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[MarkG]

I've got stuck on this job. Everything was going just fine; coolant transfer pipe out, top manifold off, thermostat and housing dislodged. But then I realised the lower manifold had to come off as well because although the thermostat is now loose, I cannot actually get it out without removing the lower manifold. OK....all bolts came out fine except for the one on the front right here



I have spent hours trying to get this bugger out today and it starting to get chewed. The trouble is I can only get to it using socket UJs and cannot get enough turning motion through them. I already bust my 1/4 inch UJ. I've been making do with a 3/8 socket because my star sockets are all too tall to get in there.

Any ideas fellas?

[tunnie]

I've had no problems getting that one out, you are attacking it from above, not at the angle this photo was taken? Go in between the intakes angling down from engine bulkhead towards front, i used from my 150 halfords set the long and stubby extension with E12/14? on there no issues.

They should only be nipped up too, unless some monkey has been there before and done it up to 10,000 Nhm

[freecall666]

trox has gone T10, use a long flat head screwdriver hammer type, get on edge of the bolts and make a ridge in it them move screwdriver so when you hit it it turns the head should come for then.

[MarkG]

Tunnie, I tried going in from the front initially but then realised i could go from the other side between the intakes by moving the injector connector out the way but the angle I have to go in at is pretty much the same. I just can't get enough force on it through the UJ

[skyblue]

Have you gone right the way down to the sandwich plate and removed that aswell as that is bolted down by several bolts  hence why toy cant lift off the two bits in one go

[TheBoy]

Remove all the bolts holding the inlet (metal casting) to sandwich plate (black plastic), then remove inlet, leaving sandwich plat in place. The remove sandwich plate by undoing the 10,000 bolts holding it down (well, 20 bolts...)

[MarkG]

Thanks for your advice fellas. Job now done. I had not realised the plate underneath was a seperate piece. 6 bolts on top and 10 on the plate beneath.

Took the opportunity to clear out the vent pipes on top of the plenum and jigged up a new plate to block off the EGR valve to plenum as well.