Replacing injector when cover bolt is rounded

[F4rbar]

Hi guys.

I have had an occasional engine light flashing which developed into an intermittent misfire. To try and solve this I replaced the spark plugs and leads, and it did fix it temporarily.
OBD2 reader says misfire cylinder 3. Today the misfire became constant so I need to do something about it.
The next thing I want to try is replacing that injector. And I have already bought one.
The problem is I cant get the injector cover off because one of the bolt heads has rounded! Anyone got a suggestion?

 

[JamesBryan]

The fuel rail guard nuts?

Good luck is all i can offer.

 

[JB21]

Maybe try this..

http://www.screwfix.com/p/erbauer-b...gclsrc=aw.ds&dclid=CK3Hj-n8iNUCFWYC0woddBwOIg

 

[JamesBryan]

Maybe try this..

http://www.screwfix.com/p/erbauer-bolt-nut-remover-set-6-pieces/6083D?kpid=KINASEKPID&cm_mmc=GoogleLocal-_-Datafeed-_-Tools&cm_mmc=Google-_-Product%20Listing%20Ads-_-Sales%20Tracking-_-sales%20tracking%20url&gclid=CjwKCAjw16HLBRBFEiwAElREqPdW8DXUPvEjH9EZ2kArDuwGekDOYNElrYLWXsuf-RXOvM2LJkD71RoC-JMQAvD_BwE&gclsrc=aw.ds&dclid=CK3Hj-n8iNUCFWYC0woddBwOIg

It's getting one in that's the problem. The hole is so small.

 

[leedsboy]

It's getting one in that's the problem. The hole is so small.

*snigger*

 

[Amos91]

Have you got 10mm or 13mm bolts on your fuel rail guard? I very much doubt you would those removal sets to fit, although they are brilliant!

You need to try hammering on a socket that's a size down / slightly smaller imperial size.

 

[Budgie]

Well placed grinder blade through the fuel rail guard.

Just be careful of the rail, for obvious reasons.

 

[Thrust-Rated]

Just be careful of the rail, for obvious reasons.

You've lost me

 

[F4rbar]

I will have a go at the smaller socket. Don't want to risk one of my nice ones though. Maybe I could get an imperial size that's slightly smaller.

I did think about just cutting it. It's only the right hand one that's stuck. Trouble is since I haven't take it off I don't know where the fuel rail is to be careful of it, if you know what I mean.

 

[Chris_Beer]

I'd be more inclined to cut it a little then use a massive hammer to split it.

It's only alloy, so better to split it rather than cut it to bits and end up chopping into the fuel rail potentially ending in fire

 

[JamesBryan]

Hit it with a sledge hammer to try and shear the stud off, they're not that strong.

 

[hipwell]

Hit it with a sledge hammer to try and shear the stud off, they're not that strong.

I sheared a stud off trying to undo a stuck on nut so yeh they are not strong at all lol

 

[F4rbar]

Might be worth a go. I'm pretty good at destruction!

 

[JamesBryan]

Worse case scenario is that you'll need a new fuel rail. But they're cheap enough 2nd hand.

 

[F4rbar]

Tomorrow morning job then. First attempt: Force a smaller socket on. Second, see if I can cut the head off. Third hammer the f out of it. Sounds good to me.

 

[Chris_Beer]

I have a spare if you want it

 

[Gus]

Are you absolutely sure the head is rounded?

You do need a thin socket to get down the hole. Most sockets won't get down the hole as the socket side walls are too thick.

I know for sure that the Halfords 1/4" 10 or 13mm sockets will go down.

 

[Gus]

All my fuel rail guard bolts have been 10 but have heard some are 13

 

[franx]

13mm ^^ yep

 

[bloke]

what socket are you trying to get on it?

 

[JamesBryan]

All my fuel rail guard bolts have been 10 but have heard some are 13

The one (yes 1) holding mine on is a 12mm haha. So random.

 

[Djw John]

Found that the manifold nuts work perfectly if anyone needs to replace theirs, they're 10mm.

 

[F4rbar]

A little progress update then...
Yesterday I undid the left hand bolt and tried again to untighten the right hand bolt. It is indeed 10mm; I can feel it catch and then slip. I had no luck getting a smaller socket on either.

I tried smacking the guard with a hammer and surprisingly got no where apart from causing a crack in the casing. I stopped when I got a whiff of petrol that worried me.

I decided I probably needed better access which requires taking the bumper off. Remembering what a PITA that can be, and being reasonably hungover I gave up for the day!
Having taken the coilpack off the upper intake plenum I spotted a crack in it and some corrosion, so will also try replacing this too.

So today I've got the bumber and crossmember off, then jumped on my bicycle and when to the local motor factors who luckily had the correct coil pack - discounted too because one the the bolt holes has cracked. I also went to Screwfix and got a bolt extractor set, as JB21 suggested.
I'm going to grab a cup of tea and crack on... wish me luck.

 

[bloke]

what socket are you trying it with??

 

[Djw John]

Have you got a 6 sided 10mm you could use? Often works better than normal 12 sided ones on something that's already damaged.

 

[F4rbar]

Not going well. The bolt removing isn't biting, pretty sure I need an impact driver for it. Yes I've tried a 6 sided socket.

Worse though is the left bolt. Where I thought I had removed the bolt and dropped it, I can now see that there's a socket stuck on it! As it's not mine it must have been from a previous attempt.

 

[bloke]

that's not a socket, nut is on wrong way round.

 

[F4rbar]

Damn. I did wonder.

I'm going to try changing the coilpack for now and reassembling the air intake. With any luck that'll fix the misfire and I won't have to do the injector.
You can bet it won't though.

 

[Djw John]

that's not a socket, nut is on wrong way round.

Which is f**king impressive!

 

[The Chubby Pirate]

You've the patience of a nun in a coma, angle grind the c**t off.

 

[npt]

Just tap a larger size socket on it and it'll come off no problem, its only on by a thread, 2 minute job lol

 

[The Chubby Pirate]

Just tap a larger size socket on it and it'll come off no problem, its only on by a thread, 2 minute job lol

How will that work? From what i'm reading its on the wrong way and its a shouldered nut thats on it?

 

[F4rbar]

You've the patience of a nun in a coma, angle grind the c**t off.

I'm definitely at the point where I would like nothing better than to hack the f***er off. Just a bit worried about cutting through the fuel rail at the same time as making a shower of sparks!

 

[JamesBryan]

I'm definitely at the point where I would like nothing better than to hack the f***er off. Just a bit worried about cutting through the fuel rail at the same time as making a shower of sparks!

Aluminium doesn't really spark when you grind through it.

 

[R3k1355]

that's not a socket, nut is on wrong way round.

Which is f**king impressive!

How on earth did they even manage to get it on in the first place?

 

[F4rbar]

Coil pack hasn't fixed it so I've got to get at that injector.
This is the culprit. Good guess on the shouldered nut. In fact it's an integrated washer, no idea how they got it on!

Well if you can direct me where is safe to cut that would be useful. Its my last resort now.

 

[Matt Cup]

When I had mine, some bright spark managed to put that shouldered nut on back to front, fortunately it wasn't on tight so I used blue tac on the end of a socket to get it off.

 

[The Chubby Pirate]

How the f**k would you even get that on the wrong way?!!

Edit; i thought you managed to get it out!

Someone could take theres off and measure back how far the rail is?

 

[Stay Puft]

The black tube looking thing to the left of the rail guard is your fuel rail, so just try to stay away from that. Cut half way into the fuel rail guard, then hammer it and surely it should just snap?

 

[cs_dave]

^ this man is a pro listen to him