Broken intake bolt?

From: David Gersic (
Date: Fri Jun 07 2013 - 17:06:23 EDT

Tracing a small coolent leak here on my '01 3.9l, and I think I found it. The
rear-most passenger side intake bolt is broken off. This bolt must penetrate
the water jacket, it seems like the coolent is seeping around the threads.
This looks like it's going to be a pain to fix.

Digging around, it looks like I need to remove the alternator and A/C
compressor, then unplug everything on the intake manifold. After that, remove
the remaining 9 bolts that hold it down, and pull it out.

Then I get to find a way to remove the remains of this bolt. I assume that
since it broke off, it's probably going to be a pain to remove. Maybe I'll get
lucky and some vice grips and PB Blaster will take it out, but I'm betting
against it. Drilling it out isn't going to be easy, because it's back under
the cowl. Maybe a right angle drill will be able to get at it back there.

I'll get a new manifold gasket, and I figure I'll replace all 10 bolts rather
than re-using the old ones. Are there any other things I should be ready for
when I go to do this?

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