re. IM bolt removal - 83 5kt non-quattro

Swann, Benjamin R. (BSWANN) BSWANN at arinc.com
Tue Jul 17 11:53:24 EDT 2001


[I removed the throttle plate section and , as luck would have it, I could
not see the lost part in the top of the IM (using mirrors and flashlight). 
I have been able to remove most of the allen head bolts on the IM ( I have
to remove the IM to find the bolt with the hose on it that I used as a plug
in the cold start injector hole, which was sucked in to the IM).  I am
having a problem with the allen wrench shaft seating completely in one
bolt.  I have not removed the exhaust manifold pipe from the turbo.  I am
thinking that I might be able to  tap the allen shaft into the bolt head,
but I want to ask for any suggestions first.  I am using the allen wrench
short shaft on a 3/8 drive.  These bolts take a 6mm allen wrench (hex
wrench).  

Thanks,  Tex Terry, II
1986 5kt auto non-quattro 4 dr sedan
Franklin, PA]

If you feel like you are going to round out the bolt head, STOP, you are.
Drive a 1/4" hex/allen driver in with a hammer.  It is just enough bigger
than the 6mm that the fit will be tight enough to break the bolt loose with
out rounding.   You may sacrifice the 1/4 drive, but I've been able to get
them back out of the bolt by putting the allen part in a vice and hammering
out the bolt with a chisel.  BTDT many times.

Ben



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