EXUP help :(

[megawatt]

I have an angle grinder to sort that valve out for you Phil

[fq-craigus]

Think you may be right there stu.

You got access to a welder ?

[Joeman]

looking at the pics they are allen key bolts so your not getting a socket on

Haha good point!!

In which case you might want to hammer in a larger allen key and try that..

As you said before... How did they change the cables?? Or have they just poked then under the cover to make it look like they changed them?

[Guest]

Joe - there are two rusted and rounded bolts. Top right, top left.

Here's the conundrum...

Below the bolt, you have about 3-4mm of working space then you hit the cover.

Above the bolt you have about 7mm then you hit the engine.

I don't want to take of the whole collector box, for the amount of hassle it's going to the garage.

Now what?

If easy outs won't do it, drill them stepping up as I go? You won't get any grips on them, not a chance.

[Guest]

God knows how he did it but he got the cabkes on with one bolt off...

[Stu]

so drill wil small bit stepping up but not going all the way through and you will eventually just drill the head off

[Joeman]

Joe - there are two rusted and rounded bolts. Top right, top left.

 

Does the top right bolt need to come off to remove the cover?

[Stu]

or the bottom left?

[Guest]

There are 3 bolts that hold the cover on.

The bottom right comes off.

The top two are the nightmares in question.

Stu - if I drill out the bolt, will I need to re-thread?

[Stu]

I dont know if they are threaded its hard to say from the pics

you may be able to get a bolt and a nut on the back if there is space

[Joeman]

or the bottom left?

 

I reckon its just two bolts..

[Stu]

looking back at the pics it does appear to be held only by two bolts

pull the bottom right and see if it bends out

[Guest]

You guys may be right - the top left one and bottom right.

So... drill it out??

[Joeman]

You guys may be right - the top left one and bottom right.

So... drill it out??

Whack in an oversized allen key first and see if you can get it to turn..

[Guest]

Ok definitely right. Look here;

http://www.r1-forum.com/forums/showthread.php?t=333817

Tried Joe, ain't happening.

[megawatt]

Just disconnect the cables at the servo Phil and then lock the valve in the fully open position.

[Joeman]

Various types of stud extractor - might be able to get one to grab the bolt.

Else chisel it round,

or file it square and get a socket on it.

Drilling would be my last resort.

[Guest]

A chisel! I could make two wholes for a flat head!!

Nice one Joe. I'll look into that Al.

[Guest]

Update time

After looking at it thoroughly a week ago, I decided to buy some gripping sockets but also that the sump plug was in the way... so bought the tools and new oil and filter.

Today;

Sump plug off, 10mm grip socket on, gripped great. Snapped the bolt head. The bolt was seriously seized. Had to drill both the exup part and the head from the socket.

Second socket came out like a breeze - lovely tools!

Drilled out the weld part of the exup and finally got access to the valve. It wasn't seized and appeared to move as it should...

Anyway, my options as I saw them were;

A) re-grease and put back together.

B) put it in the fully open position and leave cables detached.

I chose option B, not having faith in option A (and because I was curious to see what it's like straight through.

Took it out for an hour, definite increase and the power curve is a lot smoother but I can see where the exup system is useful. Maybe now it's easier to access, I might try and take it apart and put together again but for now, I'm happy with it.

The exup system is now 2 out of 4 holds (2/3 bolts and missing weld) and the cables are disconnected at the valve but it seems to be fine

Thanks for everybody's input.