Hello Everyone, I tried to replace the exhaust donut between the manifold and the cat. Not realizing the nuts are welded on I cut the spring bolts. I now need to remove the manifold to get at the nuts as I cut the bolts flush to the flange. There is no working space to do anything else with the nuts without removing the manifold. Drilling out the remaining bolt ends seems impossible as well. So, is removing the manifold something that I can reasonably do myself with the car in jack stands? It's obvious that the manifold is very difficult to get at. Or is it time to call in the pros and admit that I probably tripled the cost of having the pros do it in the first place? What's the procedure for removing the manifold if I do attempt it? Any advice appreciated! Sean
The Toyota repair manual assumes the engine has been removed, prior to removal of the exhaust manifold. You'll have to assess whether you have sufficient access to the manifold considering the space between the manifold and the firewall. If you have sufficient access, then you would first remove the heat shield (four bolts) and then you can remove the manifold (3 bolts and 2 nuts). I assume that you cut the spring bolts because they were too rusted to just unbolt, even after using rust penetrating lubricant? Or did you not try that avenue first? Obviously you would need to use a new exhaust manifold gasket when reassembling. Tightening torques are 32 ft.-lb on the spring bolts, 20 ft.-lb on the exhaust manifold bolts/nuts, and 71 in.-lb on the bolts holding the heat shield on the manifold.
Looks like it should be possible to drill out the remaining part of the bolt without removing anything else. You can just use nut and a bolt to put it back together.
