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Broken Intake Manifold Bolts

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10K views 7 replies 5 participants last post by  Lowcountry idn  
#1 ·
Hey all,

My X started misfiring last night (Cylinder 1 Misfire). I brought it home and took the plenum and everything off and noticed that three of my bolts have been broken. I am not sure if this was done by the previous owner or what, but that's beside the point. Two of the bolts have sheared off right at the top of the block, so I have nothing to grab with pliers or anything.

I was able to order a complete new set of bolts and studs from Nissan for $13 but I still need to figure out how to get the two bolts out. I thought about taking a Dremel with a very thin cutting disc and cutting a slot into the top of the bolt in order to try and use a flat head screwdriver to get them out. That will most likely be my last resort.

Are there any bits or tools that would be able to extract these? I want to avoid drilling them out if at all possible.

Thanks!

My cylinder 1 coil was pretty corroded on the inside, which explains the misfire.
 
#2 ·
If they are broken flush those are about your only two options, just be extremely careful when drilling with a hand drill and if you break an easy-out off then you will be pulling the head for sure, if you do drill it out and use a easy out if you can apply heat while doing it that will make things much easier. Good luck at least you got the misfire takin care of.
 
#3 ·
UPDATE: The dremel worked wonders! I put some penetrating oil on the bolts, and they reversed right out with ease!! I also found bolts at my local hardware store that work perfectly for the intake plenum!!! $0.50 per bolt! Plus they are 10.9 Stainless so they will be much stronger
 
#8 ·
Plus they are 10.9 Stainless so they will be much stronger
I'll make one comment - obviously won't be an issue for you but engineers don't use week bolts by accident. Bolts like this are designed to be the point of failure. If your PO had use stronger bolts - they would have stripped the head, not broken the bolts - and you would be replacing something far more expensive. The OEM bolts weren't chosen by accident.