2007 "Red Yaris" RS Restoration

[zoidberg444]

Literally a nightmare scenario for me with the exhaust manifold. I'm very fortunate on my 1 litre engined Yaris that the exhaust manifold is on the front of the engine facing the radiator. I literally just replaced my exhaust manifold last weekend. It had a very large crack in it which was causing it to set P0420. I also replaced both the Oxygen sensors with new Denso sensors. I have also had to replace the water pump (leaking and rattling) and the radiator as I think it has a pin hole leak or two which is why I was losing coolant.

In my case all the bolts came out without too much of a fight.

From what I have seen your best bet would probably be to weld a nut onto whats left of that bolt and use as much heat as possible. Hopefully it has the effect of freeing the bolt. Using a torx isn't such a bad idea either - unlike other kinds of extractors it doesn't have such an "expansive" force on the fastener which might increase the friction you're trying to overcome by getting it out. Those other extractors you have which have teeth inside the socket are fairly decent. I have a set and I have used them as well a few times successfully.

Best of luck mate - you will need it.