Ok, so I brinjibg "it" out of hibernation because it looks like the sun might be about for a full week. I've been preparing everything for a plenum pull, egr delete and injector change for a few months and expected a couple of days messing about with it all as I planned on cleaning up some dodgy vacuum lines and painting a few bits as I went. Started Thursday evening, plenum off, EGR out and the two hardliners to the plenum removed. Just the EGR to manifold feed pipe to remove.

 

Well, it's now Saturday evening, I'm about £50 lighter in my pocket due too buying extra tools. I have three knuckles left that still look relatively normal. I've possibly broke my thumb and the bolt, if you can call it that as it doesn't resemble one anymore, is still in there.

I presume my only options are too remove the passenger side manifold or pull the engine. What's easier? I'd guess, pulling the engine?

Or any other ideas please.

I have tried everything I can think of, i have to admit, that there was a point where I nearly cried. It really is that bad.

if you mean pulling the egr pipe from the manifold i think the option a lot take it cutting the pipe, crushing it flat then weld it

That's a good idea, I already cut the pipe flush with the nut. So I could get a socket on it, but I think there may be enough room to weld it up. Thanks

before welding that nut/pipe in place make sure you have taken all precautions to avoid the car from burning down to the ground !!

...keep in mind that particular manifold is very close to the (main) fuel lines and usually there's a lot of (flammable) oil residue in that area also.

cut pipe near to manifold flange..22mm 6point socket 1/2inch drive.2 extension bars or 1 long with wobbly end.Undo 22mm fitting and either buy proper blank or weld up the end and refit.Some parts removed at rear of engine will help..Do NOT weld in situ.possibilty of fire and/or metal pieces falling into exducer side of turbo damaging it...Gearbox does not need to be removed to do this as some people believe.just battery,few parts of the loom pulled forward,main positive bat connection and heater matrix water pipe nearest battery(metal one)..:)

Ill also add that the earth mounting point (around egr pipe)1x 12mm bolt and move away..You can use a 5p piece to blank off the egr fitting but needs care as you dont want to damage the thread into the manifold...;)

Thanks for the advice guys, I'll let you know how I get on. I'm leaving it for a day or two, need a break!