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#16
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So, what size bit do you think I should start with, if it comes to drilling? I think 5/64 is the nest one up that I have, just not sure how big I can go with such a small bolt.
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___________________________________________ 1992 300D 2.5 Turbo
W124.128/OM602.962/4G-Tronic 722.418 Dieselmeken 7,5mm | Sportline Interior My Build Thread |
#17
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Thinking about it, I would try the slot with the cut-off wheel on the Dremel trick first. I would also apply some heat before trying to remove the bolt. If then you don't succeed, center punch the bolt and try drilling. If all else fails, slather it with Form-A-Gasket, install the pump with the remaining bolts as was suggested earlier. Just my .02
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All Diesel Fleet 1985 R107 300SLD TURBODIESEL 2005 E320 CDI (daily) LOTS of parts for sale! EGR block kit http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html 1985 CA emissions 617 owners- You Need This! Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst. Sanden Instalation Guide (post 11): http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html |
#18
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If you snapped it off when tightening it, once the bolt head is off, there will be little pressure holding it in place. If it broke off when trying to remove it, it is stuck in place and the following will probably not work.
Cut a slot in the shaft. Use a screw driver to turn it out.
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Greg 2012 S350 BlueTEC 4Matic 2007 ML 320 CDI 2007 Leisure Travel Serenity 2006 Sprinter 432k 2005 E320 CDI 1998 SLK230 (teal) 1998 SLK230 (silver) 1996 E300D 99k, 30k on WVO Previous: 1983 240D, on WVO 1982 300D, on WVO 1983 300CD, on WVO 1986 300SDL 237k, 25k on WVO (Deerslayer) 1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix 1983 380 SEC w/603 diesel, 8k on WVO 1996 E300D 351k, 177k on WVO Last edited by GregMN; 06-19-2017 at 11:09 AM. |
#19
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If you're going to drill, use the smallest bit you have. Then work up. I believe that's a blind hole, so don't drill all the way through or you may have a real leak. I hear what's being said about welding onto the stub, but is it safe to do this on an aluminum casting? If the cover is damaged in the process, you're done.
The timing chain cover is machined as a unit with the block. If you end up needing a new cover, it's the end of the road. You're not going to pull the motor to deck the timing cover. If form a gasket doesn't work, at least you're no worse off. |
#20
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Just wanted to close the loop on this. I didn't own a Dremel (for shame!) so I ordered one online and had to wait for it to ship, but of course it didn't come with a cut-off wheel, which I finally picked up at the hardware store today.
I spent a couple of minutes getting everything assembled and masking off the gaping hole in the timing case; cutting a slot in the bolt and turning it out with a flathead screwdriver worked like a champ - super stoked! It was literally seconds of work. Thanks everyone for the tips!
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___________________________________________ 1992 300D 2.5 Turbo
W124.128/OM602.962/4G-Tronic 722.418 Dieselmeken 7,5mm | Sportline Interior My Build Thread |
#21
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Hooray! I love that trick.
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79 300TD “Old Smokey” AKA “The Mistake” (SOLD) 82 240D stick shift 335k miles (SOLD) 82 300SD 300k miles 85 300D Turbodiesel 170k miles |
#22
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Drill it , job done .Pack the open part of crankcase with dusters to stop any swarf that might get in there. Dont go and drill right though the bolt, but just enough to take the extractor You will be happy with a proper job .Drill it to take an easeout [extractor] .Good luck
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#23
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Quote:
__________________
All Diesel Fleet 1985 R107 300SLD TURBODIESEL 2005 E320 CDI (daily) LOTS of parts for sale! EGR block kit http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html 1985 CA emissions 617 owners- You Need This! Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst. Sanden Instalation Guide (post 11): http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html |
#24
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Congrats! Always satisfying to get a frustrating part of the job like that done.
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617 swapped Toyota Pickup, 22-24 MPG, 50k miles on swap |
#25
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New timing case cover: I'd be inclined to give it a try. If you take old and new cover to a shop and have them mill new down to match old, this should work. Worst case scenario is a minor oil leak. Perhaps a bead of the anaerobic sealer mentioned earlier would suffice, between timing case and head. When I pull the head and timing case off my OM603, had to loosen the oil pan to allow room to pull the case. Installed original case back on, but left loose. Installed head with new gasket and tightened case to head per torque spec, then tightened case to block and finally oil pan to case and block. No leaks.
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Respectfully, /s/ M. Dillon '87 124.193 (300TD) "White Whale", ~392k miles, 3.5l IP fitted '95 124.131 (E300) "Sapphire", 380k miles '73 Balboa 20 "Sanctification" Charleston SC |
#26
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Glad the Dremel trick worked. Have been watching this thread with interest.
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