Technical 1.3 multijet Egr removal

[matty seasider]

Is there any of you who have experience removing the Egr on the 1.3? Dannyboy or T?

My problem:

Working on a 55 plate vauxhall combo, same engine as grande Punto 1.3.
The Egr has stuck fully open, and needs removing as when I removed solenoid, the spring and plate that form part of plunger on mechanical side fell out.

When I tried to remove, found the 2 torx bolts holding Egr to head are rounded, t40 torx too small, t45 too big. Cos of its location( at back within few inch of bulkhead) I can't get mole grips in, or a dremmel in to cut a notch so a flat screwdriver could be used.

So need help, what size are the two torx bolts , as in which torx socket should fit?
What size are the 3 bolts that hold the cooler to Egr?

Any hints and tips welcome, as with Egr being stuck open, van wont start.

 

[matty seasider]

Anyone help please?

 

[D4nny8oy]

I don't know about T, but it's been years since I last did a 1.3 EGR, although I remember the grief involved!

Don't know what to suggest with the torx bolts, other than using a mirror to see which of the two sizes fits best. If it's been chewed up, I can only suggest trying to hammer the T45 on and hope the vibration helps to free-off the bolts.

I think the 3 bolts holding the cooler on are 13mm, but I'd forget trying to undo them- they're near impossible to get on in-situ and you'll just round the heads on them too. Best option is to drain the coolant and take the whole unit off as one, then seperate at the bench.