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Old 05-21-2003, 04:33 PM
sms sms is offline
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Join Date: Dec 2001
Location: Hartford
Posts: 134
Unhappy A/C Manifold bolt on 560sl is stuck!!!

Replacing the A/C compressor on my 560sl and can't get the manifold bolt that is located between the (2) hoses out. Its an 8mm bolt with a 6mm allen hex head. Access is poor and have tried everything!!! Wanted to remove this so I could replace the (2) o-rings on the hoses that go into the manifold.

Any suggestions or comments would be very welcome.

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Old 05-21-2003, 05:16 PM
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Join Date: Jun 2000
Location: Plano, TX
Posts: 2,476
I ran into this problem on my 124 chassis car. I removed the compressor and manifold hose as an assembly, then drilled the bolt head off. In my case I was pulling both out anyways; it was perhaps a bit more work removing them as an assembly. Can you disconnect and remove the manifold without pulling the radiator - I couldn't on the 124 chassis.

Anyways, the bolt is quite a common item, easily available at a hardware store, Home Depot, etc.

- JimY
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Old 05-21-2003, 05:46 PM
sms sms is offline
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Join Date: Dec 2001
Location: Hartford
Posts: 134

I aleady have removed the fan, radiator, power steering pump, air cleaner and was almost going to remove the exhaust manifold all to gain better access. If the bolt was up my bench, it would be a piece of cake. Unfortunately, it isn't. I've lubrcated. Tried varous hex wrenches (ratchet and hand). Heated it a bit (was worried about that) and now I'm trying to drill it out. Couldn't drill it from the top so I drilled from the back. Didn't have room for the drill. I'm somewhat off center ofcourse and now am worried about ruining the manifold!!!!!!.

I thought about removing the hoses with manifold, but can't because one of the hoses is bolted to the block near some sort of a/c receiver. Of course, I can't get this one lousy bolt out either!!

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Old 05-22-2003, 08:33 AM
I told you so!
Join Date: Jun 2002
Location: Motor City, MI
Posts: 2,741
I finally bought a dremel tool for my garage when I couldn't remove an allen bolt from my car. I used one of the mini cutoff wheels on the dremel to carve away the head. I was able to remove the part and more easily able to remove the stud. Maybe this would help in your case.
95 E320 Cabriolet, 131K
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Old 05-22-2003, 10:58 AM
sms sms is offline
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Join Date: Dec 2001
Location: Hartford
Posts: 134
I've come to that conclusion as well. The dremel tool will be my next purchase.

My lesson learned here is that these allen head bolts should be given maximum respect!!!!
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