well I have removed my TPI from my car BUT the ^%$^%$ intake won't come off. A couple of those stupid Torx bolts stripped out but I have tried drilling the out or at least to the point where I can maybe pop the heads off but they won't come off. Any advice for this problem?

Also I can't seem to get my MAP sensor off of the intake either

*sigh* so many problems

 

did you grind off the heads? iof not do that then gently pry up on the intake and it'll pop off. Also go to SEARS and buy their easy-out screw removal tool set. That should also work! Good luck

Jason

 

good advice. Now, before you put everything back together, go on down to a _good_ hardware store and pick up grade 8 bolts with a normal head on 'em and never have that problem again (I don't recall the exact size, but they are SAE - 3/8" maybe)

I still carry around the remnants of the intake bolt that sheared when doing my intake gaskets...

 

The correct thread size is 3/8-16, then just match up the length with one of the original bolts. I'm not sure what sensor it is you're referring to, but it shouldn't be a MAP sensor. MAP sensors only came on the 90-92 TPI. If whatever sensor you're referring to is made of brass, your best bet to get it undone is using a six point (not a twelve point) socket to get it undone without rounding it off. If you've already rounded it off, there's always vice grips or a pipe wrench!

 

i just took mine off...twice (make sure the gaskets are on right when u put the intake back on ). Well anyways i had the same problem so i started with a small drill bit and then a larger one to drill enough to pop off the head with a chisle and hammer. I had to do this with 4 bolts and yes it is time consuming.

 

...And you leave nice gouges in the intake to remind you to!!!

 

I had to help 1badrocz get those bolts out. Let me tell you....it was the biggest PITA ever. I dont know what the GM engineers were smoking when they decided to use those type head bolts but it must've been some good stuff. Must have been trying to use up those extra bolts lying around....
Anyhow, ya we had to drill the top of the bolts off using a bit roughly the size of the bolt's width, and then chisel the top off. I dont think it made any gouges in the intake, even if it did its nice and powder coated now
I never want to have to go through that again...

 

I used "alligator" pliers by Knipex on mine, and they came out great. You can pick up a set at Sears, and trust me, as a mechanic, they are WELL worth it.