Part two...
To get your TIP out, you'll need 10mm sockets and the hose clamp tool.
Use the 10mm socket on the bolt holding the TIP to the top of the intake manifold, then the one on the left hand side under the intake side of the manifold. When you're doing this one, get a feel for the area just below, as that's where you'll be disconnecting the hose clamp where the TIP goes into the turbo. Before that though, use the hose clamp tool to undo the clamp on the concertina hose near the airbox. I took them both off to be able to take the hose off entirely. Then use the hose clamp tool on the crankcase ventilation pipe and pop it off. The other end clips on, and it's good to remove it to make it easier to get the TIP out and back in again.
With everything free, use the hose clamp tool on the clamp all the way down at the turbo, move the open clamp towards the engine and then let off the clamp, leaving the clips in a position you can get the tool on again later without too much trouble. Pull the bottom of the TIP out. It should come out easily - it's just a plastic pipe in a rubber (I think?) connector.
You'll have loads more space now to get the EGR cooler out. You'll probably need it.
Yes, there are photos too. Some, anyway. Like, here's the bolt that you can't see in the place I can't even get hands in, let alone a camera.
That reminds me - get one of those endoscopes from eBay you can plug into your phone - so useful to check locations and condition of the bolts you can't see.
But yeah - loads of room now to get at the three M6 (5mm allen) bolts behind the intake manifold. One on the top, which gave me a false sense of security because it came out so easily. The one I did next was the one (as you're looking down on it) on the left. It's underneath a coolant line that made it just too tight to get anything in the head, so I took it off in the end. This bolt was harder to get out. There was a tight spot in every turn that made me worried it was going to snap, but it was OK in the end.
The bolt is under this. The coolant hose is just thick enough that it means you can't get an allen on it cleanly with the hose on.
*** SPECIAL BONUS ROUND ***
Should you take out the coolant lines both to get on the bolt head and to take the cooler out for cleaning?
I say a resounding 'yes'. While the various (non-ARL mostly) guides say you don't have to - which is true - and I set out with that intention, that bolt is difficult to get to and if you need to drill anything out, the cooler might be ever so slightly out of line as a result and it'll need drilling More on that later.
In any case, when you see how the EGR cooler works, you'll understand why it's probably clogged. It's just thin tubes in a coolant jacket that hot exhaust gas gets diverted through. What could possibly go wrong? Mine was full of crap though, and having done this, my engine genuinely feels usable again - clean it all while you're in there. Clean it all. Don't cut corners - you're never going to want to do this again. I drained the coolant into the pan I use for my oil changes. It's a good chance to change the coolant too.
*** END ***
Of all the three, the third is the hardest. In an ideal world, you'd get a 6mm allen and undo the exhaust to EGR cooler bolts. Mine are just a mound of rusty crap and will never be coming out. If I could have got those out, I reckon you'll find this part of the job much easier - then all you have to do is take off the 13mm nuts that connect to the exhaust manifold and you've got better access.
If you can do that, a winner is you.
I am not a winner.
I had to try to get at the bolt with the exhaust flex/concertina pipe in the way, and I think the best way in is from underneath. Maybe a long ball end allen might do the job here, as it's not so much at an angle as to possibly round it out. I used pretty much everything until I ordered long non-ball ended allen sockets, and when they arrived, it took about a minute to realise that thing was never coming out and was only rounding out.
I used one of these to saw the head off:
I ended up taking the airbox out too for access, but it took ages to make sure I wasn't sawing something I shouldn't be. In a space that's hard to access, sawing off a bolt head I can't see...
Then all you need to get the cooler out now is the two 13mm nuts on the exhaust manifold. I thought these would be horrible, as they looked really bad, but they were super easy. Watch out for the gasket. It's a metal one and shouldn't come off as it sits on the manifold studs, but now you know it's there.
If you haven't already, take off the coolant hose on the right and the coolant return on the left.
Now it's just the six 6mm head allen bolts that hold the intake manifold to the engine and you're done. I could easily get a 3/8 standard allen on them with a stubby extension and held the socket in place while I turned the ratchet. I cracked them all off individually first before undoing then fully - and they do crack. It was the bit of the job I was worried most about, but it was actually really straightforward.
Six years of procrastination summed up in six bolts.
Now to clean it all...
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