Ok guys I've owned this car since 1990. I've owned 2 617 turbos and I always have difficulty installing this O ring.
The "oring" I'm talking about is the large flat Oring that is slipped on the output of the airfilter. Then the black tube that goes to tthe turbo is slipped over the oring while installing the other end of the black tube over the turbo input.

Fastlane calls it a "intake pipe seal"

http://catalog.eautopartscatalog.com/mercedesshop/sophio/wizard.jsp?partner=mercedesshop&clientid=mercedesshop&baseurl=http://catalog.peachparts.com/&cookieid=1DL0POVYV1DL0PP2IH&year=1982&make=MB&model=300-TDT-001&category=A&part=Intake+Pipe+Seal

Here on skinnerbox its page 2 item numer 7

http://skinnerbox.steaky.org/Service/W123/w123CD2/Program/Engine/617/09-400.pdf

I have always wrestled with this everytime I've taken the air filter off.
This time I cleaned the housing,installed the seal and put gear oil onthe rubber seal.then carefully slipped the black plastic tube over it.

How are you guys doing this??????? As I have said I have always been frustrated doing this. There has got to be a trick.

Air filter housing is OEM and original. Seal is the correct one, checked with the dealer.

Any ideas??

Dave

__________________
1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car

After struggling with this myself, i just used a dremel to cut down the lip on the air cleaner side of the intake pipe. Now anytime i have to remove the air cleaner i just undo the intake pipe from the turbo side only and remove it along with the air cleaner housing. i dont think ill ever have to do that damn seal again.

P.S. The reason i havent been around is i moved to indiana and have been pretty busy, but im here now

I also remove it from the turbo side only if I can. And it's definitely not "just you" It's the air cleaner assy. Believe it or not, last time I struggled with the thing, I actually worked at getting the air cleaner on the tube and I reached into the air cleaner outlet with my hand against the metal basket (air filter removed, of course) and got just enough grip on that damn seal to keep it in place. I have small hands so this may not work for you, but it worked great for me.

__________________
'82 300SD - 361K mi - "Blue"

"Good judgement comes from experience. Experience comes from bad judgement."

listen, look, .........and duck.

Oring? Air filter? Turbo? Thanks for posting this.

Use KY?

__________________
Never a dull moment at Berry Hill Farm.

I found the gear oil worked pretty well. But its still a PITA.
Can you put KY there? Is that legal

Dave

__________________
1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car

This is quite interesting.

I have removed that tube at least a half dozen times and never had any problem putting it back on. When I was doing the EGR testing, it was off and on the 617 at least three times.

I never even noticed that seal.

Is it possible that the seal gets itself seated (after 20 years) in place inside the tube and when the tube is shoved onto the air cleaner it does not move back away from the air cleaner?

Maybe the seal can be glued in place inside the tube in some fashion?

Very interesting.

If you are lucky that is what happens. The other possibility is that the seal gets softened by the oil that it is exposed to, and it slips out of the pipe resess when the pipe is pushed onto the air filter housing. I am considering a little contact cement between the seal and housing. And then never disconnecting the pipe at the housing.

It's better to use muffler grease to be safe.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

It could be that the new one is a little thicker than the 617 part number. It has been replaced, at least by the dealer info, to a 603 start number.

Dave

__________________
1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car

Awhile back on another forum, I read where some one did not have the seal seated correctly.
It got ingested into the turbo intake blades and eventually into the engine.. Ruined the turbo and head had to come off.

__________________

79 240D my current toy
42 years a Diesel addict

240D sold
250SE sold
220D sold
280C sold
280S sold
300D (2) sold
300CD sold
300DT sold
300SD sold
380SL sold