A stupid mistake egr - help!!!

Hi all,

After taking a bit of advice online I decided to remove the EGR. I got it all off except the 2 hex bolts that hold it on. A post suggested hammering the valve out of the way (its broken anyway) so I can get to it. Did this and unfortunately I just cant get the bloody bolts undone. Any thoughts on tools, methods of extraction - so bloody difficult to get too...

Is it safe to drive like this (just to get to halfords a mile down the road?!)

Thanks so much.

Dan

dcowtan said:

Is it safe to drive like this (just to get to halfords a mile down the road?!)

Click to expand...

a mile down the road? I'd walk

easing oil

impact driver

or

Extractor set;

snap on /blue point stud extractor | eBay

dcowtan said:

Hi all,

After taking a bit of advice online I decided to remove the EGR. I got it all off except the 2 hex bolts that hold it on. A post suggested hammering the valve out of the way (its broken anyway) so I can get to it. Did this and unfortunately I just cant get the bloody bolts undone. Any thoughts on tools, methods of extraction - so bloody difficult to get too...

Is it safe to drive like this (just to get to halfords a mile down the road?!)

Thanks so much.

Dan

Click to expand...

Is there enough room to shock the bolts with a hammer and chisel or some heat, or both?

Rounded nut extractors will do it

Wurth Rost Off, recommended on Lz worked for me. Liberally coated bolts and then used a 6mm hex socket and 3/8 drive gave good purchase. They will go with a crack!

You're lucky you did not break the inlet manifold. A tip for the future never hammer on alloy parts. I'd get some heat on the bolts with a blow lamp then soak with plus gas or similar overnight. Dont use an acetylene torch or you'll melt the manifold.They'll be stuck because somebody has used thread lock on them. I dont recall any of the EGR hex bolts being so awkward you could not get to them. The bast*rd ones are normally the two that hold the pipe to the exhaust manifold but they also come out with a little heat. You could drive with an open manifold but you'll get no turbo pressure. It will be quicker to walk.

Thanks for all your help guys - another go with some 4in1 releaser and a better ratchet and i've done it...thanks so much!

mines were a bugger to get off, i ended up using a long breaker bar to loosen them.
In the end i had to cut them off with a grinder remove hte egr valve, then drill and tap them, ended up going up a size of bolt think there now M10

my TD5 EGR was a git as well.

All came off fine until the 2 hex allen keys holding the little copper pipe to the manifold, one wouldnt come out. had to soak it forever and get a really long hex key and a piece of pipe.

I stood on the engine and me mate kept squirting penetrating oil at it.

So the lesson here is penetrating oil. Get your egr bolts soaked for a good week before you attempt the job. Thats how I did mine & the A-frame ball joint. No worries there.

Everyone's had issues getting their bolts out and mine came off a breeze........... im worried now!