Standard Procedure - Exhaust Manifold Stud Replacement

Any exhaust manifold stud which is found to rotate during the manifold removal or installation process must be replaced following this procedure.

Fig 1: Exhaust Manifold Stud

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1. Remove and discard the exhaust manifold stud(s).
   Fig 2: Forward Lower Manifold Stud

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   NOTE:

   In order to install the forward lower manifold stud (1), it will be necessary to remove 3 to 5 millimeters if material from the cylinder block water pump casting galley (2).

   Fig 3: Masking Off Exhaust Port Openings

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2. Mask off (1) the exhaust port openings.
   Fig 4: Exhaust Manifold Gasket Assembly & Tie Strap

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3. After the ports are masked off, reinstall the USED  exhaust manifold gasket assembly. Install a plastic tie strap (2) around a stud to hold the gasket in place.
   NOTE:

   Installing the metal gasket provides a protective barrier between the cylinder head and grinding tool.

   Fig 5: Top & Side Faces Of Stock

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4. Using a paint pen, draw two 5 millimeters lines down the length of the stock. One on the top face (1) and one on the side face (2). This will be used as a depth guide while grinding.
   Fig 6: Corner-Edge & Stop Point Of Stock

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5. When marking the stock, it is only necessary to mark to a depth of approximately 15 millimeters between the corner-edge (2) and stop point (1).
   NOTE:

   The amount needed to be removed is dependent on the design of the installation tool being used. Only grind enough off to allow a tool to attach to the stud securely.

   Fig 7: Holding Tool At 45 Degree Angle

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6. Using a standard cutoff wheel, hold the tool at a 45 degree angle (1) and take several LIGHT  passes on the stock. Do not extend beyond 5 millimeters wide and 15 millimeters deep.
7. Loosely install a used stud by hand and check the grip of the installation tool.

   Only take off what is necessary. 

8. Clean all the holes using electronic contact cleaner applied to a plastic bristle/bottle brush. Do not use parts cleaner. On the five upper stud holes, be careful not to drive the brush into the engine cavity. Use the brush to draw out any residual oil or hardened Loctite. Wipe the exhaust face clean when completed with a lint free cloth.
9. Apply Loctite 277 to the manifold end of a new exhaust manifold stud. Apply the Loctite 360 degrees around the part for a minimum of 4 threads.
   Fig 8: Exhaust Stud Protrusion Length

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10. Hand start the exhaust stud. Using a stud extractor/installer tool, tighten the exhaust stud to 11 N.m (97 in. lbs.).
11. Measure the protrusion length (1) of the installed exhaust stud. The length must be between 24 - 26 mm (0.945 - 1.023 in.) when fully seated.
12. Wait a minimum of 15 minutes before installing the exhaust manifold. This will allow the Loctite 277 to fully set.
    NOTE:

    Any rotation in the loosening or tightening direction of the stud after it is assembled breaks the bond in the joint. If the bond is broken, remove the stud and start over at Step 1.