Need some help with this problem!
 

I just bought a new allen wrench set from advance auto, the kind with the hex end and the circular hex end on the other side. I was attempting to change my injectors out today, and ran into this problem. I got the upper manifold off in like an hour/ peice of cake! I get to the lower intake manifold and stuck the circular hex part in the middle row of hex screws and start to twist, and bam! the circular end gets stuck inside of one of the hex screws!:( I used the other end(the right end)hex side, and got all the rest out with no problem! Just that one! I will try and post some pictures but I dont know how to put them in the thread, Im assuming I may have to drill that peice thats stuck in there until it breaks into small peices:mad: I dont know! Please help.

Can you get some vice grips on the rest of the allen key?

I had trouble trying to get the lower manifold bolts off when I did mine too, I ended up using an allen head that attached to a socket wrench. My advice would be to try to get some vice grips on the allen key too but pics would be best so we can see what you have to work with.

I had the exact same thing happen to me when removing one of the upper intake manifold studs. I just had to get a very good grip with the vice grips. Long story short like gfnk357 said and I did get you the allen head that goes to the ratchet. Makes life a whole lot easier.

Gosh I thought I was the only one to experience this! I was proud of myself for getting that upper manifold off in like an hour (yeaa) I thought It would have taken longer but since this is my third time, I already know what to do! But I never took the lower plenum off, and I have to replace a few if not all the injectors and the fuel injection hose, but anyway, I will try and post some pictures tomarro. But I cant get a pair of vice grips on it because the peice is too small, like stuck inside the hex bolt.

It broke off? Take a screwdriver to the broken piece and tap the end of the driver with a hammer to jar the piece loose. Whenever I take those bolts out the hex bit gets jammed and needs to be turned in reverse and wiggled a little to get it to unjam.

Next time use a socket type instead of an actual allen wrench. I just went to Sears and bought myself a 6mm (IIRC) and have never had a problem with that method.

Thanks I will see if I can get the screw driver and hammer in there to knock it loose, as well as go pick up a 6mm hex socket. I thought that the allen key would be good enough as I used that end to loosen up all of the upper plenmum bolts but ohh well.

Well I tried the screw driver method, and bamming it with a hammer, but that didnt work, so now I dont know what else to do! Maybe if I drill carefully it will come apart.

maybe.

remember to use a big shop vac, and cover the ports with tape. keep shards out of the engine.

I'm curious why you need to take the lower IM off to change the injectors? As long as the upper IM is removed which includes the plenum and the (trumpet) adapter plate...you should have enough room to remove the entire fuel rail assembly. I've had luck loosen stubborn allen head bolts with a chisel and a hammer. Set a good mark on the allen head with the hammer and chisel, then hit it to turn the bolt counter clockwise and you're good!

Sorry I was reffering to the lower manifold, But I meant the middle plate that sits between the upper plenum and the lower plenum( trumpet) does that gasket have to be replaced too? yah the bolt that has something stuck in it is on the adapter plate thingy. I will see if i can drill the peice and try and break it up today.

http://i952.photobucket.com/albums/a...3/000_0005.jpgThis is a picture of what I am talking about. See the part of the allen head is stuck inside the hex bolt, So far I have not gotten anywhere! I have tried to hit it with a hammer and a phillips screw driver, that didnt work, tried to drill it, but it didnt really do anything, it did make it move a little, then I tried to see if a magnet would pick it up but did nothing. I dont know what else to do but see if I can find something like a really thing flat head screw driver, one similiar to an eyeglass screw driver and see if this thing will at least move more than it has. Anyone have any suggestions, as you can see, this is the last bolt that is stopping me from removing this thing, and removing my fuel rail! Just my luck I guess. Also does the gasket have to be replaced under this thing(trumpet) or adapter plate?

Here are more pictures of what Im talking about.:mad:http://i952.photobucket.com/albums/a...3/000_0006.jpgThe middle bolt has a peice of my allen wrench stuck in it.

Wow I may as well clean the upper intake manifold while its gonna be off for a few days, its no wonder I get spark knock somtimes when I use regular gas.

Yeah replace all the gaskets on the plenum/adapter plate,and upper portion of the lower IM...If you look closely after you clean it up, you'll see some mismatching in the intake tracts....

http://i406.photobucket.com/albums/p...tures003-1.jpg

wow how did u get yours so clean? and did the car run much better? As for my problem someone suggested I get something called an (easy out) to get that peice of bolt out of the hex bolt on the adapter plate, Ive got to do something fast because I plan to put it in the shop this week for a tranny replacement.

Still have not solved this problem. Just think Im going to take it to the shop to see if they can get this stubborn bolt out while they are putting the transmission in.

i never like those allen wrench with the circular end...they are crap for heavy duty work....

Wish I saw this before you took it to a mechanic and a 14 poster bumped it.

Take a dremel, cut a slit crosswise and use a standard driver to turn it out, then replace the bolt when you put it back together.

I got it out, But didnt go any further because the tranny was getting replaced, SO i just put it all back togather. I will most likely replace the fuel injectors sometime next week. Can that middle plate gasket be ordered separate? Or does it need to be replaced when removing it? How much does it cost?

This.

They either snap, or strip the bold head.

yes, depends, $10

Just wondering what kind of injectors your replacing the old ones with, OEM, used, upgrading or what? I just thought that since your doing all that work
I would try to upgrade or atleast ponny up for OEM yah know.

Well I am using some used OEM ones I got from the junk yard. I replaced the 2 bad ones, but now the replacements seem to be worse than the originals or am I not doing something right? This is going to be the third time in less than a week I am going to have to tear the car down to replace the injector. The first time it started missing so had it was barely drivealble. SO I went in again and replaced it, seems that the bottom O-ring was pinched on that injector, so I swapped in another used injector, put it all back togather minus the broken intake manifold gasket and she started up fine. SHe ran great for 2 days, very smooth take off, and a really quiet idle, thought I solved the problem. Now today it seems to have gotten worse. The car almost wants to cut off whenever I come to a stop. Im really frustrated with this car!