Stripped EGR bolt of death.... Out of ideas on how to remove

Hey,

I have a 2014 Gen 3 Prius and I'm in the mist of replacing the head gasket. I've removed the all of the bolts of the egr except one. The one that is in the front. I have the tool to remove the bolt, but when I went to remove, I didn't loosen the nut and the head of that bolt tore. I then removed the nut, tried several tools to get the bolt to release, ended up stripping it. I can't remove the egr due me being unable to remove this bolt. I had to disconnect the inverter cables (and I took a pic before hand when I go to re-attach them) for some more room to operate. At my wits end here.

I've tried a damaged bolt/stud tool. Think that did more harm than good. Tried to re-thread with my tap and die set, but I think the bolt is hardened and I would need a hardened kit to re-thread. I don't have a welder so I can't tac weld anything to remove the bolt. Literally at peak frustration with this thing and I'm running out of ideas... hence this thread.

Any other suggestion on how to get this thing removed? Maybe call a specialist? Is there a tool I can get that can give me enough grip to twist this off? With it being stripped, the tools I currently have don't provide enough grip and there isn't a lot of space to insert a anything large in there.

Also, I have been trying to find this very part but the online manuals I look at, the part number is different and the sites are unable to confirm if it will fit or not. Any help with identifying the right part would also be great.

Thanks in advance for any ideas I can try.

 

Thanks. I do have some locking pliers that came with a car toolkit and my biggest issue is clearance as it was hard to get a solid grip on anything. I'll order those Malco locking pliers and give it another shot.

I also see a bolt extractor set that I'll order and give this a try as well. Really screwed myself when I stripped that bolt. This has delayed this repair process a lot.

 

From what I can see.... possibly. I would have to remove some hoses and there would be a couple of screws directly under the egr that I would need to get to.

I don't have a welder atm. I'll have to get one from harbor freight. But I do have a dremel. I could possibly do that. Thanks for the input.

 

Yeah, I definitely don't have the proper tools. I've ordered a bolt extractor kit which will arrive today. Hopefully that will do the trick, else I will break out my dremel and drill a slot where I can remove the screw.

I'll pick up some penetrating oil today.

 

Yeah I have one. I just didn't remove the nut before hand.

Good news is that a bolt extractor kit I ordered came it and it did the job. I had to resist chunking that bolt down the street.

Now time to clean this egr and remove the valve cover.

EDIT: Also where did you get that manual from? Does it contain the part number for that bolt? I'm trying to get a new one ordered.

 

Nice. Thanks for teaching me how to fish!!!

My frame no is ZVW30L-AHXGBA. Using your links now to id the parts properly. Thanks again!

 

I've just ordered the part from them after confirming the frame. The site had a link which said: "This part on this page looks like it will fit better" or something to that effect. I click on the link and it's the same part no. So I ordered. It will be here later this month, and shipping is pretty crazy but hey, I will get the part I needed.

Soaking that EGR now as we speak. Valve cover is off. Will get to the headgasket tomorrow and finally replace it. Timing chain still looks good, those are meant to last the life of the vehicle irrc, and there is still plenty of paint on the chain left. Made some real progress today. Can't wait until this is done and all the parts i.e. headgasket, water pump, pcv valve, spark plugs, coils, will have all been replaced.