I'm in distress: I can't unscrew the EGR cooler

[Saikou]

I'm changing the thermostats (both the EGR and the engine one). Just one major issue: I can't unscrew those two bolts which are pointed with orange arrows.

I need your advice to unscrew them, and since I've tried to use an over-the-shelf lubricant with no use I'm starting to get a lil bit nervous about it.

My biggest fear is to shred the head of the bolt, thus letting the bolt completely useless. The handicap here is that the bolts are in a hidden area , so lets say there isn't much room in there

 

[D60]

First, is it Torx, Torx Plus, or something else? At the risk of stating the obvious be absolutely sure you're using the correct driver.

Second, given the location I think heat is your best bet. It may take a lot of heat, but it appears to me access with an O/A torch is possible

 

[vavavroom]

I'd use penetrating oil on the cold component overnight before anything else. Then try running the engine a little. You don't want to get the bolts as warm, though. Or heat the flange around the bolt with a small torch flame but avoid blasting the bolts. You want the flange with the threaded holes to expand but you don't want the bolts to expand as much.

 

[emmett442]

A little heat and vibration on those will go a long way.

A small 1/4" impact driver would help without too much risk of rounding off.

 

[Trav]

What tools do you have? These are not bad with the correct tools. That top bolt is looking a little abused already.
Small impact, torch? impact torx sockets? Spray the penetrating oil on the back side not the bolt heads, it isn't going much good there.
If you are light on tools and/or experience in removing rusted fasteners take it to a shop and let them do it.

 

[TheLastWord]

Use the right tool first:

McMaster-Carr

McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.

www.mcmaster.com

Yep, already a little abused. ^^^

 

[spasm3]

Heat, a good quality torx or torx plus bit. I'd get be the head a good whack with a hammer after heating.

Worst thing would be to get one out and break, round off the other. A shop may be your friend to do this.

 

[Trav]

Like they say if you are in a hole stop digging.

 

[Soft Cars]

You need a Torx driver in the correct size. They come as screwdrivers, screwdriver bits, L-keys, T-handles, and sockets.

 

[Saikou]

First, is it Torx, Torx Plus, or something else? At the risk of stating the obvious be absolutely sure you're using the correct driver.

Second, given the location I think heat is your best bet. It may take a lot of heat, but it appears to me access with an O/A torch is possible

I dont think you are stating nothing obvious at all, as a matter of fact, I'm not even sure given the small differences between both of them... I'd say is Torx, but I'm not absolutely sure

I'd apply heat with a torch. Just a question: Do I need to heat the head of the bolt, wait till it cools down completely and then try to unscrew it, OR do I have to unscrew it inmediately after the application of heat?

 

[Saikou]

I'd use penetrating oil on the cold component overnight before anything else. Then try running the engine a little. You don't want to get the bolts as warm, though. Or heat the flange around the bolt with a small torch flame but avoid blasting the bolts. You want the flange with the threaded holes to expand but you don't want the bolts to expand as much.

thx for the advice. I thought I had to blast the head of the bolt, not the flange, so I'd do what u say

the question is: Do I need to heat the flange around, wait till it cools down completely and then try to unscrew it, OR do I have to unscrew it inmediately after the application of heat?

I came with the idea of using an impact driver, but it doesn't fit in such a small place, there's just not enough room for it

 

[Trav]

They are Torx not Torx plus. You heat it behind where the bolt goes into, the part that looks rusty in you picture. Heat it till it is cherry red and immediately remove the bolt.

 

[Saikou]

What tools do you have? These are not bad with the correct tools. That top bolt is looking a little abused already.
Small impact, torch? impact torx sockets? Spray the penetrating oil on the back side not the bolt heads, it isn't going much good there.
If you are light on tools and/or experience in removing rusted fasteners take it to a shop and let them do it.

I dont have an impact driver or a torch, but I'd buy whatever is needed to unscrew these fooking things. I'm truly desperated, and yeah, Im short on experience but for me is harder to put everything back together and bring it to a shop, because the EGR cooler is the last thing I have to remove, and I've removed a lots of parts by now. I've drained the entire cooling system too, so if I had to bring it to a shop I would have to do the work twice

 

[Trav]

Do you have torx sockets?

 

[Saikou]

Use the right tool first:

McMaster-Carr

McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.

www.mcmaster.com

Yep, already a little abused. ^^^

if it is a torx bolt (and it seems that it is) I'm using the correct tool

and yeah, the upper one has taken a fair amount of abuse, this is the reason why I'm asking here, to avoid rounding it

 

[Saikou]

Heat, a good quality torx or torx plus bit. I'd get be the head a good whack with a hammer after heating.

Worst thing would be to get one out and break, round off the other. A shop may be your friend to do this.

I'd feel really bad bringing the car to a shop just to unbolt a fooking torx thing

 

[Saikou]

You need a Torx driver in the correct size. They come as screwdrivers, screwdriver bits, L-keys, T-handles, and sockets.

View attachment 183151

I'm using a torx socket with a rachet. If I tried to use a screwdriver or a L-key, I wouldnt have enough strenght to unscrew the **** thing.

 

[Saikou]

Do you have torx sockets?

Yeah I have torx sockets like the ones I display in the picture below.
But they are of no use in this context, since they are not able to unscrew the bolts I hold a fight against.

sorry if I sound dumb, but I'm not english

 

[Astro14]

Yeah I have torx sockets like the ones I display in the picture below.
But they are of no use in this context, since they are not able to unscrew the bolts I hold a fight against.

sorry if I sound dumb, but I'm not english

You need the other kind of torx sockets…like these…

1/4 Sq. Dr. 7 Piece Z-Series® TORX® Bit Socket Set T10-T40 Length 28mm

TORX® is recognized as one of the three most efficient fastening systems because of their ability to transfer greater torque, reduce load and virtually eliminate tool slippage. Input Drive Size: 1/2" Drive Shape: Square Socket Length: 28mm Type: TORX® Socket Set on Rail Includes: 2025Z.28...

kokenusa.com

 

[Nick1994]

Yeah you need an impact