Does anyone know the bolt size for the EGR to intake as well as the thermostat housing to engine block? Tried sleuthing online and was led astray to get M6 bolts.
For the EGR, M6 is too small. M8x1x25 or so??
For the thermostat housing, M6x1x45 was both too small and too short. Looking more like M8-60? To be clear, I don't need the bolts that join the two pieces of thermostat housing together.

Also, for the manifold line coming off of the intake to the switchover valve, does anyone foresee an issue using windshield washer fluid hose? Trying to do things the "easy" way while I determine the viability of the engine.

Also, does anyone have a picture/description of how the "EGR Exhaust Heat Shield" plate attaches to the engine? Triangular piece of metal with two bolt holes. I don't see how it would bolt to the EGR... Does it attach to the air cleaner assembly bottom?

I'm sure I'll have more questions after these...

Thanks

Bolts I don't recall except that ones into the aluminum intake would likely be a coarse thread. If you know what socket fits, that usually tells you the thread size. There are actually 3 standard thread pitches for each metric bolt size (coarse, medium, fine), which makes it more fun.

Washer hose varies, but is often rubber "vacuum hose". My 300D's have clean nylon tubing w/ rubber end connectors for the intake pressure "signal" (to vacuum valve on firewall in my 1985, direct to VCV in my 1984, as I recall). Any hose should suffice. Silicone hose might last forever.

Neither of my engines, nor a 3rd used engine I got have/had any heat shield around the EGR valve that I recall. The EGR valve is gone now, replaced by Rollguy's block-off plates. If your EGR system is still working, that is unique. Can't get replacement parts, so the EPA shouldn't throw you in jail if you rip all that convoluted clutter out (see posts).

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1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans

Thanks for the reply! Think I've got it all figured out now. Thermostat to engine block seemed to do well with two M8x1.25x70mm.

Got the thermostat housing pitting repaired (jb weld and sanding) as far as I can tell without any pressure on the system.

Figured out the EGR bolts. Valve to the manifold ended up being M8x1.25x25 or so I think, length is important too much on these since the bolt can pass through the rear.

EGR band clamps were M7x1x30 to get enough purchase on the captive nut without otherwise closing the clamp in.

Egr sheild is two small M6x1x10mm bolts. There are two holes hiding on the intake side of the manifold. The shield sort of contours around the EGR pipe and keeps that heat at bay from the turbo intake tube.

Valve cover linkage plate bolts in with four M7x1x25 mm or so bolts. Can probably be shorter with no problem.

AutoZone had some 5/32 washer/vacuum tubing so I was able to use 2 feet of that and finish cobbling together my vacuum system. Think I've got everything rerouted as correct (while also deleting 3/2 valve and EGR/thermostat switch).

So far the car seems to be holding water fairly well for filling it up with no pressure and no engine movement. Hope I can get a step up on the injectors soon can try to crank the car for it's first go round since I've owned it.