What is this? I pulled the manifolds because of smoke leaking around the gasket when I put a smoker on the engine. After I pulled the manifolds I found this tab and washer that are not connected to the manifolds.

Air injecton port.

Some models after 76 may or may not have it. If you don't have an air pump or other properly functioning emissions devices leave it plugged/ capped.

Greg

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http://www.youtube.com/hyperpack

Thank you. I will put a nut back where it belongs before I install the manifolds. I built a drill fixture to hold the exhaust manifold on my drill press to drill out the two broken bolts between the manifolds. That helped me keep things in line and drill straight through. I was surprised to find that there is only one long bolt. I thought there were two bolts in the exhaust manifold to hold the manifolds to gether and attach the throttle cable bracket. it took a lot of heat to get the nuts loose from those bolts. The gasket was very thin, and there are a lot of rough surfaces on the exhaust manifold where it joins the head, which is why they never formed a good seal after the head was rebuilt 5 years ago. From a for sale add I found from 5 years ago, very few miles have been driven since. Can I use a grinder to level out some of the higher irregularities to help get a good seal with the head when I install the manifolds without creating more problems?

That air injection port cover needs its gasket (real, not squeezed out from a tube) or you'll have an exhaust leak.

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一期一会
Too many people who were born on third base actually believe they've hit a triple.

[/attachment]I have never removed the cover from the head, so what was there is what you see. I will make a gasket to cover the hole. I have fought all kinds of symptoms as you will see if you read my first posting. In the end I put in a breaker point distributor because I was getting weird things like only 3 cylinders firing, no low idle, and no consistancy. The smoker led me to the gaskets very quickly after I turned it on. I hope this the end of the problems. The engine itself is in very good condition.

I think I have some spares of those f you need one.

Greg

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The problem I am having now is the 2 bolts between the manifolds. The center stud is fine, but the two 5/16-18 bolts broke off. I drilled them out on the drill press with my fixture, tapped them, and the threads are fine, but I can only find 3" or 4" bolts to replace them. One is 1/2" too short, and the shaft is too long on the other. I am considering stainless bolts with continuous threads at this point.

Be very careful if you go the stainless route.
Just about all stainless is China made and it's not the same quality as I remember.
If you use it, you MUST use plenty of anti-seize paste.
I have had them seize up going in and that is not fun.
Just my 2 cent advice.

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Hyper_pak

There should be a teardrop shaped gasket in the manifold set.

Ditto on stainless. I deal with it every day at work. I hate it.

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Official Cookie and Mater Tormentor.

I have two bottles of anti-seize, both aluminum and copper. I do intend to use them liberally when I reassemble the manifolds, which now is about how long it takes to clean them up and wait for the paint to dry.

good to know on the stainless. I would have thought that stainless would be just the ticket, to avoid such issues...... I do know there are at least 2 grades of stainless hardware, that hardware from 316 stainless ally is better than the 18-8 grade. I did buy (have not yet used them) a stainless bolt kit for a /6 a while back......

Just remember to not tighten the bolts until you have the manifolds torqued to the head. Go ahead, ask me how I know this.

I have literally had a 1" stainless nut seize on the bolt threading them together with my fingers. Between that and little razor sharp slivers stainless sucks.

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Official Cookie and Mater Tormentor.

I would just use a bolt and nut. They should be cheap hardware store stuff, that way when they seize, you can just easily break them.

What I hate when you setup a sacrificial bolt is when it doesn't break and the nut/bolt strips and it won't tighten or loosen..............

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Ed
64 Valiant 225 / 904 / 42:1 manual steering / 9" drum brakes

I have had this exact thing happen to me. It was quite an eye opener about using stainless steel fasteners.

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