Broken air injection bolts

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  • coreyw454
    232 I6
    • May 09, 2017
    • 91

    Broken air injection bolts

    In attempt to pass CA smog I was working on the "emissions" system and broke 3 of the 7 bolts holding the air injection rails on. is there any chance in hell i can get these things out with the manifolds on? should i just get new manifolds. I knew I should have just gone EFI. between this and all the damn vacuum lines i am gonna lose it.
    1985 Grand Wagoneer (current project)
    1973 Wagoneer (next project)
  • yossarian19
    258 I6
    • Nov 13, 2016
    • 402

    #2
    Hooo boy.
    Those aren't bolts, they are extra-special banjo fittings with a long tube sticking off the end. Good luck finding replacements.
    As for getting them out of the exhaust manifold while in the car... I tried. I failed. Eventually I just had to drill them out on the work bench.

    Comment

    • coreyw454
      232 I6
      • May 09, 2017
      • 91

      #3
      I have replacements. Im just concerned with getting the broken ones out.
      1985 Grand Wagoneer (current project)
      1973 Wagoneer (next project)

      Comment

      • yossarian19
        258 I6
        • Nov 13, 2016
        • 402

        #4
        If this is your daily driver, I'd try and bring it to a shop. This has the potential to get nasty.
        I tried everything I could think of or read about to get them out of the exhaust manifolds without pulling them. I broke two tap handles trying to use an EZ out on them, even with heat & penetrating oils & all the rest.
        I recommend mixing acetone and transmission oil 50/50 in a spray bottle. It's a fantastic penetrating oil for rusted fasteners. Much better than off the shelf stuff - any of it.
        Spray all exhaust manifold bolts, at the head and at the pipes, and wait. Then crack the fasteners loose a little bit. If they still feel stiff / scary, spray them again. And wait.
        I managed to get my manifolds off without breaking anything, and they were pretty crusty.
        If you break a bolt you are pretty much into it for pulling the heads, so take your time.

        The best I could come up with without removing the manifolds was to heat the area up as hot as a propane torch would get it & touch the stubs with a candle to melt wax into the threads. It gets "sucked" into the threads by capillary action, in theory, and makes them easier to turn. Then use a tap handle and EZ Out to turn the broken fitting out. It didn't work for me, at all, but it might work for you. If you have an acetylene torch, all the better.
        If you don't have a candle and or torch, the 50/50 mix would work too: you just want to work on the threads a bit before trying to turn them.

        Comment

        • coreyw454
          232 I6
          • May 09, 2017
          • 91

          #5
          It's not a daily driver. If I end up having to pull the manifolds I will try your acetone mix. Thanks
          1985 Grand Wagoneer (current project)
          1973 Wagoneer (next project)

          Comment

          • BadRat
            232 I6
            • Dec 06, 2015
            • 68

            #6
            Good Luck....
            All of mine came out easily on driver side, broke two on the passenger side.
            I tried every trick in the book....
            soaking them in everything I could...
            heating with a propane as well as oxy/acet torch...
            soaking and waiting and soaking and heating and cranking with an easy out, repeat over and over....
            The only thing I ended up accomplishing was breaking the manifold bosses around the banjo bolts and cracking the manifold....go figure.

            Ended up having to buy cheap replacement manifold
            Kurt; but you can call me anything you want, except late for dinner
            1988 Jeep Grand Wagoneer

            Member, FSJ Prissy Restoration Association

            Hand me that doo-hickey wrench thing, and a beer

            Comment

            • rang-a-stang
              Administrator
              • Oct 31, 2016
              • 5466

              #7
              contact this guy:

              and see if you can buy his manifolds. I think they are the same from 85 and down and change on 86 up. Anyone know for sure?

              Maybe this guy, too:
              Chuck McTruck 71 J4000
              (Chuck McTruck Build Thread)
              79 Cherokee Chief (SOLD, goodbye old buddy)
              (Cherokee Build Thread)
              11 Nissan Pathfinder Silver Edition 4x4
              09 Mazdaspeed3 Grand Touring
              00 Baby Cherokee

              Comment

              • babywag
                out of order
                • Jun 08, 2005
                • 10284

                #8
                Originally posted by coreyw454
                It's not a daily driver. If I end up having to pull the manifolds I will try your acetone mix. Thanks
                If broken, just take manifolds off and then to exhaust shop.
                Or go borrow/rent a torch.
                Heat & lots of it they'll spin right out.

