exhaust manifold question

[DrifterXRPS13]

trying to install header, but don't know how to take off old manifold. i'm missing half of the old bolts, not sure if they're broken off the head but i'm sure the bolts that are left will also break off in the head, in the case that this does happen what are my options at that point?

[574-240sx]

If you can't get them out you will have to drill them out and retap them. The manifold is a pain to get off of the car if it has never ben taken off. Just give it a few sparys of rust penatrate on the bolts and let it soak in before you start.
Modified by 574-240sx at 6:08 PM 11/12/2004

[DrifterXRPS13]

what exactly do i need to do to remove the bolts from the head? step by step would be awesome.

[s13sr20chris]

i would start by sticking a pencil eraser on the stud and trying to twist it out. that may get some of them out. then i would get an extractor set(my favorite is the straight flute snap-on extractor set~$100). drill tiny hole in center(centering is very important here) and use extractor to remove stud. if you have any left you will need a helicoil set(about $20). this will give you a drill bit to drill out stud AND threads in the head. it also gives you a tap to tap new threads. theese threads are for helicoils only and no bolt will fit them. then you thread in the helicoil. try not to drill into the heads water jackets. if you drill into the water jackets you need some rtv in the hole, on the helicoil, and the stud.

[DrifterXRPS13]

thanks for the write up but it looks like i won't need it, i took off my old bolts and put one of them into the other threads and they fit fine, looks like they just fell out over the years of engine movement.

one thing i do need help on is the removal of the egr. i can't get that bastard off, i've been spraying it with spray lubricant, and i've used a plumbers wrench that's as long as my arm, and i don't know where to go from here. how do i get it off and i also removed my aiv so what should i use to plug the bung where the aiv would go? thanks for all your help chris

[s13sr20chris]

that egr sucks. is it just too tight? or can you not fit a wrench on it? a big adjustable usually does it for me. aiv plugs are available from heavy throttle.

[DrifterXRPS13]

yea the egr does suck. it's too tight and i can't get an open ended wrench that's big enough to fit on it. i'm als puzzled on which way i would turn it to loosen it? if i'm working in the engine bay would i turn it towards the passenger side or the drivers side? someone said counterclockwise but is that from the point of view that i'm describing or is that from another p.o.v?

[s13sr20chris]

counterclockwise from the head(the flats that the wrench fits on) towards the threads point of view. flats towards you, threads on other side.

[DrifterXRPS13]

thanks for all the help, i finally got it off!