Looking for advice on bolt removal

[cgoffroad]

good afternoon everyone
I have a 1997 Jetta TDI with 190,000 miles. I am the Second owner of this car and i have had it for about 3 months now. Today I attempted to remove the intake manifold and replace it with one I have spent the last week cleaning. Using the how to on this website I got everything down to the removal of the 6 intake bolts. Then i understood why the previous owner was so willing to come down from his price. The EGR side of the intake is so plugged i could not stick a finger between the EGR post and the intake wall. I started to remove the intake bolts and all 6 of them are completly stripped. The 6mm allen key had nothing to grab onto. I tried using the recomended easy off stripped bolt remover but I could not get it to grab onto the bolt heads. I even tried soaking them in PB blaster for a few hours. Does any body have any advice on how to remove these stripped bolts.

Thanks
joe

[chittychittybangbang]

Pliers, press harder with the EZ-outs, and try try again. If you're good at welding, you could weld a stick to it and use that to torque the nuts. Or cut a slot in the heads and then use a phillips to loosen them. Unfortunately, not much clearance in there so if it's really bad, remove the turbo so you can get pliers in there.

[jjbendo]

Sears Craftsman has a product called Bolt-Out. It is the opposite off a E-Z Out. It fits over teh head of the Allen/Bolt. It has neve failed me. :-)

[YMZ]

Originally Posted by jjbendo

Sears Craftsman has a product called Bolt-Out. It is the opposite off a E-Z Out. It fits over teh head of the Allen/Bolt.

The Irwin (as well as the SnapOn) version is even better, since it has a 3/8" drive square cutout in the back... more options than the Craftsman, but in a pinch...

Yuri.


PS: the Irwin should be available at AutoZone type stores... called Bolt-Grip, I believe...

[crsmp5]

the 8mm xzn for say inner cv joints... beat into 6mm bolt holes with hammer... come right out...

next.. buy a 6mm allen socket.. wrench cannot be beat into them... that in its self should have gotten it..

[BlueMoose]

I used:
6mm allen socket pounded in with a hammer.
bolt extractors that go over the head of the bolts

I also unfastend what I thought was a fuel line for its holder on the driver side so it could move a little more while trying to get the correct angle for some of the middle bolts.

Most of the bolts I thought were stripped just required the allen socket to be put into them more "securely"(see above). To do that I took off a lot of other neighboring parts to get better access to the bolts.

Side note the dealer gave me 6 bolts that looked very different having threads all the way up to the head and were 1 or 2 mm longer. I didn't care about the look, but the length caused me to not use them.