I finally got around to start changing my wifes 2003 x type spark plugs and ignition coils but ran into a problem. I was able to remove all the bolts except the two on the front right which just kept on turning. I looked at the holes into the ones I was able to remove and noticed a small brass looking ferrell that the screw goes into, I was wondering if they can come loose and turn and this is why the other two bolts will not come put?

Thanks for reading

 

Rossy, odds are, you are going to need to use something like a dremel tool to take off the bolt head. From there, you will be able to remove the intake. From there, you can work on removing the rest of the bolt. You might be able to get some liquid super glue (not the gels) and then carefully apply some around the edge of the brass fitting. Then you can potentially remove the bolt. From there, you will need to figure out how to glue the brass fitting into the intake for a more permanent fix. The other option is to get a new lower intake piece and then install that.

 

Sad news but thanks for the information.

 

https://www.jaguarforums.com/forum/x...ld-bolt-31472/

 

Thanks for that link. Very helpful.

 

I had the same problem. I was able to get a small drill bit in from the front of the car, drilled through the plastic and a little bit into the brass insert, then used a bottoming tap to put some threads in there. It was small so maybe a 4-40 or 6-32 thread. Then I threaded a set screw in that hole I had just made. It held enough for me to get the bolt out without cutting the head off. Once the upper manifold was out I took that lower manifold out and carefully drilled more into the brass insert/nut so the set screw had more "bite". Then with the lower on my workbench, out of the car, I put another set screw in on the other side. Due to the geometry I wasn't able to get them exactly opposite, maybe 150 degrees apart and not 180. I have since removed the upper from the lower at least 5 times without an issue. I did thread lock the set screws in because I was worried they might shake loose over time.

Below is not my picture, it was taken from a different thread on this forum and I added the text, but I would point out you want those intakes covered up so you don't drop anything in there.

 

Hi Rossy,
I had a similar issue with removing my intake manifold earlier this year, two brass inserts rotating within the lower intake assembly.
I ended up applying some gentle/moderate but persistent upward pressure on the trapped bolts, while continuing to rotate them and getting the spinning brass inserts to eventually work their way out of the fibreglass reinforced plastic.
With the intake manifold off I was then able to clamp the brass inserts and then release the bolts from them.

Using a Dremel with a fine metal cutting disc you can add back some coarse knurling pattern into the outer surface of those brass inserts and clear any prior repair materials (mine had been fixed before). Then using the small engraving/etching Dremel tool ( the one with the tiny ball on the end) you can add some vertical texture lines to the damaged plastic sockets to allow any new epoxy bonding agent some additional keying. If you are doing this part of the task with the lower intake still in place on the engine, make sure you block the intakes with rags etc to stop any swarf getting where it ought not be.

There are some good high temperature epoxy products available that you can use to refit and bond the inserts back into the lower intake manifold.
Apply the epoxy quickly to both the brass insert and the plastic socket before fitting to ensure you have good coverage and penetration of both surfaces.
Give the epoxy plenty of time to cure (often 12 to 24 hours for epoxy to reach full cure strength).
Just make sure you set the brass insert height correctly as if you do not get it down into the correct position you might not attain sufficient crush of your upper intake gaskets.