set fire to it! the tooth brush piece will come right out. the intake assembly is really easy leave all the hoses and just remove the bolts/nuts about 12 i think and pull it just an inch poke your finger in each tube till you find it, i could take my injection assembly off in 15 min course ive done it 5 or 6 times

Now I'm wondering if they make metal tooth brushes...

Now I'm wondering if they make metal tooth brushes...

...or a plastic magnet... 

Plastic magnet...jeez don't i wish.

Well i decided to try the smaller tube duct taped to my shop vac idea.  I'll do it this weekend and let everyone know if i had success.  As for the EGR bolt.  Because of where it's located at i can't drill it and/or tap it.  It's at the back of the motor by the firewall in a spot to tight to fit a drill.  but I think the saving grace is that this bolt was long.

and the first 1 1/2 inches of it were smooth.  The only part still stuck is the threaded part so that leaves me 1 /12 inces to either use a self tapper of some kind or a helicoil.  Thanks for all the ideas guys i'll let you all know how it all turns out.

Quote from: spyder0069 on May 02, 2008, 06:13:25 PM

But be carefull not to overtighten the new bolt down with a helicoil as they do not as strong as a properly taped hole.

A properly fitted helicoil should be stronger than the original ally thread. In the defence industry threads in ally below a certain size must be heli-coiled.
I dropped a dowel once when removing a bike's cylinder head. Ended up having to split the crankcases to retrieve it from the gearbox. These things happen.

You gotta get the helicoil just right and not over tighten the bolt. I overtightened one and it pulled loose from the back of my head. Thread serts are better for aluminum applications but harder to find the right size, more expensive than helicoils,  and the hole has to be much bigger then the actual bolt you plan on using because the thread sert has more meat to it. In my application, I ended up tapping out the aluminum hole, putting in a fresh helicoil and using thread lock red to lock a stud in and used a nut to lock my extension housing to the back of the head, not sure if something like that would work in your case though. Good luck.

-Adam

idid the same shit with some wooden q-tips cleqaning out the intake took a while and a few beers but i got it out just lucky no real cure i can pass on to you