 | Home > Tdi > EGR Blanking - seized bolts |
 
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133  |
Ok, time to blank off the EGR valve.
Got the blanking kit off ebay including the plate, gasket, bolts and the bypass hose. How hard can this be? 
Have been coating the allen bolts with penetrating oil twice-a-day for the last couple of days but they're absolutely seized SOLID. So, of course, in attempting to loosen them, the internal Allen 'hole' in the bolt head has rounded. The proximity of the valve actuator head and adjacent bolts etc means that I can't get at the Allen bolts 'straight on' to try to drill them out and there isn't enough space around to use a bolt removal tool. I've also tried some heat on the bolts but I'm just not getting anywhere. 
Not happy!  any suggestions? |
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30th Jun 2013 11:00pm |
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| Killer90 Site Sponsor Member Since: 09 Oct 2011 Location: Hertfordshire Posts: 6478  
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Spot weld perhaps ? or use chemical metal on an allen key head stick that in and let it set that may well hold up enough for you to undo
 CSK Automotive
www.cskautomotive.co.uk Like us on Facebook - www.facebook.com/csklr Follow us on Instagram - @cskautomotive |
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30th Jun 2013 11:29pm |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
Thank killer,
Not equipped for the welding but the chemical metal idea is interesting.
Have you got a trade name for the chemical?? |
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30th Jun 2013 11:39pm |
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| Porny Site Sponsor Member Since: 31 Aug 2009 Location: Sutton Coldfield - West Midlands Posts: 809 
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http://www.machinemart.co.uk/shop/product/...=SRC-irwin
These should help... It is much easier to cut the top off the EGR valve - which allows you then to straight onto the bolts... Either cut it off, or 'adjust' with a hammer. Ian IRB The home of the first modified Keswick Green 90 - and the first 2.4 Puma through both the 200bhp and 550Nm barriers. www.IRBdevelopments.com www.facebook.com/irbdevelopments www.integrated316.com www.facebook.com/integrated316 |
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1st Jul 2013 7:13am |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
Must admit when I heated it up with a blow torch it wasn't hot enough to be glowing.
Do you try and remove it while its still red, or wait for it to cool?? |
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1st Jul 2013 7:15am |
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| Killer90 Site Sponsor Member Since: 09 Oct 2011 Location: Hertfordshire Posts: 6478
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If you fancy a go of the chemical metal, that is whats its called give it a google up
 CSK Automotive
www.cskautomotive.co.uk Like us on Facebook - www.facebook.com/csklr Follow us on Instagram - @cskautomotive |
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1st Jul 2013 7:16am |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
Thanks Ian, but I bought a set of those yesterday especially for the job, but can't get them on because of the actuator and adjacent flanged connection
I considered removing the actuator head with a grinder but didn't want to risk any swarf or other debris from entering the engine / turbo etc  |
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1st Jul 2013 7:26am |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
Googling as we speak 
Might 'dremme'l off the bolts on the adjacent pipe connection to give me more room to manoeuvre |
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1st Jul 2013 7:32am |
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| jst Member Since: 14 Jan 2008 Location: Taunton Posts: 8020 
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yes Cheers James 110 2012 XS Utility 130 2011 M57 bespoke Camper 90 2010 Hardtop 90 M57 1988 Hardtop |
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1st Jul 2013 8:16am |
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| Sonarmender Member Since: 04 Apr 2013 Location: Guz Posts: 338  
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Try pouring some Coca-Cola on it and then pour some more on it, leave it for a few hours and mig weld a old bolt to it and try to remove while the bolt is still warm, any luck it should move.
It has worked for me on many an old Lister. You only have one life, live it....forget the cost.
90XS Hardtop |
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1st Jul 2013 8:31am |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
COKE  !!!!! |
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1st Jul 2013 9:58am |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
Finally got the top bolt off.
Combination of ...... brutalising the EGR actuator head (to improve access) Removing the washer reservoir (to improve access) WD40 Heat 13mm broken nut removal tool Socket extensions & breaker bar Once this was off the lower was a doddle as the action of loosening the valve itself loosened the bolt. 
HOWEVER........... on inspection the top bolt had sheared off 
Tried to remove this with a combination of.... Heat WD40 and a left hand thread screw / stud extractor Only the stud extractor has now also sheared leaving both it AND the snapped stub in place. Trying to drill these out is getting nowhere (even with new drill bits) Really running out of patience now - this '20 minute job' has now taken two weekends and multilple visits to Machine Mart / Screwfix. |
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7th Jul 2013 8:36pm |
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| frenchy Member Since: 05 Feb 2012 Location: Liverpool Posts: 133 |
A question for those much more knowledgable than myself........
If I grind the area around the broken bolt smooth and attach the EGR blanking plate with the single lower bolt only and liberal coatings of Fire-gum( or similar) will it hold or blow off and leave me stranded somewhere down the M6???  |
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8th Jul 2013 10:46pm |
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| Splitpin Member Since: 07 May 2013 Location: Midlands Posts: 100
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I would say yes
You could do with drilling a hole |
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9th Jul 2013 5:49am |
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