this problem?

Thanks

 

[yoshimitsuspeed]

Is the stud broken flush with the head or flush with the manifold?
If it's flush with the manifold I would take that off, If there is enough bolt left you want to take two nuts and screw them both on all the way then tighten them against each other. Then you just want to put the wrench on the inner nut and try to twist it off. Since I doubt there is enough stud to get two nuts on the next best bet is Vise Grips or something like that. Those bolt extracting sockets and stuff you can get at sears look pretty schnazzy and would be one of the next things I would try. I don't have any personal experience with these so I cant tell you if they work as well as they say they do.

If the stud is sheared flush with the head you have a little more work to do. You will still want the manifold off since it will make your job a lot easier, and it's probably not going to be easy any way you cut it. you might as well get a new manifold gasket while you are at it to get a good seal when you put it back together. Also replace all your manifold studs and nuts to reduce the chance of this happening again. Use OEM or better, if you look around on this site you can find sugestions for better studs, I think ARP may make some but I am not sure.

You will need a drill, pilot drill bit, large drill bit, center punch, a can of penetrating oil and a bolt extractor which you should be able to get at Sears or probably a hardware store. A reverse drill bit is nice since you will drill in reverse and if the bolt is somewhat loose it will unthread, exhaust mani bolts are rarely loose though so you would probably be fine with a regular bit.

Soak the manifold bolts as long as possible in penetrating oil, Preferably a few times a day for 1 or 2 days.

The large drill bit should be just a little smaller than the bolt, small enough that while you are drilling it out you dont angle out and dig into the threads. Your extractor should be as big as possible other wise they can break and they are a pain to get out.

Use the center punch to get a good dent in the center of the stud, next drill a hole with a small pilot bit (I would use a 9/64 or so) keep the hole dead center and drill 1/2" deep or so. Next drill your larger hole (If you need help someone at the hardware store should be able to help you match up a proper drill bit, with a proper extractor for your bolt) Keep the hole dead center. Tap the extractor in with a hammer then use it to unscrew the bolt, being very careful not to break the extractor.
Well I think that should do it.

 

[TDC GSX]

Thanks for your reply. The stud is flush with the head of the block. This will help out a lot. Would it help to take the whole head off along with the exhaust manifold, so that I have full access to where the stud goes and I am able to get to it better than if I left it in the car(The Head)? It sounds like a lot of work, I would agree but it has to be done to prevent more damage.

Thanks

TDC GSX

 

[Mackzero]

You can get the stud out w/o taking the head off. That is A LOT of unneeded work to do for something like that. If you do take off the head, get ready to spend some money fixing EVERYTHING else that you find wrong, which will be quite a bit.

 

[92awddsm]

Thanks for your reply. The stud is flush with the head of the block. This will help out a lot. Would it help to take the whole head off along with the exhaust manifold, so that I have full access to where the stud goes and I am able to get to it better than if I left it in the car(The Head)? It sounds like a lot of work, I would agree but it has to be done to prevent more damage.

Thanks

TDC GSX

It would be easier to remove the fans and radiator to gain total access to the head instead of pulling the head itself. It will also be cheaper because you wont have to buy a new hg. My buddie and I just did this on his car a couple of months ago and it was easy. It took about 30-45 mins for us to remove the manifold, drill and extract the old stud, install new, and put everything back together. He is a very competent mechanics and I am an ASE automotive machinist so Im sure this made things go a little quicker. Just take your time and be gentle.

 

[TDC GSX]

Thanks DSM Tuners for your help

TDC GSX

 

[Tallen]

For gods sake, do NOT use a small extractor. You don't want to break it.