'Blanking plate' flange, Stripped thread,

[Biobongo]

One thread for the two bolts for the flange where the blanking plate to the EGR goes is stripped & I need to hlicoil it. It is the one nearest the offside so is 'easier' to get at. The other may be damaged.
However for both bolts it looks difficult to do the job in place.
Has any one done this job?
What has to be removed, as a minimum?
Thanks.

[chipvan]

crickey,i was thinking of doing this my self!

hope you get it sorted ok
jez

[Biobongo]

Waiting for the Helicoil & tool to arrive. Hopefully tomorrow. Then a case of what has to be stripped just to get room to do the job. Looks like no one else has had to do it. I will keep you posted.

[Doone]

If you decide not to helicoil THIS LINK could help (to fix a stripped bolt anywhere).

[Biobongo]

Thanks Doone.
I have ordered the Heli coil & tools anyway & I know that should make a good job. Can you tel me what is the best way to get at it, what needs to be removed. One bolt is partly, other totally under the center engine cover where the gear lever & Hand Brake is.

[Miles69]

Just had to do this myself due to a heavy-handed mechanic. You will definitely need to remove the elbow to helicoil it properly. Removal of the elbow is simple:

* Remove 2 bolts holding egr pipe to elbow – should be easy if they are stripped!
* Undo jubilee clip that holds air intake pipe to elbow.
* Pull off air intake pipe.
* Remove 12mm bolt that holds vertical steel pipe to front of elbow – use a long extension on your socket and work from passenger side.
* Remove two 12mm bolts that hold elbow to intake manifold.
* Pull elbow off!

You don’t need to remove the engine cover panel but it makes life much easier if you take all the bolts out and slide it over to the passenger side.

I had both bolts on the elbow helicoiled at an engineers for about 30 quid. Then I made a blanking plate and fitted it between the pipe and the elbow. The car no longer whistles and is a bit sharper to drive.

Good luck.

[westonwarrior]

When you say you ordered the kit what did you order exactly? any chance of a link?

I did this too and its not uncommon but should be an easy fix mine is held by 1 bolt at the moment

[Biobongo]

OK Job done.

Thanks for your help miles69. I did start taking that center cover off but when I found I had to release the Gear linkage in addition to the hand brake cable I managed without. My box spanner extension for that upright tube was not long enough but managed to get in there OK with a ring spanner, it was less than hand tight any way with a few other bolts left loose also. A blanking plate had been fitted but it was very thin, so I made a new one. Bought the bongo last Feb from a well known dealer, I have only covered 2000 miles since then. It was serviced & blanking plate fitted at same time, as part of the deal this must have been when the threads were damaged or at least they would have been found. I am the first registered owner since import. Only a 3 month guarantee.
Fiddly job not difficult. Fitting the Helicoils was the easiest bit.

westonwarrior, I got the Helicoil kit from
http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... 0327169072
You will have to past it over.

[chipvan]

would the standard gasket be made of metal??

as i may have had it already done,i can feel a thin bit of matel sheet between the joint....

may save me doing it

[Doone]

would the standard gasket be made of metal?? as i may have had it already done,i can feel a thin bit of metal sheet between the joint

How thin is thin? There is usually a thin gasket, which is probably the thin piece of metal you can feel. Decent blanking plates (as sold by Allan) shouldn't be that thin.

[Miles69]

Glad it all worked out for you Biobongo. Now a question for you ... how long did it take to do the helicoils? I've never had the courage to attempt a helicoil.

Chipvan - on my car the gasket between the egr pipe and elbow is made of metal - I don't think you'll know if its a blanking plate or gasket until you strip it down.

[Biobongo]

[quote="Miles69"]Glad it all worked out for you Biobongo. Now a question for you ... how long did it take to do the helicoils? I've never had the courage to attempt a helicoil.

Drill out with the drill provided, tap a thread with tap provided, wind
in helicoil with tool all provided, knock out tang tool provided.
Instructions & method provided for each stage. Working with Aluminum,
in this way, is quite easy. If you have a scrap piece of cast Aluminum,
you could do a test piece first to gain confidence. Could do both in
about 15 mins, but take your time.

Here is a link to a video of how to do it:-

http://www.youtube.com/watch?v=RFYa6sjh ... re=related

The size is M6 & that is what my previous link was for. Also when
tapping the thread to take the coil, you should wind the tap back a
quarter a turner for every full turn & apply oil WD40 is OK. That is not
shown in the video.

[chipvan]

Thanks for the replys,yep its just a thin bit..

I was going to blank off egr but now iam a little worried!!should i be ??

jez