So in the process of what should have been a fairly simply process, a bolt is now broken. Me and a friend were doin a quick swap for the megan racing header to the buschur ported and jet coated one. We got all the bolts off no problem until the very last one. It is the one where the manifold bolts up to the turbo, left side, towards the motor. its a b**** to get to to begin with but we got to it with an extension and a swivel and started going at it.

About half way out, it seized. We tryed everything to get the damn thing out. PB Blaster was the first choice. No such luck. So last night we brought over a friends torch to try to heat the metal and get it out. Might not have been the smartest idea, but it was out last option. To bolt then snapped. So tomorrow we will drill and tap it and hopefully nothing goes wrong.

Moral of the story, dont use home depot bolts on your Evo. The End.

 

Sorry to hear your dilema, I've had a similar experience and believe me it sucked, the torch ended up being the winner in the long run, but I'd suggest second time around to get yourself some stainless steel studs

 

or buy them from the dealer because they're special bolts that are made to handle a certain amount of stress.

 

yeah i bought mine from the dealer had to wait a few days since there special order...

 

I had the same thing happen with dealer bolts. Machined them out at a friends shop. I think the bolts just go through too much stress all together.

 

pretty normal for those to seize... call amber at FP & get some bolts from them.

 

Sorry to hear.

This happens all to often. Next time (and there will be a next time lol) as soon as you pull the car in to let it cool so you can start working on it, hit it with the pb soak it and let it soak for an hour or two or even three, it does help. Good luck fixing it!

Evan Smith

 

I feel your pain. I have had at least 4 sized bolt issues relating to turbo manifold O2 installs. To quote Robert "Use the anti-sieze *****!"

 

I feel your pain. When I installed mine it cost me a radiator....yeah don't even ask.

 

I always use OEM bolts, always replace them every time whether they look like they need it or not, and always crack them loose while the engine's still hot. Never broke one yet.

 

After going through the same type of B.S. on my GTI, I always use anti-seize on _all_ bolts that get hot (unless they need locktite). You know you will be taking the stuff apart at some point, so why not make life easier? Just my 2 cents. Make sure you've got some good drill bits for the removal or you will be wasting a lot of time trying to get that out. I've found that even home depot bolts will loosen up, though I would use OEM quality when possible...especially where heat / stress is an issue. Sometimes I will use lithium grease.

 

Same thing happened to me, I was so pissed. it was the bolt towards the front of the car though. I ended up having to drill it out and retap it... not so bad, just annoying.

 

I believe the exhaust manifold studs come close to the water cooling jackets in the block so be careful how far you drill.

 

Yah, well I'm gonna ask anyways. How?

 

Yeah, anti seize is the key for future issues. Also, when you finally get the bolt out and re-tap the hole use the tap on the other ones to deburr the hole and find the tap for the bolts too and deburr those it helps like no other. Same on the bolts on the block deburr and anti seize