So I've been following the very helpful guide to get the EGR off my MK1 VRS, so I can fit a darkside delete kit.

 

The 2x6mm allen bolts holding the EGR are being stubborn. 6mm allen key doesn't fit, 5.5mm slips. Looks like it's been attacked before and over tightened. You guys have any tips or suggestions? 

Use a Torx bit and tap it in first.

1 minute ago, sepulchrave said:

Use a Torx bit and tap it in first.

There's no way I can get a torx with a hammer in there 

Are you using good bits? If it's tight sometimes cheaper or non-standard bits may not fit right.

 

If it persists, get an extractor and buy new bolts.

10 minutes ago, LightRain said:

Are you using good bits? If it's tight sometimes cheaper or non-standard bits may not fit right.

 

If it persists, get an extractor and buy new bolts.

bits are brand new, I'm worried about stripping the heads trying too hard, maybe a large hammer might suffice 

Are they of a good brand and up to standard? To be fair I have never had a problem caused by using the cheaper bits. However, if your bit set is just a bit out and the head is on the extreme of end of tolerance, then this could cause your trouble. Getting a hammer in there to knock the bit on may work, if it fails, you always have the extractor route.

If the end of the bit is worn or deformed then grinding it back a bit often helps, if its not going all the way into the cap screw then check to see if there is something in their blocking it, if its just the radius at the bottom of the socket then grind a slight chamfer.

 

Looking carefully at the photo looks like someone has deformed it with a 5 or 5.5mm bit and maybe even a torx bit.

 

Its hard to hammer an allen key in which is what you tried, the hammer blows glance off the curve, you really need a good 6mm Allen bit in a good 3/8" drive holder which you will be able to hammer in, maybe using an extension.

 

Definitely looks doable and not beyond salvage, I come across fasteners like that all the time.

How about small set of stillsons on the bolt head. Not sure about access to the other bolt mind but might get you away .

Irwin bolt remover sockets would probably do it if you can borrow some. They'll grab the outside of the head.

 

undo it from the turbo end first, then remove it as one piece and get it on the vice 

Brilliant.

 

What @JWvrs25 said. I've had to the do the same for mine as it was awkward to get to. Really easy once I removed it from the end.

 Map out may be easier with no visible sign of tampering, if possible on your version of VRS engine.

 

 

5 hours ago, JWvrs25 said:

undo it from the turbo end first, then remove it as one piece and get it on the vice 

Great idea I'll have a crack at it tomorrow