Any ideas? 1Y Inlet Manifold removal

[dieseldave]

So, with loads of help from the good folk on this forum I have undertaken my first full engine transplant (the first of many I've got a feeling!) I dropped out the 1.61y NA lump and replaced it with a 1y 1.9 out of a seat IBIZA, swapped all the necessary bits over and jobs a good 'un.

Trouble is (well one of the troubles!) that in my excitement to get job finished off and see if the thing would actually run, I bolted the exhaust manifold on without putting a gasket in, then bolted the inlet manifold on. In the process I managed to round one of the allen key bolts holding the inlet manifold on.

As the exhaust manifold is predictably blowing like a presidential intern, I need to remove the inlet maifold to get the exhaust manifold off to seal it properly (incidentally what is the best way to do that?) but I can't get the inlet manifold off due to the rounded allen key bolt.

A drastic solution I'm looking at is buying another inlet manifold and chopping the original up in situ so that I can get at the studs with a stud remover or summat, but wondered if anyone had a slightly more elegant solution...

There will be no prizes for hindsight related suggestions I'm afraid

[armyphil]

Try hammering in the next size Allen key on or a similar but larger sized torx drive hopefully you'll be able to get more purchase on it and get it out

[dieseldave]

I like the hammering idea

Should have thought of that!

Will give that a go

Sometimes when you've been swearing at something for a long time you lose focus!


Cheers

[lhd]

Are you sure you need to remove the inlet to refit the exhaust manifold and are you using th CS inlet and exhaust manifolds?
Although not a 1y I refitted my 1.6n/a head the other day only to realise I should have fitted the exhaust manifold first.
I did have to remove the lower engine mount to refit it and although a tight squeeze it was do-able?
Rob.

[dieseldave]

Aha! removing the engine mount! that'd do it... however I managed to find a third way. Managed to get the stuck 6mm allen bolt out when I noticed that hex bits (like from a cordless screwdriver etc.) are ever so slightly bigger than 6mm... so I managed to Hammer in a 1/2 inch drive to hex bit adpater (lying in bottom of toolbox - bought from screwfix for nut spinning with cordless drill) and then use a spanner on the 1/2 inch drive end of it to turn it...

B*stard bolt came out straight away!

You may notice it's been a while since I started this job/thread... in the meantime I've got married, been on honeymoon and been working away from home for past 3 months...

Now to get the Bus back on the road!!

Thanks for all help