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.
Broken air injection bolts
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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.
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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 manifoldKurt; 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
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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
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Originally posted by coreyw454It's not a daily driver. If I end up having to pull the manifolds I will try your acetone mix. Thanks
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
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Originally posted by rang-a-stangcontact 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
'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
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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 off1985 Grand Wagoneer (current project)
1973 Wagoneer (next project)
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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
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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
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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
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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
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