I just put a 1.6 8 valve in my zuk. I had my header on order so I just hooked up the stock exhaust manifold to check the engine, leaks, timing, etc. I snugged up four of the nuts just to hold the manifold on since I wasn't going to be driving it any until I got my header. Well, I got my header and was going to bolt it on when I discover the lower hole closest to the firewall has a broken bolt snapped off in it. I guess when the salvage yard pulled it from the wrecked tracker they snapped it off [img]images/graemlins/cussing.gif[/img]

Anyhow, now I need to know how to get it out. Isn't there a tool you can buy to do this?

Also, I went ahead and bolted my header on and it wasn't leaking so is it ok to drive it until I can get the broken bolt out?

The tool is called a screw/bolt extractor, you can pick one up at most auto/hardware/industrial supply store. As for driving with the missing bolt, I wouldn't do that over time the heat may cause your brand new header to warp and leak!

Broken bolts [img]images/graemlins/spank.gif[/img]

I knew eventually somehow they could break, always wondered if you were screwed out of an engine or what...sorry to hear about your loss, keep us posted on how it goes

i have had to have broken head bolts extracted before. i was far too impatient so i just had the machine shop extract them for me. cost me a little over $30 each time. i would have wasted a rare afternoon off getting those suckers out so $30 was well worth it for me.

$30, was that with the engine in the vehicle or did you remove the head?

sorry i wasn't very clear. the engines were removed for build up and when i tried getting the head bolts out one snapped on each one. i took the engines to the machinist out of the vehical. i imagine a desent machinist could get your broken bolt extracted with out you having to take the head off because the area is accessable if you removed the exhaust manifold after you get there.

i just have had horrible luck using the various bolt extractors myself. i know some people are very good at it but i am not. for me it is hard to drill or extract a hardend bolt/stud that is surrounded by soft aluminum. maybe someone knows the proper way to do this effectively by themself and can shere their knowledge with us.