                Or if have access mig, weld some small grade 8 bolts to them and try that.
                Tony
                88 GW, 67 J3000, 07 Magnum SRT8

                Comment

                • babywag
                  out of order
                  • Jun 08, 2005
                  • 10284

                  #9
                  Originally posted by rang-a-stang
                  contact this guy:

                  and see if you can buy his manifolds. I think they are the same from 85 and down and change on 86 up. Anyone know for sure?

                  Maybe this guy, too:
                  https://modesto.craigslist.org/pts/d...227113905.html
                  passenger side same all years.
                  '80-up drivers side same

                  '79-down drivers side won't work w/o y-pipe modifications.
                  Tony
                  88 GW, 67 J3000, 07 Magnum SRT8

                  Comment

                  • coreyw454
                    232 I6
                    • May 09, 2017
                    • 91

                    #10
                    I ended up doing what Michael King did here on the thread I am linking below. I have smog appt this coming tuesday. just need it to pass and then hopefully by next emissions test its fuel injected.

                    spent most of the morning yesterday pulling a set of air injection manifolds off a junker, ALL the banjo's came out great:) ...should have known my luck would run out somwhere...forward to my rig....tools-check...bolts soaked in freeall-check....coffee and nicotine-check:cool: ...things are goin great get the passenger side off
                    1985 Grand Wagoneer (current project)
                    1973 Wagoneer (next project)

                    Comment

                    • rang-a-stang
                      Administrator
                      • Oct 31, 2016
                      • 5466

                      #11
                      Good luck! Make sure you get your cat really hot before you go!

                      Did you "fix" anything since your pre-test?
                      Chuck McTruck 71 J4000
                      (Chuck McTruck Build Thread)
                      79 Cherokee Chief (SOLD, goodbye old buddy)
                      (Cherokee Build Thread)
                      11 Nissan Pathfinder Silver Edition 4x4
                      09 Mazdaspeed3 Grand Touring
                      00 Baby Cherokee

                      Comment

                      • rang-a-stang
                        Administrator
                        • Oct 31, 2016
                        • 5466

                        #12
                        Any updates? Did you pass smog?
                        Chuck McTruck 71 J4000
                        (Chuck McTruck Build Thread)
                        79 Cherokee Chief (SOLD, goodbye old buddy)
                        (Cherokee Build Thread)
                        11 Nissan Pathfinder Silver Edition 4x4
                        09 Mazdaspeed3 Grand Touring
                        00 Baby Cherokee

                        Comment

                        • coreyw454
                          232 I6
                          • May 09, 2017
                          • 91

                          #13
                          smog numbers are good. but failed EVAP. need to replace fuel filler and vent hoses. they are ordered.
                          1985 Grand Wagoneer (current project)
                          1973 Wagoneer (next project)

                          Comment

                          • JeepJeepster
                            350 Buick
                            • Sep 04, 2014
                            • 835

                            #14
                            So you JB welded a 1/4" brake line back into the manifold?

                            I just took the manifolds off. Think I ended up snapping 1 bolt off but I had no issues drilling it out. My mission wasn't to put new banjo bolts in though, I was plugging them with bolts.

                            what did they fail on the EVAP? Had a leak somewhere?
                            2004 Jeep Liberty
                            1998 Jeep ZJ 5.9
                            1994 Jeep ZJ I6
                            1989 Jeep Grand Wagoneer 360

                            Comment

                            • rang-a-stang
                              Administrator
                              • Oct 31, 2016
                              • 5466

                              #15
                              roger that. Evap got me 3 times (twice officially and once informally). Mine was a failed fuel return line at the top of the tank and the line that went from the evap to the fuel filler neck via the check valve in the rear quarter panel. Make sure you check those, too when you install your filler neck.
                              Chuck McTruck 71 J4000
                              (Chuck McTruck Build Thread)
                              79 Cherokee Chief (SOLD, goodbye old buddy)
                              (Cherokee Build Thread)
                              11 Nissan Pathfinder Silver Edition 4x4
                              09 Mazdaspeed3 Grand Touring
                              00 Baby Cherokee

                              Comment

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