Well this is not good. I was replacing valve covers with the 2004 covers and changing spark plugs. Once everything was done, I went to install the upper air intake collector. I managed to mix up a bolt and tried forcing it in, when I noticed the threads of the wrong bolt had aluminum shavings!!

Once I found the right bolts, I noticed the bolt would turn forever and not tighten.

What are my options for getting this fixed? Tap the bolt hole for go for a larger bolt?

Also, I notice after swapping the valve covers a oil burning smell (or rubber burning, or plastic) after driving 10-20 minutes while stopped. So I went back and popped off the rear cover, applied more 1 minute permatex gasket and put everything back.

Well I was rushing to get everything done and managed to sheer a bolt head off. It's the bolt that holds this metal plate to the intake manifold where the throttle body wire harness clips to.

So I've got a bolt extractor set and just need to find a bolt to replace the broken one with.

Arrrrggh. Maybe I'll get pics or something.

 

drill and retap?

 

+1, as long as it doesn't leak you will be fine.

 

Plus two I guess if doesn't work than go next size up...Good luck messed one of mine up but it was where the top meets lower intake manifold after I did spacers haven't fixed yet but no leaks, with the RTV .....

 

Are you guys not following the torque specs. of these bolts? I would hope that they're not failing when you try to remove them.

 

Retap using a larger tap? Or the same size?

 

Helicoil kit time!!!!!!!!

 

Great then I guess I should return the 60 piece tap and die set to harbor frieght. Sigh.

 

No keep it.....It a great tool tool set to have......

 

haha so much for trying to SAVE money!! I'd rather repair the threads so I can use the same bolt for the upper intake manifold collector to the lower collector.

 

The helicoil kit will repair it so the existing OEM fastener that was installed there originally can be used......I think you wanna upgrade to a larger fastener is that correct?

 

I am a total novice when it comes to this. In fact I am getting the terminology mixed up.

The factory service manual labels the bend after the throttle body the Intake manifold upper collector. The intake manifold lower collector (which is held on using three bolts and two nuts) is next. That is bolted to the intake manifold.

Terminology out of the way, I tried to force in the wrong bolt in the hole in the intake manifold which holds the lower collector. (see EM-9).

I would like to repair the bolt hole so I can re-use the existing OE bolt.

I just need to know what to buy to accomplish this.

 

Helicoil.