Boy this is fun. I FINALLY got all the glow plugs out, changed them, and now I'm trying to put the intake manifold back on. No can do, and I'm the one who took it out.

How do you get this thing back in? It looks like the throttle cable has to go over 2 of the intake tubes. I can get it over one, but not the other.

Thanks,

Jeff 1991 300d, 128k

I'm sorta in the same boat as you. I took my intake off to change out the glow plugs in the '92. In the process, i broke some of the plastic retaining clips for the metal fuel injector lines and one of the rods that connect to the injection pump. I'm waiting on parts, but if i get it all together, I'll snap a pic of how the cable is routed on the '92. Your '91 should be similar

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2001 Dodge Ram 2500 Cummins Turbo Diesel - 4x4, auto, 3.54 gears, long bed
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'92 300D 2.5 Turbodiesel - sold
'83 300D Turbodiesel - 4 speed manual/2.88 diff - sold
'87 300D Turbodiesel - sold
'82 300D Turbodiesel - sold

This is why I don't get into very involved car repairs. I'm great at getting things apart. not so good at getting them back together.

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" We have nothing to fear but the main stream media itself . . . ."- Adapted from Franklin D Roosevelt for the 21st century

OBK #55

1998 Lincoln Continental - Sold
Max 1984 300TD 285,000 miles - Sold
The Dee8gonator 1987 560SEC 196,000 miles - Sold
Orgasmatron - 2006 CLS500 90,000 miles
2002 C320 Wagon 122,000 miles
2016 AMG GTS 12,000 miles

You dont have to remove your intake manifold for replacing GP, we did it W/O removing the Intake Mani when we replaced our GP form the 300SDL, its tight but its easier....

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Current Garage
2008 Mercedes GL320 CDI 188k mi Repair/Work in progress
1994 S350 160k mi Garage Queen & prepping for repairs
2005 E320 CDI 203k mi Healthy & Daily Driver
1994 S350 357k mi Retried as parts car
1984 300TD 214k mi Blown OM617 Poss OM603 Swap??

Sold
1987 300SDL 200K+
1994 S320 181K mi
2008 E320 Bluetec 127k mi
1999 S420 130K mi
1980 240D 360k mi
15+ Others that has come, stay and gone

GONE, BUT NOT FORGOTTEN
1995 E320 SE 220k mi
1984 300SD 350k mi

Maybe you can do that on an '84 W123 model, but not a '91 W124. The manifold has got to go.

jeff

I think he's talking about the SDL, not the SD. The 603 motor in the SDL has a similar intake setup as the 602 in yours and mine

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2001 Dodge Ram 2500 Cummins Turbo Diesel - 4x4, auto, 3.54 gears, long bed
-------------------------------------
'92 300D 2.5 Turbodiesel - sold
'83 300D Turbodiesel - 4 speed manual/2.88 diff - sold
'87 300D Turbodiesel - sold
'82 300D Turbodiesel - sold

I have a 1992 2.5 turbo diesel and I changed gps without taking manifold off, it is tight but can be done.

Go try to find one thats together, or at least pictures.

Maybe another 300D owner can post pictures of that area.

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1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!