In this video, I show you how to easily remove a broken intake manifold bolt with a washer and a welder. This process is on a 5.3L LM7 (LS style) engine, but it's the same as a 4.8L, or a 6.0, and probably even the 6.2L. This problem is really common on LS swap engines because people tighten old intake manifold bolts too tight and they are very easy to snap off.

To get the broken bolt out, the most important factor is the get good weld penetration of the broken off bolt. Once it is welded to the washer, you have more options. You can weld a nut or a bolt, or even an old screwdriver to the washer. Once something solid is welded to the washer, the broken intake manifold bolt will usually come right out. If it is still tight, you can heat the surrounding area with a torch.

5.3L LM7 Intake Manifold Bolt Torque Specs
First Pass 11 Foot Pounds
Second Pass 18 Foot Pounds
Tighten the bolts beginning with the center two bolts. Alternate from sidetoside, and work toward the outside bolts.

ICT Billet Intake Manifold Bolt Set Part Number 551400 https://amzn.to/3jw7afT
ICT Billet Exhaust Manifold Bolt Set Part Number 551696 https://amzn.to/2UmH8kQ
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