Disco 2 EGR removal

Well..... Was going to blank off the EGR, however, previous owners must have tried and rounded the hex head on the lower bolt. Anyone got any ideas? I've tried torx bits but can't get enough of a swing on a hammer to create a tight fit :/

Try Irwin bolt grip grip tool, sets are quite cheap.

Cheers Tonyj66, have you had any experience with these? Do they grip round heads?

I have used them once on a rounded off bolt, worked well. if you soak the bolt with plenty of WD40 or something like that for about half an hour so that it can penetrate, can't see why it wouldn't work.

Cheers dude, I'm going to get myself some and try it! I'll let you know how I get on

I would advise that you use a product such as "PlusGas", it IS a releasing agent.
If you check further, although everybody and his uncle says WD40, it is in reality a paraffin based water dispersant, with a few aromatic hydrocarbons added.
The WD40 company does sell other materials, and I think there might be one specifically for releasing rusted bolts, but the stuff you buy on supermarket shelves isn't it.

Ok, thanks Brian. I'll try some of that instead of wd

Get it hot!!

Better get it freezed : http://www.halfords.com/motoring/pa...l-treatment/halfords-shock-unlock-spray-400ml

Cheers guys, I brought some of them Irwin bolt grips from homepage however, they only have a starter set of 5. Of course these just aren't the right size so waiting for the other 5 of the set to arrive. Thinking about buying a blowtorch too on the recommendation of getting it hot

Cheers
Coops

Coops979 said:

Cheers guys, I brought some of them Irwin bolt grips from homepage however, they only have a starter set of 5. Of course these just aren't the right size so waiting for the other 5 of the set to arrive. Thinking about buying a blowtorch too on the recommendation of getting it hot

Cheers
Coops

Click to expand...

Before you start getting a blowtorch on things,which can be bad,look at the item sierrafery suggested from Halfauds,the man knows his stuff,believe me he does.

Is it the 10p or 15p engine? If it's a 15p then you can put the blank into the flange between the flexible pipe and the exhaust gas cooler which sits on the front of the engine, it then blocks the flow of gas, I had the same problem and did not want to shear the Allen bolt in the manifold, which would mean drilling it out before I could use the vehicle again.
Left it like that until I put on a manifold which had been skimmed, I had the luxury of getting the bolts out in my own time with no risk.

The exhaust running temp is far higher than a diy blow torch could ever reach!!!! On my turbo cars they run cherry red, try that with a b&q special!!!!!
I'm a fitter/machinest in the aircraft industry and deal with this sort of thing daily!! Heat is your friend, yes I agree freezing will help certain situations but not all!!!!
Far less damage occurs to mating parts if done correctly, I'm not talking about a £100 casting I'm talking about 250k gearbox casing

I must say I've never had success with that freezing stuff. Probably user error.

It works well if the object being frozen contracts quicker than the part it's in.
I find with rusted bolts heat and the good old shock treatment!!

Haha I get that the blowtorch isn't going to be as hot as the exhaust running temp, but getting the disco to that temp and then trying to work on it would be a little tricky. Suppose the blowtorch would be able to heat the part and surrounding area a bit more accurately. As for shock treatment I'd have to remove the rad and inter-cooler to get a good whack on it. I have about 3inches between the rad and the extension to work with :/
Cheers for the input though guys, learning as I go here

Coops

could you not cut a grove into the bolt head to then get a flat head into it?