I will soon be starting a header install on my 94 camaro. The stock manifolds are pretty rusty, and the bolts holding them on are also really rusty.

I'm very concerned about twisting the head off of a bolt, or worse, breaking on off inside the head.

I never drive the car on weekends, so I'm thinking about drenching the bolts in PB blaster for the next 3 weekends before I do the install. Would this method help them to break loose?

Are there any other good tips/tricks for getting off really old manifold bolts?

 

My manifold bolts were in similar shape. I spent close to a week hosing them down with PB Blaster. I went through several cans. However, when the day came to disassemble, every bolt broke free with almost no effort on the ratchet.

 

There's always the possibility of a bolt/head breaking. I sprayed the
bolts (manifold and exhaust flange) for two nights in a row, allowing
the bolts to soak overnight. Be sure to spray at the bolt's head and
where the manifold (the bolt hole) mates to the head.

When you go to loosen the bolt/nut, put the socket on, apply some
pressure, then slowly push (or pull) using enough force to break the
bolt loose - don't "jerk" on the breaker bar (or hit with a hammer),
as the sudden force may snap the bolt at its weak point.

Don't forget to remove the temperature sensor on the driver's side
of the engine - if you knock it while removing the manifolds, it will
break at its connector socket. You can't easily see it with the stock
manifolds on, because they route "over" the sensor. Here's a photo
showing the sensor (look just to the left of the 2 center primaries):
http://picasaweb.google.com/calder.c...32328402025650