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Old 09-05-2019   #16
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Re: Engine block exhaust manifold stud snapped

the end of the bolt is only 1.5mm inside the head?
That doesn't seem like it has enough of the head to hold onto?
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Old 09-05-2019   #17
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Re: Engine block exhaust manifold stud snapped

Please All, use correct wording when talking about technicall parts !!

Screw: threaded rod with a head, which can have various shapes
Nut: usually hexagonal, it matches the screw's thread
Bolt: assembly of the two previous parts
Stud: "headless" screw

And BTW the OP talks about "cleaning the maniverter" That makes absolutely no sense, translated in French (my native language) it could be retranslated as "cleaning the handling" or "cleaning the way to manipulate things". Manifold is the correct name for that part.

BRs, (grumpy) Bernie
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Last edited by Bernievarian; 09-05-2019 at 10:29.
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Old 09-05-2019   #18
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Re: Engine block exhaust manifold stud snapped

Quote Originally Posted by llamallama View Post
the end of the bolt is only 1.5mm inside the head?
That doesn't seem like it has enough of the head to hold onto?
What I meant is that the stud has broken so, that there is a "hole" of 1,5 mm in the head. The broken part of the stud probably has about 12-13 mm of it still inside the head. See the attached illustration.


Quote Originally Posted by Bernievarian View Post
And BTW the OP talks about "cleaning the maniverter" That makes absolutely no sense, translated in French (my native language) it could be retranslated as "cleaning the handling" or "cleaning the way to manipulate things". Manifold is the correct name for that part.
Well, it's is the word Fiat and many others uses for that part The combined manifold + catalytic converter. If it didn't have a built-in catalytic converter, then it's just an exhaust manifold.
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Last edited by torniojaws; 09-05-2019 at 14:44.
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Old 09-05-2019   #19
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Re: Engine block exhaust manifold stud snapped

Ah yep, got ya
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Old 09-05-2019   #20
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Re: Engine block exhaust manifold stud snapped

I wouldn't worry about trying to get it out,
Just seal it up and that's it,
You would still be able to get the manifold off,
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Old 10-05-2019   #21
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Re: Engine block exhaust manifold stud snapped

Quote Originally Posted by llamallama View Post
I wouldn't worry about trying to get it out,
Just seal it up and that's it,
You would still be able to get the manifold off,
Might lead to gas leaks and wry maniFOLD!
The MIG welding method has been described many times in this forum and has proven its efficiency...

BRs, Bernie

BTW: manifold + converter = maniverter ... How about a manurbo ??

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Old 10-05-2019   #22
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Re: Engine block exhaust manifold stud snapped

Quote Originally Posted by Bernievarian View Post
Might lead to gas leaks and wry maniFOLD!
...
BTW: manifold + converter = maniverter ... How about a manurbo ??
...
How about clutchmission?
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Old 10-05-2019   #23
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Re: Engine block exhaust manifold stud snapped

How about clutchless like the konissegg

Woot
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Old 10-05-2019   #24
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Re: Engine block exhaust manifold stud snapped

@torniojaws - have you seing my thread about the same issue? Just drill that stud with 6mm drill 1.5cm inside and then use heat gun + extractor (that conical tool with anti-clock-wise thread. If it doesnt help, just drill it with 8.5 like me, use thread tool 10 and use new stud 10
Just like Bernie said - if you dont solve this issue, it might lead to gas leaks and wry ex manifold. I had also wry manifold and sanding it to flatness was hard manual job
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Last edited by Rado77; 10-05-2019 at 12:00.
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Old 10-05-2019   #25
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Re: Engine block exhaust manifold stud snapped

Yup, I have a set of left-handed cobalt drill bits + extractors ordered and on the way, along with 8 new bolts
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Old 4 Weeks Ago   #26
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Quote Originally Posted by torniojaws View Post
Yup, I have a set of left-handed cobalt drill bits + extractors ordered and on the way, along with 8 new bolts
Let us know how it works ;-) Plus pictures if you take some...
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Old 4 Weeks Ago   #27
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Re: Engine block exhaust manifold stud snapped

The most difficult with this drill and extract method is to center the drill bit in the remaining stud. If there ain't enough deepness to install a centering tool as I previously showed, you could reinstall the manifold and use it as a guide, using a dowel where the stud is missing ...

BRs, Bernie

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Old 4 Weeks Ago   #28
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Re: Engine block exhaust manifold stud snapped

Well, the 8 studs for the manifold arrived, but still waiting for the drill bit + extractor. The studs look correct (well, they should be since the part number matches ).

But meanwhile, I noticed that the head gasket appears to be leaking. Not sure if they are all related, but if the cylinder cover is warped, it's beyond me and my equipment. It would probably be an expensive repair at around 1000 EUR (1100 USD), which is quite close to the actual value of the car itself :P But let's see what the service says. If it's more than 1000 EUR, then I guess I'll just sell the car for parts and get something else. It's a shame, as the car is otherwise in good condition (passed the inspection just a few months ago) and it's a fun car.

Here's the full chain of events btw:

1. Brought the car for the yearly inspection, where it failed due to emissions (they measure it from the exhaust pipe)

2. Following a tip, I filled it with a 40/60 mixture of E85 (ethanol fuel) / regular 95 RON, and then I drove around for about 25 mins at around 4000 rpm +/- something.
3. The car passed the inspection with mostly 0 emissions, with occasional spikes at just below max passing emissions. After the inspection, I filled the car with normal 95 RON fuel to max.

4. But after that, the car smelled quite bad for a week, but then it started to get back to normal.
5. However, there still remained a lingering bad smell in both the exhaust fumes and also under the hood.
6. I noticed that the pre-cat oxygen sensor was actually smoking from around the hole even when idling, even though it was tightened to spec. I then thought it's just some WD-40 residue burning off, which I applied a day before the next step on the studs and the exhaust pipe bolts.

7. So then I washed the catalytic converter (this thread), and used new gaskets for the manifold and the exhaust pipe side, plus applied new copper paste on the pre and post cat oxygen sensors. That's when the stud snapped, but it didn't show any signs of leaking, flames or odd behaviour.

8. After that, the car still worked well (the oil temperature never rose above nominal), but still smelled quite bad. I didn't see any oil near the cylinder cover.
9. Then after driving for a week or so, I checked how it looked and then I noticed the area just below the cylinder cover having a little bit of oil across the length. Kind of odd, because I never touched that part - just the manifold that is much lower.
10. That's when I stopped driving it, and now I have the service booked for Friday.
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Last edited by torniojaws; 4 Weeks Ago at 15:58.
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Old 4 Weeks Ago   #29
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Re: Engine block exhaust manifold stud snapped

Okay, got the verdict back, and it isn't too bad. I probably could have done it myself, if I knew it was just the gasket. No machining needed.

The oil leak is from the cylinder gasket, and the cylinder is not warped.
The bad smell is because of a cracked breather hose.

So probably not too expensive.
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Old 4 Weeks Ago   #30
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Re: Engine block exhaust manifold stud snapped

Thanks for the update !!

BRs, Bernie
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