intake mani- skip one bolt?
 

So, I got my ported intake manifold and throttle body back from Buschur today and decided to take my car apart tonight. I got the intake manifold off in about 2.5-3 hours, not bad for a first timer!

Now, with my awesome luck, when I was putting all of the bolts back into the head with the new manifold, I must have grabbed a seemingly identical bolt to the others but it must have been about 3-5mm longer, as it got snug before it was all the way down. I noticed this as it started to torque, and decided I better back it off to see what the deal was. Went out really easy, so it occurred to me it might have just been tweaked from the other bolts being tight. Well, not the case, as soon as it got snug and met the lightest torque, it broke. :)

So, off came the manifold, and in with the drill bits. Drilled a small bit in, got some good depth, then decided to go another wee bit further with that bit. Sure enough that bit snapped off in there. So, it would not come out. A few bigger bits and extractors later, I am no where.

I love cars :)

This is the centermost top bolt holding the intake manifold on. I'm putting a fresh gasket on. Any chance if I just skip this bolt it will hold 100% pressure and not leak from that spot?

Let me know your insight.

Re: intake mani- skip one bolt?
 

Even if it does hold, the dsm gods will come back to haunt you. Just get an easy out and back the bolt out.

Re: intake mani- skip one bolt?
 

Skip it, you'll be alright. Now it's a true dsm at heart.

Re: intake mani- skip one bolt?
 

For sure!

Re: intake mani- skip one bolt?
 

Like I said, I tried an extractor and one of the drill bits broke off inside of the hole I made. :(

Think it'll hold 30psi? I'm pretty leery....

Re: intake mani- skip one bolt?
 

Don't you read good? easier said then done.

I am with mo, nice 4 door DSM.
The only other way to see is put it together and do a boost leak test.
Good luck.

Re: intake mani- skip one bolt?
 

Re: intake mani- skip one bolt?
 

Let er buck

Re: intake mani- skip one bolt?
 

Man that sucks.. Last resort would be to drill a bit bigger than the bolt and retap it.

Re: intake mani- skip one bolt?
 

you'll have to go get diamond tiped bits to get it out and that'll just be a pain in the ass. let it go i left one bolt out of my car cause im lazy and the manifold seals fine

Re: intake mani- skip one bolt?
 

I broke one of my fuel rail bolts off in my head(you should think that steel would strip out aluminum before the bolt would break) Anyways What I did was took a screwdriver or chizel and used it to make a groove in the bolt so I could try and use a straighthead screwdriver to try and get it out. OR I stuck the corner of the screwdriver into the top and hammered it in a counterclockwise to loosen the bolt. If that makes any sence. good luck with it man!

Re: intake mani- skip one bolt?
 

Thanks for the advice guys. I offered my secret helper some cash to have a go at it, otherwise I'm just going to bolt it up tonight and let'er rip. I do boost leak checks often enough that if it doesn't leak right away and starts later, I should catch it.

Re: intake mani- skip one bolt?
 

I wouldn't skip it, but thats just me.

Re: intake mani- skip one bolt?
 

I don't know if I'd skip it either, I'm kinda fussy. You are real lucky it's on the front of the motor and easy to get to. If it was on my car, I would probably skip it.

Re: intake mani- skip one bolt?
 

I will be over later with the diamond bits to get it out

Re: intake mani- skip one bolt?
 

+1. sry i didnt know which bolt you were talkin about before.

Re: intake mani- skip one bolt?
 

I wouldn't skip it either. You know damn well the gasket will blow out at the worst possible time (racing a Ferrari) and it will run like ass.

Re: intake mani- skip one bolt?
 

Awesome Mark! I am just out of drill bits and patience, I hope you have better luck than I did!

If it comes down to it, I guess I'll just pull the head off, take it to a machine shop, and do a full timing belt and water pump job on the thing. It's due soon anyways, the car just rolled over 50k miles.

Re: intake mani- skip one bolt?
 

one thing I have done in these cases (especially when drill bits or extractors break off) is get my trusty dremel and a thin 3/16" carbide burr and take the hardened tool that broke down to the surface again and start drilling (carefully) again. 9 times out of 10 this has worked for me.

Good luck!

Re: intake mani- skip one bolt?
 

Oh you can get these carbide burrs for dremels and die grinders at grainger

Re: intake mani- skip one bolt?
 

I have used them but nwa donated a ton of diamond bits to me when I was still working there

Re: intake mani- skip one bolt?
 

The intake manifold is still on the back of the engine bay, its the new evo the Intake manifold is up front. I would get the broken bolt out.

~John

Re: intake mani- skip one bolt?
 

FYI for anyone else, carbide tipped masonry drill bits work the best for these types of things. The drill bit will not break like a normal one, they have some flex to them. They also work great and drilling out broken drill bits, if you can get at it well. Diamond burrs work good too.

Re: intake mani- skip one bolt?
 

I can't really tell from the pics or the writing in the first post, but is the bolt broken off with nothing sticking out of the hole? If it had any on there, you'd probably be in a better situation.

Good luck with the diamond bits, but I am with the people who would get it out. I have helicoiled a head before and it's really not hard, plus helicoils, once installed, are stronger than the aluminum threads anyway. I'd definately try other things first though.

Re: intake mani- skip one bolt?
 

well it is all fixed and retaped to 8 1.25
tkr
mark

Re: intake mani- skip one bolt?
 

Holy crap popsicle THANK YOU MARK and your dad! Over an hour grinding with a diamond tipped bit, and it holds PERFECT. I was sweating bullets this morning, and tonight I will sleep well!

Re: intake mani- skip one bolt?
 

from all the anal right

Re: intake mani- skip one bolt?
 

I definitely was not psyched about the outcome this morning and today, felt like a good solid stick up the butt!
http://scheides.com/misc/pics/beatdown.gif http://scheides.com/misc/pics/omg-onoes.gif

All is well now :)

http://scheides.com/misc/pics/jsimpson-carwash.gif
http://scheides.com/misc/pics/breakbear.gif