Hi all, I was putting my manifolds back on after changing out gaskets and putting new o-rings in my injectors and i over tightened one of the secondary fuel rail bolts and it split the aluminum. I primed the fuel system to check for leaks, there were none. I still don't trust that the bolt will come loose and a leak will form later, or there might be a leak under load. Should I just try to JB weld the split back together or should I try to source a new lower intake manifold? If anyone else has had this problem and resolved it, please chime in and any other advice is welcome.

 

you can re-tap the threads the next size up, you MAY have to slightly drill the mount for the rail a bit for the new bolt. Take it to a machine shop if its something your not too familiar doing. Otherwise a new intake would be the next step.

I just re-read this, if you are saying the whole aluminum split wide open, try to take this to a machine shop and see if they can hook you up. They work with metal all the time and might be able to help you out.

Do not JB weld anything, JB weld doesn't work well contrary to popular belief. There are other alternatives that are way better, and a machine shop would also know about these also.

I just had a similar issue with the lower starter bolt. Whoever owned this transmission before me must of over-tightened the bolt and messed the threads up. I left it as is and made sure the upper bolt was snug while the bottom bolt as snug as it can get. But if I ever get a chance, I will take out the transmission bell housing to re-tap the threads. But this is not a critical component that can mean the difference between an engine fire and a healthy engine.

 

after taking this picture, i have another question, can i just put a nut on the bottom? If not I guess I'll try a machine shop before trying to get another USDM manifold.

 

get that welded, then use a nut or have them re-tap it.

 

for what it is worth,just get another lower manifold.
you are going to be Screwing around with Jb weld and ****,then once it is on,you will have it in the back of your head that Something MAY happen.sometime,somewhere.
Screw that!..get another Lower manifold,and Pitch that Piece of manifold you are workin on.
ya Fugged it up!..Don't sweat it,..just Buy a used 25 dollar manifold..and you are Golden!

 

this is caused by using the wrong secondary fuel rail bolt, there's a left and right bolt...one runs out of threads and causes the aluminum to push outward if you try to tighten it in the wrong place. if you look at how much thread is on each bolt you will see what i mean.

my suggestion is to replace the LIM, or have it professionally welded.