Rounded Injector Bolt, 1.6 HDi

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akube
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Rounded Injector Bolt, 1.6 HDi

Post by akube »

Hello all! I am certainly new here!

I have a 2008 Citroen C4 Grand Picasso with 150k miles on it. Silly me has gone and rounded one of the hex bolts that hold down injector number one from the left!

I wanted to have a go at changing the copper seal but I was too lazy to remove the cowl and ended up rounding the bolt because I didn't get a good clearance !

Please is anyone able to suggest a tool to remove the bolt or somewhere I can remove this bolt? Drilling isn't an option because it would ruin the threads I think.

Thanks in advance !

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myglaren
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Re: Rounded Injector Bolt, 1.6 HDi

Post by myglaren »

Welcome, shame it is under such circumstances.

Have you room to try one of these things:-
81fbXQTVxuL._SX425_.jpg
Some members have had success with these where others give up on the job.

akube
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Re: Rounded Injector Bolt, 1.6 HDi

Post by akube »

Hi Myglaren, thank you very much for you suggestion. Unfortunately I don't think I have room to use that tool :(
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RichardW
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Re: Rounded Injector Bolt, 1.6 HDi

Post by RichardW »

You might get in there with an Irwin reverse flute socket - but there's not a lot of room! A torx bit hammered in might get it out - they are not too tight.

Bob L'eponge
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Re: Rounded Injector Bolt, 1.6 HDi

Post by Bob L'eponge »

If it was rounded off using a 12-point socket, then a 6-sided socket might well do the job, or a 'surface drive' socket. Failing that, as noted above, hammering on Torx socket might well work - they are only tightened to 11 n/m or so. Take care to replace all the studs - they are 'stretch' (or torque to yield) types and are known to fail if re-torqued repeatedly or tightened to the incorrect value.

rob78
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Re: Rounded Injector Bolt, 1.6 HDi

Post by rob78 »

Tack an old Allen key in should be able to get a 1.5mm rod in there if you have a stick welder kicking about.

akube
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Re: Rounded Injector Bolt, 1.6 HDi

Post by akube »

Thank you all for your suggestions, I will post an update when I give it another go!

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Chris570
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Re: Rounded Injector Bolt, 1.6 HDi

Post by Chris570 »

Word of caution here, I tried to replace the studs on my engine (with about 135k on it) and one of studs snapped at the top and that dropped into the combustion chamber.

The car now has a new engine.

Be bloody careful and learn from my mistakes!!!

RichardW
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Re: Rounded Injector Bolt, 1.6 HDi

Post by RichardW »

Bet there were some choice words after that!! The very definition of a bad day...

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white exec
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Re: Rounded Injector Bolt, 1.6 HDi

Post by white exec »

Must own up to doing the same myself, when, in my teens, I de-coked a friend's 6-cyl PA Cresta.

With head off, I was using a round file to clean out the head waterways, and didn't notice that a cm of file had broken off and fallen into the head cavity. When the head was lowered back on to the block, the bit of file managed to fall, unseen, into one of the pots.

Amazingly, the engine started up and ran fine, until the next day - when the file-end took its revenge and impaled itself into the top of one of the pistons, bending a valve for good measure.

Needless to say, I wasn't asked to open it all up and repair. That was left to the owner's brother, who owned a transport firm nearby.

Lesson learned. I was forgiven, though. :-?

akube
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Re: Rounded Injector Bolt, 1.6 HDi

Post by akube »

Ahah thanks for the warning folks. I was already planning on plugging up any exposed holes With a cloth if I opened up any of them

Sharkie
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Re: Rounded Injector Bolt, 1.6 HDi

Post by Sharkie »

Clean it out and hammer new torx bit in.
You may also want to grind a mm off the bottom of the torx bit since it is rounded and provides no grip.
Other way - only welding or drill it, so you can remove injector. Then you are left with a few mm nub you can weld on a new head.

There's also the chisel method, but that also requires sacrificing a tool.

akube
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Re: Rounded Injector Bolt, 1.6 HDi

Post by akube »

Hello everyone, I have an update!

I managed to get it out using a reverse threaded socket! I am so happy right now :))
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