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SPI Performance (2000-2004) The place to chat about any 2.0L Split Port Injection engine performance, tuning and exhaust related upgrades.

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Old 05-03-2014, 11:11 PM   #1
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Exhaust manifold bolts...

I'm sorry If this is a repost but I can't find anything about it with the search function in tapatalk.

I have
2003 split port

My problem
Two of the bolts that go into the head are broke off and completely flush with the head. In my efforts to try and quiet my car down I'm noticing more and more the horrendous manifold leak. Is there an EASY way to fix this? Is it as simple as carefully turning the broken bolts out and threading new in? Or will it need more serious things such as a drill and tap.

I'm capable of doing all of the above but can't be without my car for a day or so. So I need to know what I'm going to need to acquire to do the job before I pull it apart.

I'm already figuring I'm going to spray all the other bolts with a good penetrant the night before and.

Any help is greatly appreciated!

I can get pics tomorrow if you guys want to see exactly what I'm talking about.


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Old 05-04-2014, 03:26 AM   #2
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Moved to "SPI Performance" as these people here might have better answers for you.
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Old 05-05-2014, 04:37 PM   #3
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Can't give any great answer, you'll have to try it & see how it goes.

Have the gasket & studs avail. & make it a weekend project.

If they're flush with the head (not the manifold) drill & easy out to unscrew is the first trick to try. After that it's careful drilling & picking out the crescent of steel remaining (you never get the drill perfectly centered). Tap to clean the threads helps after drill & pick out if needed. Spare bolt in the same size can be used as a tap if you grind slots thru the threads with a narrow cutoff wheel.

Not a fun job, hope they thread out easily for you.
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Old 05-05-2014, 05:36 PM   #4
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I've always used the mig and build up the stud 'till you can get a pair of vice-grips on it, or tack a nut to it and then turn it out. just did it to 2 studs when swapping engines from the wifes car to her new-to-her car.
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