How to Repair Broken Exhaust Manifold Bolts

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.