Exhaust manifold heat shield bolt sheared

[rapandi]

Hi team

 

One of the bolts that holds the heat shield to the exhaust manifold got sheared off by PO. 

 

I am lost as to how I can pull the sheared shank of the bolt out????

 

Any ideas???

 

Regards

 

Raj

[Simeon]

That will be very stuck in place. You can try drilling a hole and using an ezy-out of an appropriate size. Failing that, drill it out an re-tap the hole the next bolt size up. 

 

Just a bit of trivia, that hole goes all the way through to the runner. When I replaced my manifold recently, I left the hole without a bolt. When I started the car, I could hear a high pitched whistle and could see a small, condensed plume of exhaust coming from the hole. 

[D.martijn]

Before drilling it out I would try to weld a nut on top of it. it's still sticking out a bit so i should be possible.

If the nut snaps off, I would resume to drilling it out like Simeon suggested.

[wegweiser]

if it were me, I'd get an acetylene torch, or find a shop with on and a friendly employee. Heat the surrounding metal red hot. Take a tiny chisel and see if you can move it... or an easy-out while the manifold is still hot. I've learned (the hard way) to never remove these without first heating things up. 

[Dudeland]

1 hour ago, wegweiser said:

if it were me, I'd get an acetylene torch, or find a shop with on and a friendly employee. Heat the surrounding metal red hot. Take a tiny chisel and see if you can move it... or an easy-out while the manifold is still hot. I've learned (the hard way) to never remove these without first heating things up. 

+1 on this, weld a nut to the top and heat the hell out of it (cherry red) that is the only way this is coming out. 

[oldguy]

If it were me...  I'd give up on getting it out..  chuck it up in the mill..  Drive a 5/16" end mill into the hole and helicoil it.  To drill it, you're gonna have to grind it flat and center punch it.  At that point I'd drill out from the center with larger and larger left hand drills but you're gonna be a while

[Son of Marty]

I'd forget about it and run the later 320i gasket with the built in heat shield. 

[Mike Self]

When you do get it out...use a stainless steel bolt liberally coated with anti-seize paste.  The original thread size, BTW is 6x1mm.

 

mike