How To Fix Damaged Timing Chain Tensioner Threads In An OM603 Head For $5.99
 

:vbac47679Mechanics hate him! This man uses one weird trick to repair a stripped out or cross-threaded timing chain tensioner hole in an OM603 head for only $5.99.
Press START SLIDESHOW below to find out how!:vbac47679

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I went to install a timing chain tensioner in an aluminum head and noticed it wouldn't thread in. After forcing it a bit, damaged threads ensued. It turned out the threads on the used timing chain tensioner were flattened which wouldn't allow it to go on without damaging the delicate threads in the head.

Until now, this would have required replacing the head or the entire engine; at the very least, a $200+ Helicoil. Not today, Satan! :devil::whip:

Purchase an M24X1.5mm plug for $5.99 and free shipping on eBay. This one is shaped perfectly with the way the threads taper off under the head.
https://lh3.googleusercontent.com/H6...w=w800-h453-no

Clamp it in place and start cutting off the sides of the head.
https://lh3.googleusercontent.com/dr...A=w800-h453-no

Cut it down to where the threads start, so the threads will grab and it will pass all the way through the hole.
https://lh3.googleusercontent.com/fk...w=w800-h453-no

The finished product. They do sell headless plugs, BUT be warned they have tapered threads, so they will not work!
https://lh3.googleusercontent.com/qp...Q=w800-h453-no

With the cam sprocket removed and the timing chain off to the side, the chain rail can be moved away for access to the inside of the timing chain tensioner hole.
https://lh3.googleusercontent.com/TH...Q=w800-h453-no

Stuff a rag behind the chain rail to prevent the newly-made tool from dropping down inside the engine. Lower down the tool with a magnet.
https://lh3.googleusercontent.com/RA...Q=w800-h453-no

Start threading in the tool by pushing from the back and using a 12mm hex key socket.
https://lh3.googleusercontent.com/iM...w=w800-h453-no

Thread the tool out until it starts to get difficult to turn, and then go back and forth a few times until the threads are repaired. Crisis averted! :bluegrab:
https://lh3.googleusercontent.com/R_...w=w800-h453-no

Bloody brilliant!

:lol:

Driving my new 35 year old 300D, I have new appreciation for the OM603. Much nicer engine.