Help Extracting Stripped Torx Bolt

[Mark Herzig]

I could sure use some help from you guys that do this for a living.

I have a '95 E300D and I'm removing the intake manifold. There are 4 of the 15 bolts that are stripped and I need to go to the next level figuring out how to extract them.

I just put the manifold on last weekend after replacing all the fuel lines and installing a new wiring harness. I over torqued the bolts... somewhere around 26 lbs. I did not use new bolts but used the ones that came off. So the bolts are not stuck with age... just MY ignorance....

Here is what I have done so far to get them out:

1) tried to use the torx socket attachment to extract.. bolts stripped.
2) tried the Craftsman 3 pc. Screw-Out™ Damaged Screw Remover Set... Absolutely no help...
3) tried the Craftsman Bolt-Out™ Damaged Bolt/Nut Remover Set... Again no help. The #5 fit right over the torx bolt and would not grip. #4 too small and #6 too large.
4) Got, but not tried the Craftsman 7Power Extractor Drill-Out set... Thought I'd use with my 14.4 volt variable speed drill.

But before I execute #4, I REALLY would like to pick the brains of you talented mechanics who REALLY know how to do this stuff.

One of the bolts is the last on, closest to the firewall on the bottom... Any clues how to get to it... the drill will not maneuver that way...

ANY ideas will be greatly appreciated. I have an injector line with a pin prick hole in it that spews diesel... this is what I'm needing to replace.