Before you begin make sure you have your thermocouple, a new turbo gasket set, and Brian Carlton’s EGR block off plate.

1) Disconnect negative battery cable. Actually do this…I did not and it cause some excitement later on.
2) Remove air filter and any other stuff that will be in the way
3) Remove turbo oil line EGR, and exhaust downpipe
4) Remove the 6 bolts that hold the manifolds on (one is hidden behind where the EGR was) and the turbo support bracket (you will see it under the turbine housing)

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

5) Pull the turbo and manifold back off of head
6) Remove turbo snaking it past the oil supply line (it would be much easier if the supply line was removed, but you need to drain the oil for that)
7) Bring manifold inside and set on some cardboard so your wife won’t kill you.
8) Remove bolts that hold turbo to exhaust manifold
9) Realize that bolts are stuck, spray with penetrating oil and have a beer


Thanks to the wife for snapping that last picture...although I think she may have been taking it to show the divorce lawyer.



More to come!

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

I'll mention that the turbo support bracket is a MAJOR PITA to get at and remove...

and how exactly did you manage to get the exhaust manifold off without removing the intake manifold???

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RIP: 80 300SD
RIP: 79 450SEL
2002 E430 4matic (212,000km)
2002 ML500 'sport'

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FACEBOOK: PANZER450

The support bolt wasn't too bad, I just had to crawl under the car to get at it.

To remove only the exhaust manifold I simply only pulled on the exhaust manifold. I did later remove the intake manifold as well to replace the manifold gasket.

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

Glad to see I'm not the only person that wears the PepBoys overalls!

Howdy,

I will assume that this is an incomplete photo essay......was wondering exactly where you intend to mount your Exhaust Temperature Gage/Pyrometer's Thermocouple???

I intend to also install a Pyrometer for my Exhaust Temp...however I had not considered dismounting the Turbo.....I was/am going to simply purchase a new Exhaust Header Pipe......mark the existing one at the point where there is sufficient clearance in car.....as close to the Turbo as possible.....remove the existing pipe, truck both parts down to my welder dude....then have my "Superwelder" weld a spigot onto the new header pipe, in location where marked on old pipe, drilling a hole, of course......then installing the new header pipe, with thermocouple installed.....and then wiring the pyrometer up.

I intend to watch this thread, perhaps I will find a better location to mount mine, but....so far it looks like a whole lot more work.....

Note: I became divorced quite a few years ago.....one of the little things that I learned was....never put your wire wheels in the dishwasher......you're doing a good job with the wife so far...lol

SB

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Diesels:
'85 300D, "Max, Blue Benz", 155K, 27.0 MPG
'84 190D 2.2, "Eva, Brown Benz", 142K, 40.2 MPG
'77 240D (parts car)
'67 Eicher ES 202 Tractor "Otto" (2cyl, Air Cooled, 30HP)
Gassers:
'94 Ford F-150, "Henry", 170K (300 Six) 17.5 MPG
'85 190E 2.3, 148K....Parts Car
'58 Dodge W300M Powerwagon (Flat Fenders) Less than 10 MPG

19) Clean gasket mating surfaces on manifolds using a wire brush, emery paper (if necessary) and a paper towel.
20) Clean gasket mating surface on head and install gasket
21) Put turbo and manifolds back in engine bay and connect thermocouple to fitting.
22) Install manifolds. It may help to loosen the turbo support brace to get the manifold into place.
23) Tighten all bolts and nuts, reinstall oil lines and downpipe.
24) Realize that you forgot to double check that the oil return line was aligned. MAKE SURE YOU CHECK THE OIL RETURN LINE BEFORE YOU INSTALL THE TURBO AND MANIFOLD!!!

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

25) Try to remove oil return line to fix mistake
26) Realize that the EGR runner prevents the return line from being installed with the turbo in place.
27) Curse long retired Mercedes engineer and the federal government.
28) Remove manifold again to fix oil return line.
29) Reinstall manifold again.
30) Install air cleaner check all connections, start car and check for exhaust and oil leaks.
31) Go for a test drive and enjoy your new gauge.

Unfortunately my pyrometer fogged up when I turned on the headlights. Grr! Then on the test drive my speedometer cable started howling.

More projects...

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

Ok, looks good. But I have to ask the dumb question: What's the point of knowing exhaust temp?
Sorry in advance for asking...

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Paul
2004 E500 4matic; 72,000mi

When the exhaust gets too hot bad things can start to happened. Not really an issue when the car is stock, but I plan to turn up the fuel and add an intercooler soon.

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

Ahh, cool.

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Paul
2004 E500 4matic; 72,000mi