Inlet Manifold Removal Issues due to EGR Valve

[silverzx]

As a couple of you may know I started doing my FMIC today.

The FMIC is all mounted and fits behind the bumper which required hammers, angle grinder and black hammerite. I still need to make mounts but thats an easy job.

My problem is I've removed all the inlet nuts from the studs and have tried to slide the inlet off which is rubbing/hitting the EGR valve. Dave's kindly suggested I put the nuts back over the studs and double nut them to then take the whole studs out. After doing that to all of the 6 studs should then allow the manifold to effectively slide right out upwards. The only problem with this is its tight down the back (and the engines already dropped forward) and getting the nuts done up enough to get another nut on seems impossible as if there isn't enough thread on some of the nuts to actually fit two nuts on. Also when you've only got chunky 13mm spanners and a chunky halfords socket set it's tricky to get them done/undone and takes a lot of time.

Also I would obviously just remove the EGR vavle (which is two allen key heads) but both have already been kindly rounded off for me.

I'm hoping someone can tell me theres a magic tool for removing rounded off bolts so I can nip into town and buy it tomorrow morning. If not then just a suggestion on how to remove them. There isn't really space for a grinder or drill down there.

I'm going to also try buy some bolts that use a 10 or 13mm head to replace these silly studs with if I can get them out. Also some thinner nuts if I can find them so I can try and get two on.

Heres a couple of pictures for anyone interested:

1) Fitting FMIC behind bumper



2) Fitted behind bumper


3) Engine how it stands


4) Car how it stands



As always help appreciated, thanks to people who have already helped.