KA24DE Manifold Studs, and not breaking them!

[unicoder]

Hey! I am installing a turbo on my car, and was having no issues on any of the manifold bolts or exhaust bolts. Lot's of PB Blaster was helping with that!

However when I went to bolt the new manifold on, the first stud broke off in the head, with just my hand in a 3/8"s ratchet and hardly any torque at all.

I drilled and tapped it one size bigger, but don't want to risk this on any other studs. So I bought brand new studs and want to make sure I install it and do it correctly.

Question: I have read in past builds you hand tighten the stud, then torque the nut on with the manifold, is that how I should do it this time?

Thanks!

[TheRealSy90]

Thread the stud all the way into the head. No reason to torque the stud into the head.
Why did you tap the broken stud hole a size bigger instead of just removing the broken stud?

[unicoder]

Thread the stud all the way into the head. No reason to torque the stud into the head.
Why did you tap the broken stud hole a size bigger instead of just removing the broken stud?

No matter how I tried I couldn’t get it out. Eventually just drilled it out but I drilled too large a hole. It was my first experience with a broken stud

[apex128]

That sucks. What you can do is just thread them in by hand, or do the double nutting method and put them in with 'hand tight' amount of torque (very little). The way you do the double nutting method is by putting two nuts onto the stud, tightening them together, and then using the inside nut to turn the stud. I snapped a stud on my head, and I just drilled it out and put a bolt in there. Its kind of a pain to line it up sometimes, but it seals fine. Also torque sequence is very important for manifold stuff. My header was leaking and all i did was retorque with the sequence, and it fixed the leak. Good luck

[chapman.dm]

For future reference you can use alum to dissolve a stud out of aluminum.

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