morrisdan613 · Dec 21, 2020

Hi guys I was giving my 2004 td4 a service and I took the inlet manifold off to change the gaskets. When putting it back on I snapped two of the eight bolts on the top of the manifold. Anyone know how easy they are to remove? And can you get new bolts or do I need a new manifold? Thanks in advance.

Nodge68 · Dec 21, 2020

How did they snap? They shouldn't be anything like tight enough to break off, they're on tightened just enough to prevent them unscrewing, which won't snap them off.

Depending on which have snapped, depends on what you need to do to rectify the situation.
If it's the 8 upper bolts near the injectors, then they might come out with mole gtips, as they're screwed into brass inserts in the cam cover.

If they don't come out, a replacement cam cover will be needed.

morrisdan613 · Dec 21, 2020

Nodge68 said:
How did they snap? They shouldn't be anything like tight enough to break off, they're on tightened just enough to prevent them unscrewing, which won't snap them off.

Depending on which have snapped, depends on what you need to do to rectify the situation.
If it's the 8 upper bolts near the injectors, then they might come out with mole gtips, as they're screwed into brass inserts in the cam cover.

If they don't come out, a replacement cam cover will be needed.

I overtightened when putting back on. Will try with mole grips. Can you get new bolts for it?

Nodge68 · Dec 21, 2020

morrisdan613 said:
I overtightened when putting back on. Will try with mole grips. Can you get new bolts for it?

Ah. Try not to do that again.

They really only need tightening just enough to compress the O rings and stop them unscrewing.

They're trapped bolts, so knowing BMW they'll not be available separately, but they might be.
I'll see if I can find a part number, but a second hand manifold will probably be cheaper.

morrisdan613 · Dec 21, 2020

Nodge68 said:
Ah. Try not to do that again.
They really only need tightening just enough to compress the O rings and stop them unscrewing.

They're trapped bolts, so knowing BMW they'll not be available separately, but they might be.
I'll see if I can find a part number, but a second hand manifold will probably be cheaper.

Ok thanks for that. Very much appreciated

Arctic2 · Dec 21, 2020

Rover 75 diesel inlet manifolds are cheaper than the FL1 manifold, when fitting tighten down only to nipping point, then do another 1/4 turn. same with the nuts & long bolt.
Rover 75 diesel inlet manifold | eBay

Alibro · Dec 22, 2020

The torque settings for these bolts are really low. Something like 10 or 15Nm but easy to check if you Google it. Really just nipping them up.
If you broke the bolts you were over tightening them by a factor of 3 or 4 times.

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