i would like to extend thanks to any and all who helped out with my questions about my 1991 940se turbowagon 225K (and thanks to you all, counting). i replaced the timing belt, front seals, belts, all crankcase ventilation hoses and parts, and the wagon has just left the driveway for the first time in two months. as i have only a cursory knowledge of auto mechanic skills (i learn from doing, i.e. my mistakes) this board has been an absolute boon to my saavy, and rather than laying out 3-4k for a new ride, i spent $150 and some time to resurrect what i thought, due to my limited knowledge, was the dead.

here's to you all, and i will contribute $ to the board asap!

now, if anybody knows a mechanic in nj who will helicoil a plug thread with the head on.........i can't imagine doing that myself.......
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'75 164e(?), '87 240gl(350K), '84 240 gl(233K), '91 940se(225k+?)

Good for you. The plug thread thing is not that bad, and personally, I'd rather do that job than a timing belt. The fix is not really a helicoil, but rather a "shell." In other words, after tapping out the hole to a larger size, you use a thin insert instead of the helicoil "spring." I understand the fear of of doing radical surgery on your baby - kind of like sewing up a cut on your kid. However, it's not that bad. The insert comes as part of a kit, which includes a special tap. The tap is made with an extended nose that guides it into the hole and prevents you from tapping the hole out sideways. You can coat the tap with grease to keep most of the cuttings from going into the cylinder, but I don't regard that as much of a problem. Any stray cuttings that get into the cylinder won't get past the rings and will get blown out the exhaust the first few revolutions after the job is done. Go for it!

where can i get such a kit? i bought one a a local auto parts dealer but it doesn't seem to fit right, or maybe i'm just to tentative to get it to bite. is there a brand you'd recommend? should i coat outside of the insert with loctite or something prior to installing? thanks.
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'75 164e(?), '87 240gl(350K), '84 240 gl(233K), '91 940se(225k+?)

I have seem the kitd at the larger NAPA stores.

The heli-coil (insert) will be larger than your present threads in your plug hole. I never use any loc-tite. Just follow the instuctions than come with the kit. Don't forget to break off the tang after you install the insert. Piece of cake job, just take your time with the tap.

JJ