603 intake manifold - what tool?
 

I have 11 of the 12 intake manifold bolts off. How do I get the one tucked under the flange on the #5 cylinder? I can't get it from the IP side because the glow plug harness is in the way and is held by this bolt. I can't get it from the valve cover side because of the flange. I tried a hex key but I can't get enough torque on it because of the proximity to the firewall.

The only thing I can think to do is shave my 6mm socket bit. Is this what folks do?

BTW, the crossover pipe does not have the customary 5mm coat of crud. As far as I can see into the manifold, there isn't 5mm of crud either.

I also found a cracked hose at the manifold fitting. Without a full boost signal to the ALDA, this SDL outran the SE. Amazing.

lrg, if you read this, remember when I said it was ridiculous to think that oil was coming out of the #1 intake runner? Guess why I'm taking off the intake manifold :)

Sixto
91 300SE
87 300SDL

Run, don't walk, and buy yourself a set of Bondhus Hex & Balldriver® T-Handle Set. Go to this web size for pixs.
http://www.bondhus.com I bought mine for about $45 for the specific purpose of removing the intake manifold of my 87 300TD. Worked like a dream. I used a vice-grip on the stubborn ones. These allens have a rounded end that allows a significant miss allignment and still gives a good non-slip bite. I have used them for many other applications and the nice long reach makes them invaluable. Off course you can not torque them but when I did my manifold, I tighten them as much as I could and I have no problem.

Henry

P.S. I don't own any stock in this company.

I got mine off/on by using a 1/4" hex, knuckle, and extension. It just fits in and I could get plenty of torque on it. Anything bigger than a 1/4" won't fit.

I just went thru this to put in new glow plugs on my SDL.

I took off the solid injector lines, but the 3 rear bolts in the back were a bit of a bastard. Some say you can do this job without removing the injector lines, but I dont see how and it only takes a few more minutes.

Some I got from up top, and some I got at a near 90 degree angle going underneath the manifold, all because of those damn screw holes for the injector line holders.

I used a 6MM hex bit, a swivel and a 12" extension.

Not too bad of a job, just a little time consuming.

BTW I was using a 3/4" drive

Snap on sells the "bondex" type of allen wrenches also. I highly recommend having a set in the tool box. Sears may even have them now.