bankz5152 · Jul 24, 2013

My mechanic failed to install my EGR blank correctly, instead fit the blanking plate to the metal pipe coming off the manifold, not to the manifold itself.

I didn't notice till I felt a drop in power, the pipe has split. For the time being I have managed to bodge it so the car runs.

Problem is the two Torx bolts have rounded completely. So far I have tried

- Hammering a larger Torx bit in
- Hammering an Allen Key in
- Hammering a Torx socket over the top - Cheese inside tough outside!
- Epoxying an Allen Key in
- Mole Grips

Not enough space to get a drill without taking the rad off & intercooler off. I'd rather not.

any other ideas?

Dippypud · Jul 24, 2013

Irwins ...

Irwin Bolt Grip Remover 5PC Base set 394001: Amazon.co.uk: DIY & Tools

gemsdad · Jul 24, 2013

Dippypud said:
Irwins ...

Irwin Bolt Grip Remover 5PC Base set 394001: Amazon.co.uk: DIY & Tools

to big dippy,same has happened to my td5.

andrewblueboy · Jul 24, 2013

could you not weld a nut to it

gemsdad · Jul 24, 2013

andrewblueboy said:
could you not weld a nut to it

not enough room bud.

Spunka · Jul 24, 2013

never mind that. wot ya done with your hazard switch

Dippypud · Jul 24, 2013

gemsdad said:
to big dippy,same has happened to my td5.

Feck !!!

they go up to 3/4"

gemsdad · Jul 24, 2013

Dippypud said:
Feck !!!

they go up to 3/4"

nooooo,the sockets are to big for the bolt head.

Dippypud · Jul 24, 2013

gemsdad said:
nooooo,the sockets are to big for the bolt head.

:doh: doh, silly me -

They start at 5/16" or 8mm

What size is the head on your TD5?

gemsdad · Jul 24, 2013

Dippypud said:
:doh: doh, silly me -

They start at 5/16" or 8mm

What size is the head on your TD5?

dont knowbut that small socket looks to big.i will check it tomorrow.

flat · Jul 24, 2013

cold chisel?

gemsdad · Jul 24, 2013

flat said:
cold chisel?

tried it,just shears the metal of the round head.

Spunka · Jul 24, 2013

sounds bad
You could try removeing the manifold put in a vice and weld ( as some one said) something to it, the heat will help shift it

flat · Jul 24, 2013

gemsdad said:
tried it,just shears the metal of the round head.

oh rubbish

its either going to be manifold off then or radiatior/intercool out i reckon and extract it on a bench

hoopfish · Jul 24, 2013

If it was me,i would take it back to "my mechanic" and ask/tell him to put it right!

gemsdad · Jul 24, 2013

flat said:
oh rubbish

its either going to be manifold off then or radiatior/intercool out i reckon and extract it on a bench

if i cannot get the pipe off,i will cut the pipe and use an ally plug in the pipe,well sealed of course.

bankz5152 · Jul 24, 2013

I rang him, no answer. Sent a text so he should get back to me soon.

Kinda ****ed off though because I was going to do it myself, and would have done it right, just through it in with a few other bits to save me time.

Bought those Irwin's hopefully they should do the trick.

gemsdad · Jul 24, 2013

bankz5152 said:
I rang him, no answer. Sent a text so he should get back to me soon.

Kinda ****ed off though because I was going to do it myself, and would have done it right, just through it in with a few other bits to save me time.

Bought those Irwin's hopefully they should do the trick.

the top bolt you should be able to get at,the lower one might be a problem.good luch though,let us know how you get on.

bankz5152 · Jul 24, 2013

Well I was thinking if I get the top one off I should be able to 'break the seal' on the bottom one making it easier to get out.

I shall, will be having a crack on Friday.

jamesmartin · Jul 24, 2013

which bolt do you mean allen bolts to ex manifold or inlet

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