Size of Crossover Pipe Bolts on OM603
 

I need to use a thread repair kit on the manifold side of my crossover pipe. This is the rectangular end, not the round end. After installing a new gasket, the hex-head bolt closest to the front of the car does not want to snug up and is leaking oil vapor and is smelling like hot oil.

What I am trying to find is the size of the helicoil kit I'll need. Again, I went back to the parts store and they insist they will need both parts...the bolt and the receiving end before they can determine which size helicoil kit is needed. Any advice would be appreciated.

The car is an 87 300SDL.

Lance you need to find another parts store! The bolt should be enough. There are tools that fit to the threads and can tell them exactly what thread size is required. CarQuest was able to do this for me. I imagine NAPA or even Ace Hardware may be able to help as well.

-brian

I'm beginning to think that too. I sent someone to the store with the bolt and they sent her back with blue Threadlocker!! You know...LocTite! Sheesh!

If I have a chance, I'll try to measure the threads on that bolt today. If you're REALLY bent by all of this, I can sell you a used intake manifold ;)

md21722 --

Looks like your stable is similar to mine. How do you like your TDI? I've got almost 210k miles on mine and I love it.

Seems like the manifold rethreading thing isn't working too well. Any ideas? If you have connections to a used manifold, I may be interested!