2 BROKEN BOLTS when trying to change exhaust manifold gasket :( PLEASE help!

02-16-2012, 02:32 AM
Recently I've gone to war with my 2001 Suzu Rodeo.

Changed spark plugs, wires, coil pack. CPS. Alternator. Fuel Sending Unit. Valve seal gasket. Got rid of 7 obd codes. Biggest problem was P0301 (misfire cyl 1). Was pretty proud of myself as I had never even changed my own oil prior to this. And now i'm 7 obd's down...

Had one last code to tackle. P0128. Bought a replacement t-stat and decided to change exhaust manifold gasket while I was down there.

While removing the manifold... not one, but TWO bolts broke off in the block that normally hold the exhaust manifold up.

Bought a reverse drill bit set... no luck. Angle isn't sufficient to get the drill down into the engine compartment.

DOES ANYONE PLEASE have any tips or ideas how to get these CRAP bolts out????

I've made it this far... and my truck was running SO WELL... now I feel like I've just lost my car.


Cat Fuzz
02-17-2012, 12:18 AM
Pull the front tire and rubber curtain and see if you can get in that way.

02-17-2012, 07:27 PM
Thanks for the idea, Fuzz...

Ended up breaking two different reverse drill bits. Threw in the towel, had it towed to a shop who then electro-arc'd it for $160.

Then found out the manifold itself is cracked... so had to drop another $200 on that.

Hoping the car will be good for some time to come now.

cleaned EGR valve.

replaced - valve cover gasket, exhaust manifold gasket, exhaust manifold, camshaft position sensor, spark plugs, wires, coil pack, fuel sending unit, air/oil/fuel filters, thermostat, alternator aaaaand ive got a new a/c compressor on the way.

whew. that was fun.

02-17-2012, 07:29 PM
Hey CatFuzz... just noticed your vehicle...

"99 Rodeo LS 3.5L Stroker V-6, 4wd, 31x10.5x15 2 inch Trooper lift, Aisin manual hubs"

That sounds amazing. Do you know if I wanted to swap my motor with one of the 3.5L like you have... is that possible? would I have to change other elements out as well? transmission etc? chip?

Cat Fuzz
02-17-2012, 11:08 PM
The 3.2L and the 3.5L are identical in every way except for the internals. They are a direct bolt-in, plug and play swap. My particular engine WAS a 3.2L. I swapped in the crank, rods, pistons and oil girdle to effectively make it a 3.5L. The only 3.5L that is NOT swappable is the direct injection 3.5L found in some 2004 Isuzu's.

The 3.5L is a 3.2L with a longer stroke and cams with a slightly longer duration. I didn't swap the cams and the tiny little bonus is, no one can ever tell it's not the original 3.2L since it still has "6VD1" cast into the side of the block. A 3.5L would be a "6VE1"

02-18-2012, 12:39 AM
what about going from a 4cyl to a V6 ?

Cat Fuzz
02-18-2012, 12:45 AM
That will be a bit more work. You'll need the ECM and wiring from a V-6 donor truck at least. Not sure on other specifics but the transmission might be different also.

02-18-2012, 12:50 AM
Yup I had somewhat figured it might be like that. Especially the tranny. Oh well.... will have to save that dream for later down the pipe... thanks again, CatFuzz

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