I'm helping my nephew replace the timing belt in his 2003 Neon. Compression test shows 3 of 4 cylinders with minimal or no compression. We're taking the head off to repair but have run into an issue with getting the exhaust manifold heat shield off. The bolts that hold the shield in place appear to be 7.5mm (best guess). 7mm is too small and 8mm is too large. A 9/32 socket is a smidge too small also. The engine is still in the car and I'd prefer to keep it that way if at all possible.

The question is simple: what size are the factory bolts that hold the heat shield in place on the exhaust manifold? We've been to multiple parts store and a Dodge dealer parts department with no luck.

I can't find a YouTube video that shows how (there was an awesome one for the timing belt that saved us our sanity). No amount of googling seems to yield the answer. We don't have shop manuals. I'm a Saturday mechanic so obvious is not always obvious.

Anyone have a good suggestion here? I'm just short of grinding them off, taking the Exhaust Manifold out and drilling/tapping new holes.

If the answer is 7mm, then I'm open to anyone that has a good trick to get them out when the sockets don't fit and there's not enough room to persuade a sacrificial socket.

Help.

Thanks in advance.

StlUnc

 

They are M8x1.25 bolts, according to the Dodge parts manual.

 

darthroush

Thanks for the quick reply. I think that relates to a 13mm socket though. Could that be the exhaust manifold bolts? The 8mm I tried was too large. It would fit but under torque, it spins on the head (which appears to still be well formed). The 7mm and 9/32 sockets are too small.

Thanks

StlUnc

 

Those bolts start out life as 8mm, but they go through so many heating and cooling cycles they're subjected to a lot of corrosion and it's very common for them to round off, especially the one closest to the flange where the exhaust pipe connects. Some penetrating oil and a good 12 point socket helps. I am curious though; it sounds like you're trying to remove the exhaust manifold with the head installed? If so, it's much easier to remove it with the head, then remove the manifold from the head.

 

try removing them from underneath the car. .. take a look.

 

richards83 and arnonefrank13

Thanks for the replies. Both are good points and suggestions. I did try an 8mm 12pt socket with no luck. The bolts don't appear to be rounded. I'm going to try accessing them from under the car with a pair of vise grips. If nothing else, I'll be taking a grinder to them later this week when the weather clears.

I have considered taking the manifold/exhaust bolts off and pulling the head with the exhaust manifold but last week when I was under the car (when it was dry here) I was only able to remove 1 of 4 bolts. Those may be easier to attack from under the car but it looks like any way I go, I'm going to be grinding soon.

I'm still open for further suggestions. All have been good so far but I appear to still be stuck and looking at a cut-off wheel.

Thanks to all who have offered suggestions and those that have reviewed the posting. I appreciate the feedback.

StlUnc

 

I've never had a problem removing the four nuts from the exhaust manifold to pipe flange, but I do them from under the car with an air ratchet and about 3 feet of extensions.

 

My Lord, I'm having the same issue as OP. There are 3 bolts holding the exhaust manifold heat shield. There is a 1/2” bolt that is higher up and two bolts/nuts lower down (I don't know which because I can't get the MFer off) on each side of the shield. Just like OP said, a 7 mm is too small, an 8 mm is too big. I tried US Standard sizes but I'm just stripping the SOB.

I haven't tried removing them from underneath yet, I'll try today, but I doubt that will help.

I may have to terminate them with extreme prejudice. Desperate times call for ......F'n ....bolt murder or something.

Oh, and I sprayed some penetrating spray yesterday. Hopefully that helps.

Anyway, hi ya'll