Removing intake manifold

[seedym]

I was trying to get my intake manifold off in order to fit a new 'O' ring, as per the instructions in the Pierburg 2E2 FAQ above. However, one of the six fiddly allen-head bolts had seized, and I've mashed the end of it trying to get it to turn. It still won't budge, there's no room to get a chisel on it or a dremmel to cut a groove. What can I do? I've wasted two weekends on it now, and I'm getting frustrated. Will the exhaust manifold come off easily enough to create a bit more space to get tools in (that ought to help get at the other really recessed bolt that I haven't even tried to get out yet). What sort of money would a garage charge to do this? My dad's getting a bit fed up of me always asking him for help and then getting nowhere!

[takethefifth]

You drill a hole into the knackered screw head and then use an 'Easy out' or some equivalent reverse threaded remove tool.

http://search.ebay.co.uk/easy-out_W0QQcrlpZ1143946142Q5f10136QQfcclZ1QQfclZ4QQfnuZ1QQfsooZ2QQfsopZ32QQkeywordZeasyQ20outQQrprZ78

[seedym]

there's no room to get a drill in behind it, that's the trouble!

[mattneck(Beavis)]

an you get in to file the sides and spanner it out?

[takethefifth]

Ah and i guess the screwhead that's gone is one of the ones that prevents you from removing it so you can get the drill into it?

If so well that is a twit.

I'm not very familiar with the carby setup so hopefully someone else will have an idea of something else you could remove to get access.

[hobbiniho]

as said above probably the best way is to flatten to sides and get a spanner on it just make sure you make the spanner a tight fit so it wont round off on you 

[meg1980]

In the time you spent two weekends mucking around you could of taken the head off removed inlet manifold removed old stud,reasembled head and then refitted it job done.Good luck

[rubjonny]

as above your only option is to have the head off.  lucky for you the carby has the 'toilet bowl' connection between the manifold & downpipe so its easy to split!  If it was a GTI with the 6 bolts you would be in for a world of hurt.

Try again with the allen tool, I thought one of my bolts had rounded but it turned out the tool wasnt seating fully due to rust & crap buildup, get in there with a screwdriver if you cvan and make sure you dig out all the crud!

[DogDay]

I also went through the pain... on one of the middle bolts I rounded it out.. ended up finding a piece of hex bar - basically a long allen key that was about .2 mm oversize and hammered the bastard in as tight as a nun's chuff. worked for me.
 
I assume its one of the inner bolts & not the outers....?

as far as using an easy out - they have a nasty habit of shearing and making things worse

Good luck

[rubjonny]

on the one i thought id rounded i hammered a 13mm socket over the top, bloody pain int ass to do though