Replacing Glow plugs

[evdama]

Still stuggling! does anyone know what size the bolts holding EGR pipe onto the exhaust manifold are, think they are hex and 5mm to loose 6mm to big, could they be 5.5mm also took 6 nuts from metal intake manifold still holding on is there 1 more, looks like a hex bolt in the middle at the bottom. its almost impossible to see from above any ideas

Could they be Torx?-my MK3's seem to be entirely held together by the things.

[adam3rdcanvey]

I could not remove these bolts! I think they are 5.5mm allen head but mine were seized up. I used an irwin seized bolt remover tool to finally get them out, bought on amazon... is very effective!

Are you taking the whole manifold apart then?? Only the plastic intake manifold needs removing for glowplugs replacement, there is a crimp clip that connects the egr exhaust outlet to the valve on the manifold, this comes off easily using a small screwdriver and can be replaced with mole-grips or long nosed pliers....

[terryd999]

Thanks for the advice, it sounds like we had exactly the same problem, I got a excellent stud remover from 'lazer', found on amazon,
I cut the heads off bolts with a small and delicate 4" angle grinder(no room for shakey hands) then removed EGR pipe to get to studs.
The EGR valve, pipes and intake manifolds were very clogged with black oily gunk, once i got this out and back together with new intake manifold gasket(£15 for 3 bits of cereal box)it starts and run much better.