V8 intake plenum removal - front bolt rounded - ideas?

[ballbag]

Fellas,


Removing the intake plenum to replace coil packs, discovered the last @$%&&@& to refit it rounded the front bolt.


6 sided socket not doing the job. Removed the a/c compressor for access with a spanner. Carefully tried a set of vice grips too. All failures.


Any ideas other than jihad against previous culprit?

[Eevo]

weld something onto the rounded bolt so that pliers can grab onto

[ballbag]

Yeah was thinking about welding a socket to it. No access to a welder until Saturday sadly...

[Road Stone]

How about hammering a slightly smaller socket into the rounded head so it "bites" then undo?


Did this with my stuck locking wheel nuts and it worked!


Cheers, Jerry

[bee utey]

A flat ended pin punch around 8mm in diameter and a medium hammer. Hit the punch firmly to mushroom the bolt head and hammer the socket on afterwards. Failing that drill through the head and replace the bolt with a standard hex head jobbie after.

[ballbag]

Might give the punch a go, bee utey. Little worried about steel bolt wrecking alloy manifold thread though.


Also thought about removing alternator and front section of plenum/upper manifold for better access. Then cutting a groove in head with hacksaw or thin cutting disk and attempting to turn with screwdriver, or impact driver if space permits.


Reckon I'll end up drilling the damn thing. I'll post up results!


Cheers all.

[Jazzman]

Try this. The imperial ones are cheaper. Once the nut is rounded I don't think it matters if you use metric or imperil ones of these.


I got mine from Bunnings or Mitre10. Worth $45 for your time and effort.


Once you've used this you will need a new bolt.


http://www.ebay.com.au/itm/like/130710321528?limghlpsr=true&hlpv=2&ops=true&viphx=1&hlpht=true&lpid=107&chn=ps

[ballbag]

Haven't seen those before. Thanks mate.

[Roverlord off road spares]

Try this. The imperial ones are cheaper. Once the nut is rounded I don't think it matters if you use metric or imperil ones of these.


I got mine from Bunnings or Mitre10. Worth $45 for your time and effort.


Once you've used this you will need a new bolt.


Irwin 5PCE Bolt Remover Grip SET 394001 HV656779 | eBay (http://www.ebay.com.au/itm/like/130710321528?limghlpsr=true&hlpv=2&ops=true&viphx=1&hlpht=true&lpid=107&chn=ps)

Yep I have them also, picked them up from Total tools, and they are handy for future miss adventures.

[ballbag]

Victory! Alternator off, injector plug off, go-go gadget fingers to get plenum elbow bolts out.

Clear access for gripper socket + impact driver = one happy discoballbag.

Thanks Jazzman.

[ballbag]

Wow. Those coils are the most difficult thing I've ever encountered on a motor vehicle! What a mission.

[bee utey]

Like anything, when you've done the job once the next time gets easier. You need to undo the top two bolts out of the coil bracket and just loosen the bottom ones two turns. Then the plenum can easily be manoeuvered out. When the coils go back in remember to not do up the bottom two coil bracket bolts until the top ones are in. I used two long 1/4 drive extensions and a 7mm socket to reach the bottom ones with the plenum still on the engine.

If you drop a bolt you have to start from scratch.;)

[ballbag]

Air con lines, harness and LPG coolant lines all in the way.


If the coil harness wires were a foot longer I'd reposition the bastards.








Ignition lead plugs fouled air con lines on the way out. Had to remove leads from coils to get coils out.


What's the go, leads on or off before remounting coils?

[Collins]

I would definitely fit the plug leads before refitting the coli packs.\
I recently fitted new coils and initially found it difficult to remove/replace, however the second time around, due to an incorrectly fitted coil lead, with a little more patience, I found it was not overly difficult. Just have to get the coils on the correct angle.

[Jazzman]

Victory! Alternator off, injector plug off, go-go gadget fingers to get plenum elbow bolts out.

Clear access for gripper socket + impact driver = one happy discoballbag.

Thanks Jazzman.



No worries anytime! Glad I could help.

[JBM770]

Ive only ever had the top screws holding the coilpacks, they're difficult enough as it is to deal with.