I'm trying to replace my injectors and of course there's one bolt that someone has previously tried to work some magic on. I've tried cutting a slit for a flat head, tried vice grips/pliers, welding a bolt to it, drilling it further, I can't seem to get this thing to come loose and I'm about ready to set the car on fire. Anyone have an idea???

 

You might have to cut the head off and extract what’s left after the runners are off.

 

How would I cut the head off? There isn't any room to get a grinder or anything in there

 

Do you have a dermal with a cut off wheel ?

 

Yes but not a wheel big enough to reach between the pipes beside the bolt. A wider one would also hit the fuel rail before the bolt head

 

Looks like it is long enough to get one of these on it.

 

Air chisel to try to rotate the head. But I’m sure your still limited for room. I’m out of ideas since you tried to put heat on it bye welding on a nut.

 

That would definitely fit and probably work, I just already spent $50 on a different remover tool that did nothing so I don't want to spend another 100 on a maybe haha. This bolt will be the death of me, I've been at the thing for days and even after numerous soaks in penetrating oil, it hasn't budged

 

Just keep stepping up in drill bit size until the head is gone and then repair once the manifold runners are removed.

 

https://www.harborfreight.com/electr...aft-44141.html



This guy with a carbide bit is one of my favorite tools. You could have the head off the bolt in less than a minute.

 

Oh damn.. but would that be able to fit in such a tiny area?

 

Here cheaper at lowes

https://www.lowes.com/pd/IRWIN-BOLT-...r-Set/50146292

 

sure. It has probably a 6-7" reach

 

Bastard file. Couple minutes and what's left of the head would be history. Use antiseize during reassembly.

 

What's a bastard file?

 

It's a moderately coarse metal file.

I'd keep drilling it, looks like you're half way there drilling already. Drill till the head's gone.

 

http://lmgtfy.com/?q=What%27s+a+bastard+file%3F

 

[QUOTE=Drew;6237525]http://lmgtfy.com/?q=What%27s+a+bastard+file%3F

That's a little harsh. Humorous, but harsh.

 

Leave it on and pull all the lower bolts off and pull the other side runner off. Then you can remove the plenum and runner off together then deal with that bolt on the bench

 

Can you use a dremel & cut a slot in the head to use a flat screwdriver?

 

Your previous drilling is on center. Use a 1/2" bit and keep going until the head is gone. Then you will have something left to grab onto after the runner is removed.

 

 

Was going for the humor. Figured it was the fastest way to let Google answer the question better than I could.

 

You said your about ready to set it on fire? Keep welding on that bolt and you will!

 

Thumbs up for the IRWIN. Cheaper than the craftsman and work the same.

 

 

Funny. I have that exact set, it's never once worked when I needed it. Usually it's too loose, or too tight to actually grab the whatever.

 

Could of used a cold punch and made an indentation on the outer edge of the bolt, then hit the cold punch with a hammer in the direction you want the bolt to move (loosening)

It's my go to method at work and very rarely fails me.

 

 

I'm gonna try that later, I haven't been able to get a proper sized wheel in there to cut a groove but I'll try a few of the other things and hopefully be able to knock it loose

 

Hammer and dull chiesl, work on the left edge. Once you break it loose it usually can get it out easily. Only if experienced and light trigger finger use air chiesl. If it is cross threaded drill out and rethread or heil-coil. I would put the bolts next to it back in to relieve pressure in that area. We did them at the dealership back in the day, replace with new bolts. Taking off with plenum is other option but it's secure on the engine to at least get it loose.
Joe

 

 

 

Get a proper drill bit and drill the rest of the head off. 10 seconds and it's done.

GD

 

 

Update: there was no room to get the drill in level enough to drill the head fully off, only the bottom of it so I took another swing at a hammer and chisel, still wouldn't turn. Both the plenum and runners were banged up and tired looking, and had an obnoxious amount of carbon build up, so I did what any respected mechanic would do and broke out the sawzall. To clear it up, I had a spare set of intake runners that were in much better condition, or else I wouldn't have done the hack job. Anyways, now it's off and I'm on to trying to loosen the fairly rusted fuel lines running to the rail. Think a blow torch would work?

 

Think a blow torch would work?
It is worth a try. When you are able to reassemble, use anti-seize on all threads.