Club 80-90 Forums

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

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

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

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.

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