How to Repair Broken Exhaust Manifold Bolts

What You'll Need
Penetrating grease dissolver
Adjustable wrench
Torque wrench
Propane torch
Fire extinguisher
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 grease cutter for 6 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

Drill 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 1 bolt to the auto shop for correct replacement bolts.

Step 6 - Replace the Exhaust Manifold Gasket

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 with your fingers. With a torque wrench, tighten the bolts to the correct tolerance as specified in your owner's manual.