Thread: EGR removal...

Dave .... or anyone ...

I need your wizardry. What happens when the bottom bolt at about 8:30 o'clock in the plate onto the manifold won't come out because the internal hex is stuffed ....

get next size hex key and hammer it into the head.

if you can apply heat the expansion may result in breaking the grip.

after that you might have to call the professionals

reply sent in PM and copied and pasted to here

depends on what youve got access to.

I usually have at it with the #2 easy out from my easy out kit after.

you can try removing the top bolt, then knocking the blanking plate round anti clockwise, spraying it with wd4- then locking on a set of small vice grips.

hammering in the next size up torqz bit sometimes works.

putting a bolt into it then giving it a weld with a stick welder (youd want to be good)

thats the first round of semi friendly solutions

Had a calming beer ... now to get nasty with the mongrel bastard of a thing

Originally Posted by Anderzander

What about just replacing the pipe with something like this

I think most of the problems with the little rubber bungs that come with the kits is that they perish and leak - and that's not good for the brake circuit.

Hence why one should use EPDM or Silicone caps

Ah

The joys of landies ...........
Have to improve access to the mongrel thing .........

Remove top radiator hose and heater pipe from head ... loose about 1 litre of coolant I'll worry about bleeding it later ...

Try to remove heat shield from over turbo ... of course the bolt into the turbo housing through the hole at the back won't budge

Drill out side rivets to said bracket . Can't get drill to rear 2 rivets .
Out with the 4" grinder and carefully remove heads of rivets ... almost carefully, not too much damage to shield in vicinity of rivet heads

Ahh .. now I have a clear go at the offending bracket bolt. No bloody way it's going to come out .. rounded the head nicely

Finally tap EGR manifold flange to side so I have more room .. still can't move the bludger ...

I'm off to drown my sorrows....E2.
A mate's dropping round in the morning with a kit of bolt removal bizzos so hopefully better luck tomorrow.

Meanwhile the mongrel thing in all it's unrunable glory is blocking the driveway so I can't get the other vehicle out ...

I had my exhaust manifold off when I did mine (while replacing the head gasket). I had the same problem but a pair of vise grips got it. With the manifold off the was plenty of room to get onto the allen bolt. They had to be real tight to get enough grip to turn it.

Is removing the exhaust manifold an option for you? I'm sure you've spent enough time on it that you could have had the manifold off by now.

Originally Posted by awabbit6

Is removing the exhaust manifold an option for you? I'm sure you've spent enough time on it that you could have had the manifold off by now.

That's my next option .... if tomorrow's efforts don't bear fruit.

I'm afeared if I go down that road, trusting my luck I'll snap a couple of manifild studs ..