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Thread: EGR exhaust allen bolts

  1. 9th June 2009, 08:00 AM #1
    timbo72
    timbo72 is offline Fossicker
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    Question EGR exhaust allen bolts

    Hi all,
    I have a TD5 EGR kit ready to install and tried to do it on the weekend.
    I started at the exhast end (knowing these bolts would be the hardest bit). Knowing the bolt was soft, I sprayed WD40 in and gave it a couple of light taps with a hammer beforehand.
    Using a 5mm allen key in a ratchet and extension bar, I managed to strip the inside of the keyhole. Unfortunately I still managed to strip the allen keyhole.

    I dont really want to drill it out and retap the hole, due to its horrible location. I was hoping someone else has done this before me?
    any ideas
    thanks
    tim
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  2. 9th June 2009, 08:42 AM #2
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    aferrier
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    Hi Tim,

    When I did mine, I was paranoid, after reading a similiar fate of others. I sprayed WD40 the night before, heated the engine/manifold and crossed my fingers. Luckily they cam out whole.

    Try running the engine for a little while to expand the iron/steel of the exhaust manifold. Dose the bolt with some Loctite Freeze-release spray (Repco) and then use a bolt extractor like an ezy-out or you could also try the next size allen key and hammer it into the stripped area to get a grip.

    I replaced mine with stainless equivalents after I got them out.

    Alistair
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  3. 10th June 2009, 02:13 PM #3
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    Hitower
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    Question

    Hi Tim,

    Sorry to hear about your predicament as I have had this happen on head bolts in Mazdas.

    On the side though could you tell me were you got your EGR bloke off kit from and how much you paid as I am having trouble getting in contact with both of the forum sites sellers.

    Neither of them will return my messages and yet their items are still part of the AULRO markets.

    Thanks for your assistance.

    Tony
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