Exhaust Manifold Fastener Hole Repair

WARNING: This page is about a different car, the 2020 Jeep Renegade. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Broken exhaust manifold studs, bolts and damaged threaded holes can be repaired using this procedure and the (special tool #2073500090, Kit, Cylinder Head Thread Repair - 2.4L MAIR).

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IDENTIFY WHICH HOLES REQUIRE REPAIR

Visually inspect the threaded holes (1) prior to removing the exhaust manifold from the cylinder head.
Clean out the suspect holes with compressed air.
With the exhaust manifold still in place, install a NEW exhaust manifold fastener in the suspect hole and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
If the fastener makes full contact with the exhaust manifold flange and can be tightened to specification, repair is not required.

BROKEN FASTENERS

Remove the exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL AND INSTALLATION .

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Cover the air inlet tube with tape (1). Cover the generator (2).

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Fully insert the 2073503090 Drill, 1/4" (2) in the 2073501090 Fixture, Drill and Tap Alignment (1).

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Install the 2073509090 Stop, 1/4" Drill Bit (1) against the fixture and tighten the set screws (2).
NOTE:
The 1/4" drill bit will be used to partially drill out the broken fastener(s).

NOTE:
The drill stop must be used and set correctly to prevent drilling past (too deeply) the threaded hole.

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Insert the 2073502090 Drill, 13/32" (2) in the 2073501090 Fixture, Drill and Tap Alignment (1).

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Install the 2073508090 Stop, 13/32" Drill Bit (1) against the fixture and tighten the set screws (2).
NOTE:
The 13/32" drill bit will be used during the thread restoration procedure.

NOTE:
The drill stop must be used and set correctly to prevent drilling past (too deeply) the threaded hole.

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Cover the exhaust ports with painters tape (1).

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Install the 2073501090 Fixture, Drill and Tap Alignment (1) on the cylinder head. Arrange a minimum of three of the #1 - 2073505090 Guide, 13/32" Drill (2) and fasteners (3) around the hole to be repaired. Tighten the fasteners (3) securely.

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Install the #3 - 2073506090 Guide, 1/4" Drill (1) in the hole to be repaired and lock into place.

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Apply a cutting fluid (1) throughout the drilling process as needed.

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Using a right angle drill (1), drill until the drill stop (2) contacts the drill guide (3).
NOTE:
Apply a cutting fluid and blow out chips throughout the drilling process as needed.

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Clean out the hole with compressed air (1).
Proceed with THREAD RESTORATION .

THREAD RESTORATION

Remove the exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL AND INSTALLATION .

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Cover the air inlet tube with tape (1). Cover the generator (2).

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Insert the 2073502090 Drill, 13/32" (2) in the 2073501090 Fixture, Drill and Tap Alignment (1).

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Install the 2073508090 Stop, 13/32" Drill Bit (1) against the fixture and tighten the set screws (2).
NOTE:
The drill stop must be used and set correctly to prevent drilling past (too deeply) the threaded hole.

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Cover the exhaust ports with painters tape (1).

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Install the 2073501090 Fixture, Drill and Tap Alignment (1) on the cylinder head. Arrange a minimum of three of the #1 - 2073505090 Guide, 13/32" Drill (2) and fasteners (3) around the hole to be repaired. Tighten the fasteners (3) securely.

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Install the #1 - 2073505090 Guide, 13/32" Drill (1) in the hole to be repaired and lock into place.

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Apply a cutting fluid (1) throughout the drilling process as needed.

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Using a right angle drill (1), drill until the drill stop (2) contacts the drill guide (3).
NOTE:
Apply a cutting fluid and blow out chips throughout the drilling process as needed.

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Clean out the hole with compressed air (1).

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Install the #2 - 2073507090 Guide, Tap (1) in the hole to be repaired and lock into place.

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Using the 2073511090 Socket, Tap (1), thread the 2073504090 Tap (2) into the hole until it bottoms.
NOTE:
Apply a cutting fluid and blow out chips throughout the tapping process as needed.
Remove the 2073507090 Guide, Tap from the 2073501090 Fixture, Drill and Tap Alignment.
Clean out the hole with compressed air.

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Place the coil (2) into the 2073510090 Tool, M10 x 1.25 Heli-Coil Installation (1).

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Thread the coil (2) into the installer (1) until one full coil is exposed.

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Thread the coil (2) into the hole with the installer (1).

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Verify the coil (1) is fully installed below the gasket surface.
NOTE:
It is not necessary to break off or remove the tang from the installed coil.
Repeat this procedure to restore the threads on any other holes that require repair.
Remove the 2073501090 Fixture, Drill and Tap Alignment and the tape from the cylinder head and air inlet tube.