Td5Kai · Jan 5, 2019

I have come to do and egr blank.
So in prep I have been soaking all the bolts in wd40 and other penetrating fluids for about 2 days.
They have all come out a dream apart from the last one that joins it to the manifold.

And after giving it a bit of pressure the head has just snapped off.(see images,)

And Ideas as to what I can do.
I can't drill it out as it's in such a tight spot the drill won't fit in.
Will I just have to take the whole manifold off?
Thanks.
Kai

jamesmartin · Jan 5, 2019

yes soak those nuts first and fit a decent socket and give them a good tap first with a hammer the shock helps

Td5Kai · Jan 5, 2019

jamesmartin said:
yes soak those nuts first and fit a decent socket and give them a good tap first with a hammer the shock helps

As in that's what I did do...

And they have all come out but one that snapped off leaving bolt in the manifold...

jamesmartin · Jan 5, 2019

Td5Kai said:
As in that's what I did do...

And they have all come out but one that snapped off leaving bolt in the manifold...

manifold is off then as thats what im talking about

bankz5152 · Jan 5, 2019

Start soaking all the manifold bolts with Plusgas (WD40 isnt a penetrating fluid). Run the engine for 10 - 15 mins, warms up it up and helps to remove them. If youre REALLY lucky none of them will sheer but they likely will so get spares. Id suggest the Wurth extended studs + the copper flashed nuts.

Should take to long to do. However the same thing happened to me, I could not drill it out. Went through 4 drill bits and about 2 hours trying. I was using colbolt bits and drilling fluid. I ended up buying a new dewebbed manifold.

Frosted · Jan 5, 2019

Need to heat it up ideally, I guess its to small to weld a blob on the end?

Cut a slit in it and use a hammer & impact driver to free it out?

Failing that drill it out and re tap it?

I did exactly the same thing the other day taking off the exhaust from manifold.

Td5Kai · Jan 5, 2019

bankz5152 said:
Start soaking all the manifold bolts with Plusgas (WD40 isnt a penetrating fluid). Run the engine for 10 - 15 mins, warms up it up and helps to remove them. If youre REALLY lucky none of them will sheer but they likely will so get spares. Id suggest the Wurth extended studs + the copper flashed nuts.

Should take to long to do. However the same thing happened to me, I could not drill it out. Went through 4 drill bits and about 2 hours trying. I was using colbolt bits and drilling fluid. I ended up buying a new dewebbed manifold.

Thanks
Yes.. I have just taken the manifold off. None of them sheared.
So I have drilled out the bolt that had snapped and 're-tapped it, and it now good to go.

Just a quick one what's the best way you have found to remove the studs...I'm going to put 3 new ones on the manifold by the turbo.

I'm not an expert so would be glad of some advice.

Thanks

Scooby22 · Jan 5, 2019

If you have enough thread and room put two nuts on the studs you want to remove and lock them tight together then with a spanner on the back nut wind it out. You may have to hold the front nut with another spanner.

Td5Kai · Jan 5, 2019

Scooby22 said:
If you have enough thread and room put two nuts on the studs you want to remove and lock them tight together then with a spanner on the back stud wind it out. You may have to hold the front nut with another spanner.

Cheers....I'll let then soak for a while....and the give it a go

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