I need help Removing rounded bolt
 

Hello, board, I am in a sticky situation here. I was changing my injector seals, when the allen bolt hole for the #2 injector got rounded out. Now I have 5 injector seals done, and one that needs to be done. The thing that sucks the most, is that the #2 injector seal was the one that needed the most attention. Any tips on how to remove it?

Kool Tool
 

Great $20 tool - look at "Bolt Out" at Sears product #52160

Do they have it out for rent at autozone???

I don't know what kind of access you have to the bolt but I use a disc cutter (or dremel w/ fiberglass cutoff wheel) to cut a slot on top of the bolt. A normal screwdriver or ratchet w/ flat blade socket can be used to remove.

Good Question
 

I have never rented any tools from Autozone

Whatever solution you use to get a grip - also be sure to soak the bolt several times with penetrating oil and let it continue to soak overnight. Very good stuff for loosening up corrosion!

Ken300D

Pick the next size-up Torx bit and hammer it in.

Works every time...............

Vice grips can clamp on tight and help get the bolt out as well.

torx works every time , even if you have to grind alittle off and hammer it in so its stuck and it will come out with some
rust spray

FYI:

WD 40 is not a penetrating agent. I hear very goog things about PB Blaster.

Ok I will definetly try these methods.

Thank You

If you can not get a pair of vice grips around the bolt head you are in for a bit of an ordeal. Try cutting the bent part of the correct sized Allen wrench off. Grab the strait shft with vice grips, insert the shaft into the Allen head and start tapping with a shop hammer. Hit it reasonably hard for a minute or so. This shocks the bolt and will often break it loose. I doubt that MB used anything like Loc Tight on these bolts but over years of expanding and contracting with the engine heat will cause them to stick. As other say you can find the next size larger either metric or SAE Allen wrench and drive it in. Grind a very small chamfer on the end before you drive it in so that it doesn't roll a burr up as it goes in.

Mite wanna try a 12 pt socket