Second Attempt Thread Repair

[Citroënbender]

Three out of four holes were usable with the original M6 thread.

An M8 bolt was centre drilled (as suggested on here) and wound into M8 Helicoils near the top of the bolt holes (this area was originally without threads). So the long series 1/8” bit was quite well centred, then went up a mil or so. At this point it was determined that the holes weren’t actually filled with bolt stumps but a mixture of swarf and diesel “coal”. Picks, solvent, compressed air and a chasing tool made from high tensile M6 rod were used to remediate the original threads.

Except 4, which was stripped. So the Helicoil will probably suffice for that unit alone, with the first three using factory style fixings.

I’m going to order a specialised repair kit as a backup but reckon we’re onto a fix as it stands. Injector seats refaced tomorrow and hopefully a running Vito by Monday night.

[roKWiz]

Originally Posted by Citroënbender

Three out of four holes were usable with the original M6 thread.

An M8 bolt was centre drilled (as suggested on here) and wound into M8 Helicoils near the top of the bolt holes (this area was originally without threads). So the long series 1/8” bit was quite well centred, then went up a mil or so. At this point it was determined that the holes weren’t actually filled with bolt stumps but a mixture of swarf and diesel “coal”. Picks, solvent, compressed air and a chasing tool made from high tensile M6 rod were used to remediate the original threads.

Except 4, which was stripped. So the Helicoil will probably suffice for that unit alone, with the first three using factory style fixings.

I’m going to order a specialised repair kit as a backup but reckon we’re onto a fix as it stands. Injector seats refaced tomorrow and hopefully a running Vito by Monday night.

Well on its way to the public reveal.

[Citroënbender]

If it runs, perhaps yes.

Although I’m not sure what the reveal would be of. It’s not like a #vanlife TV show, there is no spice rack or vegetable bag.

[Citroënbender]

The centering guide:

Installed for use in #3:

And our very simple chasing tool:

Finally, everything blown clean, all swarf gone, cams and gears moly lubed for initial protection.

[Citroënbender]

Also have one of these kits on the way as backup. About $140 to my door.

https://fjwsales.co.uk/product/injec...es-benz-cdi-m6

Tooling prices vary hugely, this is the cheapest vendor of what appear to be identical sets in various brandings/boxes. The extra inserts alone often cost more.

[Citroënbender]

Van has been in daily use for a few weeks now, it will need fettling but overall seems quite happy. I think it’s coming back in about seven weeks for a solid check and service, plus new turbo inlet pipe.