Went to do what I thought would be a simple task for a Sunday job and it ended up turning into a pain in my ***. Even snapped a bolt inside the block but was able to take care of that thankfully, got that bolt replaced and on the way to the next side. where the intake manifold sits on top of the engine one of those hex key bolts was being a pain in the a** and I ended up stripping it. Any recommendations to get it off? I'd like to be able to take care of this tomorrow after work. It's the one in the middle of the intake.

From the the looks of it these plugs haven't been replaced since the car was bought and the car is at 120k. Still runs great thankfully

 

Drill the head off the hex bolt. Find a drill bit that fits the inside of the hex. Take your time and try to drill strait down. As the bolts are stainless. once you break the head off the bolt you should be able to pull off the manifold. You should have enough material to grab it with vicegrips and remove afterwards.

 

Sometimes you can hammer a torx bit into a stripped hex head bolt and go from there. Unfortunately if you stripped the bolt using the right tool then the threads are stuck and you will still have a hard time removing the bolt after drilling off the head. If you stripped it by trying to force a metric bolt with a standard key then you should first try using the proper metric allen wrench or bit to remove it.

 

try a tool called an ez out https://www.google.com/url?sa=t&rct=...39782543,d.cGw

 

Depending on the remaining surface area on the head of that bolt and the area you have to work with, you can try putting a slice in the top via a Dremel to use a larger flat screwdriver bit in a socket to get it out.