2000 Accord SE (4 cyl, AT) has an "L" shaped bracket that holds the exhaust manifold to the block. The threaded boss or lug has broken away and moved about 1/16 inch downward. I saw one reference to a service bulletin but I can't find any more information on it. What are the chances a low-melting aluminum rod (maybe Alumalloy or similar) can be used to weld this back without messing up the metallurgy of the block? Has anyone else dealt with this?

 

Im not familiar with welding on much of anything, so I would suggest you calling a welding sjhop and ask them what they would us, while you have them on the phone I would also ask them how much the would charge to do it...

WheelBrokerAng

 

Is the bracket #1 shown below? I don't see how the bolt can move at all if the head broke off. The bracket can move since it is bolted in two spots. You may be able to remove the bracket and get vice grips on the exposed bolt to remove it. An easy out may work as well.

 

What broke? The threaded boss on the manifold? Or the boss on the block? If it's the block, I'd be afraid to do any welding on the block.

An excuse to buy a header? Lighter weight tubing might not need that bracket.

 

To PAHONDA, yes the bracket is number one in the diagram. To Jimblake, it is the boss on the block - the bolts and the manifold boss are fine. The manifold and exhaust pipe don't move and I can't find any damage under the car so I am presuming the casting was faulty and heat/cool stresses caused the break. Does anyone have a tech-help phone number at Honda America that might be helpful? If welding is not the route to go, maybe I'll use some JB Weld and see if that holds. I've used it successfully on the old tractor I'm restoring but not on anything that will get this hot.

 

So I am on the same page. Are you saying the block where the stud for nut 11 goes is broken around the stud?

 

No, it is the threaded boss that bolt #7 screws into. Nut 11 is one of the eight that goes on the studs in the head and holds the manifold. I presume the bracket is just there to dampen vibration but it may be to protect the manifold from movement if the exhaust pipe is hit.

 

I think it is too support the weight of the manifold which is pretty much what you said. I did a head gasket on my 95 Accord and that bracket was broken. Also one of the manifold bolts was broken off flush and looked like it came from the factory like that. I don’t have an answer to correct it but if you search the treads someone about a year posted one related to it. They pulled the head with the exhaust manifold still attached and broke the bosses off of the engine. I didn’t follow the thread for a solution. How did you find out what that the boss broke off.

 

Chris, the bracket is still attached to the manifold and the bolt and boss are dangling on the other end. Thanks for the clue about an older post - I will search it out tonight.