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#1
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Rounded off nut, suggestions?
Well, I finally did it... I was out in the sleet today trying to get one final job done on the W201/190D before heading out for time with the family down south. The goal was to get the fuel injectors out to send to C Sean Watts for a rebuild. I might have been able to do it by just loosening the hard lines and pushing them aside, but I've heard bad things about how fragile they are in the later motors. I also need to replace the delivery valve o-rings badly, they're leaking all over the place. So, it made sense to remove the input manifold to get at everything: with that off I can remove the hard lines from both the injector pump and the injectors, and also get at the delivery valves cleanly.
The inboard side of the air filter box is held in place by four nuts, two fore and two aft. They were tight on the front, but I got them out OK. On the back I nearly stripped the top one but bore down on it and it loosened. The last one is down low, and the stud for it comes out from the oil filter canister body; I started out with a 12 point 10mm socket, and I couldn't budge it. I felt the socket give a little, the tell-tale sign of buggering it up. I quickly switched to a six point socket, and tried to budge it. No go, though it rounded some more despite all the force I could put on it. Gave up, went to the store; came back with Liquid Wrench lubricant, freeze spray, a micro butane torch, and a Sears Bolt-Out Plus set. I lubed it, tapped it, froze, heated it, froze it, heated it, and then finally completed the rounding process with the Bolt-Out Plus. The bolt out plus has flutes on it that are supposed to grip the head tighter as you turn it, but in this case the nut is cheap and it just shaved the remaining corners off quite neatly. So, now that damn rounded nut sits there laughing at me, and I got nothin. I can't get a nut splitter on it, no room. I could buy an extra long chisel, and maybe drive it around. I could buy a grinder and maybe jam it in there to grind one side off. Got any ideas, besides waiting for Spring? Kurt
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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride! - '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member). |
#2
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How about using a dremmel with a cut off wheel? I have used it a few times in some tight places
Charlie
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there were three HP ratings on the OM616... 1) Not much power 2) Even less power 3) Not nearly enough power!! 240D w/auto Anyone that thinks a 240D is slow drives too fast. 80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works |
#3
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Any chance of getting some vice grips or locking pliers on that sucker? Sometimes if you can get a real good bite on the bolt head and then some sort of cheater bar and slowly apply pressure . . .
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'95 E300D ("Tank") - 231,000 miles '79 240D ("Biscuit") - 197,250 miles (Sold) '83 240D ("Ding-Ding") - 217,000 miles (Death by deer) ______________________________________ "Back off, man. I’m a scientist” ~ Peter Venkman |
#4
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Quote:
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#5
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I thought all nuts were round??
oh.. you have a pm |
#6
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There is a heap of threads about "stuck nuts" maybe even the ones jt20 speaks of !!
![]() The absolute worst I ever had to do was to cut one off (yea we do that to bull calves all the time jt) using a hacksaw blade in a pull type handle. If you can get a hammer there, you may be able to drive a slightly smaller socket on to the nut. Good Luck.
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Grumpy Old Diesel Owners Club group I no longer question authority, I annoy authority. More effect, less effort.... ![]() 1967 230-6 auto parts car. rust bucket. 1980 300D now parts car 800k miles 1984 300D 500k miles ![]() 1987 250td 160k miles English import ![]() 2001 jeep turbo diesel 130k miles ![]() 1998 jeep tdi ~ followed me home. Needs a turbo. 1968 Ford F750 truck. 6-354 diesel conversion. Other toys ~J.D.,Cat & GM ~ mainly earth moving |
#7
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I would say, Vice Grips or one of those tools like a socket with a cam in it that grips rounded nuts or possibly a nut splitter.
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-Evan Benz Fleet: 1968 UNIMOG 404.114 1998 E300 2008 E63 Non-Benz Fleet: 1992 Aerostar 1993 MR2 2000 F250 |
#8
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Nothing works better on round or rounded than a pipe wrench. I have a 6" I put a pipe extension on for extra leverage.
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85 300D turbo pristine w 157k when purchased 167,870 July 2025 83 300 D turbo 297K runs great. SOLD! 83 240D 4 spd manual- parted out then junked |
#9
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83 SD 84 CD |
#10
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Go to Autozone, NAPA, or your favorite auto-parts store and buy a set of IRWIN internal-helix sockets. They have a sharp reverse-helix that bites into the bolt head, I removed a couple of head bolts with them (the head bolts other than being very tight, are in internal-hex and round on the outside). About $15 for a set.
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![]() Gone to the dark side - Jeff |
#11
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Don't forget to spray your favorite penetrating oil on it.
Also wouldn't hurt to use some heat on the sucker. Propane or the always trusty MAPP gas. ![]()
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-Typos courtesy of my mobile phone. |
#12
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X2, I go right for the pipe wrench on a rounded off nut or bolt if it will fit. Never have I had good luck with vise grips, I just use vice grips for clamps.
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#13
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Quote:
The trick to vice grips is getting them on there nice and tight, which sometimes requires using another tool to squeeze the handles together - channel locks or something of that nature. But if you can get them on there tight enough they can do the job - then you have to undo them, but at least you have solved your first problem. Never tried the pipe wrench, sounds like a good one though.
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'95 E300D ("Tank") - 231,000 miles '79 240D ("Biscuit") - 197,250 miles (Sold) '83 240D ("Ding-Ding") - 217,000 miles (Death by deer) ______________________________________ "Back off, man. I’m a scientist” ~ Peter Venkman |
#14
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Dremel and diamond bit
With virtually no access I would go in with a dremel straight diamond bit and cut through the side of the nut. Once you are through the nut should spread and come off. This is a nice controllable process compared to chiseling heating and beating. It will be slow but should ultimately work. Cheers Dan
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It's always something simple 91 300D 603.960 (from japan) 194K 92 Toyota Diesel Landcruiser HDJ81-t 116K 02 Golf TDI new head courtesy of PO 87 300D 97 BMW 525 TDS Wagon 5spd bunch of Onan and other diesel generators |
#15
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Quote:
Thanks, Kurt
__________________
- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride! - '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member). |
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