Freelander 1 air intake bolt snapped.

Hi All, After a bit of help and any support greatly received. Just changed the thermostat for the kid one in the top pipe as the old one was sticking open. Looks like I've snapped another bolt on the air intake manifold. I've manged to one of the snapped bolts out of the head and just wondering how to get the snapped bolt out of the manifold it's self. I have a donar manifold with bolts but can't see and obvious way of getting the bolts out as them seem to have an anti loose heel. Is it just brute force? Also when inputting the thermostat had hell of a job getting it in far enough to get a good connection for the jubilee clip, again is there a knack to this or just brut force. Will probably look to get new pipe as when removing the metal band I've nicked the pipe so rather be safe than sorry so will need to remove the new thermostat and replace on the new pipe so hoping there is an easier way than just pressing it in as a bit of a bugger to get far enough in the pipe.
Thanks

Just a, quick add on anyone know the part number for the hose where the in line thermostat is housed?

yantojarc said:

Looks like I've snapped another bolt on the air intake manifold. I've manged to one of the snapped bolts out of the head and just wondering how to get the snapped bolt out of the manifold it's self.

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Just used the whole replacement manifold, and stop twisting the bolts off. They need to be GENTLY nipped up, nothing more. They are holding a plastic manifold, to a plastic cam cover, so don't need to be wrung up wheel nut tight.

Hi Nidge68, I ve learnt my lesson now but the bolts must be very brittle as not much pressure applied this time but still snapped two, less pressure next time. Thanks for your suggestion on using the other manifold but it looks like the sensor on the side has snapped off and looking quite rough. That's why I was wondering about taking the bolts out to use on the existing manifold, but if I can't will leave it. On the radiator pipe is it just called the top radiator hose, as when searching for this some odd results come up. I will say after the change of thermostat my FBH us is a lot quieter now, I presume this is due the engine reaching the correct temperature.

yantojarc said:

Hi Nidge68, I ve learnt my lesson now but the bolts must be very brittle as not much pressure applied this time but still snapped two, less pressure next time. Thanks for your suggestion on using the other manifold but it looks like the sensor on the side has snapped off and looking quite rough. That's why I was wondering about taking the bolts out to use on the existing manifold, but if I can't will leave it. On the radiator pipe is it just called the top radiator hose, as when searching for this some odd results come up. I will say after the change of thermostat my FBH us is a lot quieter now, I presume this is due the engine reaching the correct temperature.

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I think you would be shocked at how NOT tight they need to be. Really really NOT tight.
Get yourself a 1/4 inch torque wrench and set it to 10nm (if I recall correctly) for the bolts and 12 for the bigger nuts.
If you correctly torque them it's almost impossible for them to break.

Cheers Alibro, think I've learnt my lesson now! Any ideas on how to take the bolts out of the manifold, I presume it's brute force but best to check after snapping them in the first place. In my defence the first ones snapped a while ago whist undoing the bolts in the first place.

yantojarc said:

Thanks for your suggestion on using the other manifold but it looks like the sensor on the side has snapped off and looking quite rough.

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You can remove the MAP sensor, and fit the one from yours.

yantojarc said:

Any ideas on how to take the bolts out of the manifold, I presume it's brute force but best to check after snapping them in the first place.

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I don't think they're very easy to remove. I'm sure they'll held in with some form of clip, unfortunately I don't have a manifold I can check on now.

Thanks for reply both. Wasn't sure what the sensor was but will check tomorrow as Nodge68 you are right if possible it would be easier to fit the other manifold if possible.

All done. Managed to put a small screw onto the snapped Map sensor and pull it out which allowed me to swap mine over to the other manifold. Also managed to remove the last broken bolt with a pair of mole grips and fitted the new manifold...... With no broken bolts! At the same time managed to remove the thermostat apply a small amount of silicone grease and refit correctly. So all jobs done..... for now. Thanks to Nodge68 and Alibro for all your help.

yantojarc said:

All done. Managed to put a small screw onto the snapped Map sensor and pull it out which allowed me to swap mine over to the other manifold. Also managed to remove the last broken bolt with a pair of mole grips and fitted the new manifold...... With no broken bolts! At the same time managed to remove the thermostat apply a small amount of silicone grease and refit correctly. So all jobs done..... for now. Thanks to Nodge68 and Alibro for all your help.

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No worries mate, you;re welcome.
Everyone has a different idea of what "nipped up" means.
I used to work on laptops for our local court service so was in judges chambers almost every day as were a couple of my colleagues. One of them used to tighten the screws in the laptops so lightly I always knew when he had worked at it because most of the screws had fallen out. Invariably I had to do the best I could to resecure the case and lid with whatever screws were left over.
He was the opposite of you.
A good rule of thumb is to always use a 1/4" socket set for bolts up to 13mm so you have less leverage and are less likely to do harm. Using a torque wrench will give you a feel for how tight different Nm feels, and as said earlier you would be shocked how NOT tight 10Nm or 15Nm is.

Glad to hear it's now sorted.

yantojarc said:

All done. Managed to put a small screw onto the snapped Map sensor and pull it out which allowed me to swap mine over to the other manifold. Also managed to remove the last broken bolt with a pair of mole grips and fitted the new manifold...... With no broken bolts! At the same time managed to remove the thermostat apply a small amount of silicone grease and refit correctly. So all jobs done..... for now. Thanks to Nodge68 and Alibro for all your help.

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It's strange how you manage to goof us simple things like breaking the manifold bolts, yet manage to to some of the awkward bits like the thermostat, which is IMHO a pig of a job to do on these vehicles.

Hi, thanks for your previous help with everything from tyres to ro windscreen wipers and lots in between ! Not sure if you can advise but my son has a core plug issue with his Td4 2003, it's one my old cars so feel a bit responsible. He has a water leak from a core plug on the near side of the engine but I'm struggling to find one or even the part number. When I search for it all that shows are core plugs for disco's or range rovers, any ideas on where or what to search for? Thanks.

There's only 1 core plug that I can think of on the M47R, which is on the gearbox end of the head, to the right of the vacuum pump.
There must be more plugs on the block, as they are an important part of the casting process.
However.
If you can't find a listed replacement, then you'll need to measure the bore with a set of calipers, and get a suitable sized replacement that way.