I have a misfire code on cylinder number 1 and 6. Number 1 was no problem but when I went to change number 6 I found I was in for a struggle. Had to unhook the fuel rail on the drivers side because the bolt holding the cop in place is directly under it. I can put the socket on the bolt but unfortunately the bolt is stripped out just enough that the socket wont grip on it. The parts stores around here dont carry a remover tool small enough. Drilling it out is next to impossible due to its location. Under the fuel rail and above that is the egr. I have sprayed the living devil out of the bolt with some pb blast. Nothing is working. I will try to get some sort of pliers in there if I can. My question is this: Is there something else I could try? Any suggestions are welcome.

 

tough situation ,
I don't know what a cop is ., is it coil on plug . i see allot about those here but just guessing from what i read .
if you're using a six point socket try a 12 point of the same size and try to tap it on . and vise versa 12 pt. to six .
if that doesn't help go to the next smaller size in standard or metric and try to tap that on . it sounds like it is a small headed bolt and it probably is not that tight. you may need to use an extension don't bang the heck out of it . the extension may get stuck . but firm tap hopefully will seat the socket .
good luck let me know how you do .

 

What size socket fits or should fit the head of the bolt?

 

is a 9/32 or a 7mm nothing smaller will fit no matter what

 

Irwin makes socket that grips rounded bolt heads but 10mm is the smallest that I've seen or have. But they might make smaller, you also might try a small pair of vice-grips.

I was wrong mine goes down to a 5/16" or 8mm but thats still bigger than you need

 

are you able to attack from a side , If so use a needle nose type of vise grip .
grab the head not from the tip of the tool but from further back .
grip it tight and put intermittent jolts or stabs to break loose , or better a
*closed end * wrench , again tap it on from on top w/ an extension or other socket . I bet it is not to tight . use intermittent pressure like a air hammer does .
how about taking a cold chisel and reshape /cut a few flat sides . or from the side take a fine file and reshape the side/s . to be able to seat a socket .
or how about cutting a slot on the top of it to use a screw driver .
take a reg. vise grip and from on top grab tight very tight . will you be able to turn it .

 

just tried to attack from sides cant be done. I will try to take a chisel and tap a slot in the top so I can possibly use a flat head on it.

 

I would be afraid it would split off part of whatever is left of the head. But then, Murphy has a permanent residence on my shoulder.

 

Sears carries a Craftsman socket set which will remove stripped bolt heads.

 

I have a set of stripped bolt removers that go down to 7mm possibly even smaller. I bought them at harbor freight. I don't know if they still carry them or not but you should be able to find a set somewhere. they work like a charm.