Stripped allen bolt on AC bracket

[nueve11]

Hi Guys,

Going to the process of replacing the oil pressure sending unit on a 1988 Carrera, removed everything until I got to the Allen bolt on the AC bracket. The allen head is stripped and I can not get a good grip, tried hammering torx into it but it did not work. As you know not much space to drill it out or to grab it from the side. Any suggestions?

Thanks,
Rey

[Ronnie's.930]

Do you have an air hammer with a chisel bit? If so, you might be able to get it in there and situate the bit so that it hammers counter-clockwise, and once the bolt moves even a little, you can probably finish removing it with torx.

[Bob Kontak]

What is the diameter of the head? Irwin Bolt extractors may grab around the outside.

[nueve11]

Thank you guys for the reply! I did try to use an extractor but their is no room on the outside of the Allen bolt, the bracket is tight to it. I will see if there is room to sneak an air hammer in there, tried an angle drill but there is no room. How hard is to move the fuel rail out of the way?
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1988 Carrera Coupe

[impactbumper]

picture of the bolt? (serious question)

[nueve11]

I can only see the bolt with a mirror, it is call the "hidden" bolt in some threads! It is located under the AC bracket in the passenger side where the two pieces of the bracket meet, is just before the fuel rail.

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1988 Carrera Coupe

[VW_NUTT]

I believe this is the bolt you are talking about. Sorry for the blurry pic. There is only 2 nuts that hold that smaller bracket on. You will likely have to move the fuel rail a bit to remove the 2 brackets at the same time.

[michael lang]

No, there is enough room to get the bracket out without removing the fuel rail. I know because I must taken that bracket on and off a couple of dozen times trying to get everything to fit. He will however have to unplug the harness on the injector for #4 cylinder. During my recent rebuild I was trying to do a heat backdate while keeping the a/c in my car. Unfortunately I was not able to do that because of the heat exchanger tubing. He will have to remove the bracket in the front of the engine that the a/compressor sits on top of. Then when he gets the whole bracket out he put it in a vice and then drill out the roughly 2 inch long bolt that is connecting the two components.

[Lapkritis]

I would go back to the torx. What happened when it didn't work? Torx too big or too small? Try a different size in the direction of failure. It'll work.

[nueve11]

Yes that is the bolt, thanks for the photo. I did see the other 2 bolts but was trying not to disturb the fuel rail. I have never taken the fuel injectors out, can I move the rail without pulling the injectors off?

[nueve11]

The torx was tight but when I tried to turn it, seems like it was a bit small. The next size seems to be too big, not a lot of space to hammer it tight. I think I used T45 & T50.

[RSTarga]

Is it too deep to get a reverse drill bit on it? Spray with some solvent first let it sit for awhile.

[nueve11]

Not really too deep, but there is no room for the angle drill in there. Gerry post # 7 shows the Allen bolt, my car is an 88' and perhaps it changed then. My bracket also goes farther than yours under the fuel rail.
Thanks!!!!

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1988 Carrera Coupe

[matthewb0051]

Try a long flat head screw driver and try to angle it to catch two of the corners in the allen head. I've had some luck with allen bolts that way before. Maybe tap it in place with a hammer when you get it lined up.

[VW_NUTT]

What I think you need to do is: remove the air box cover to get a bit more room. loosen the fuel rail bolts, remove the connector on injector #4&5. gently twist the injector to clear the bracket. As seen in the following picture the injector plugs are in the way. remove the engine tin on the right side and remove the bolts that hold the larger AC bracket on. Then lift the whole mess out. Its a 5mm so I'm not sure what the next closest imperial size would be. I tried to take a picture of the bolt from the side but cant seem to get a clear shot.

[nueve11]

Guys thank you so much for all the suggestions! I will try again the next day or two. Also thanks for the details on removing the fuel rail, I think I am going that route after one last try tomorrow! I have the exhaust off the car, I removed it so I can move the bracket out of the way I hope to do it myself and not giving up. (Can't let this thing beat me)
Thanks Again!!!!
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1988 Carrera Coupe

[Tidybuoy]

I had a similar problem today while replacing the head gasket on my 944 - I stripped one of the allen head bolts that holds the camshaft housing on.

I used a bolt extractor that I got at sears. You place into the allen hole, then tap it in tight with a hammer. After that, you can use a socket wrench on the extractor. It came right out. Of course, now I can get the extractor out of the end of the bolt.

[nueve11]

Thanks Vern! That type of extractor may work on my situation. No time to work on it today but I will try tomorrow w/ that type extractor. VW_Nutt thanks for the advice on removing the two injectors, I can see how that will clear the path without disturbing the fuel rail. Learning a lot!!!!!
Thanks.

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88 Carrera Coupe

[86 911 Targa]

pm sent.

Gerry

[Tidybuoy]

Just remember, you have to tap the extractor in with a hammer so that the threads dig into the hole. After that, it grips like crazy.