A couple months I bought a KKK turbo off a member here and installed it on my 84 300D with a turbo install kit from Febi. Last night driving 65 down the highway I started hearing a shrill high pitched noise, so I pulled over, thinking that maybe I had a bearing spinning or an accessory seized up. Turns out that the shreak I heard was the sound of the turbo, with sound and exhaust escaping from the bottom of the exhaust manifold where it bolts to the cylinder head. I am pretty peeved that this leak has opened up because the work is messy and tedious and the kit was something like $70. I don't want to do this work over, but it looks like I'm going to have to.

Do we know what might cause this leak to develop? The FSM doesn't give a torque setting for the nuts that hold down the manifold and there isn't room to get a torque wrench in there, anyway. Is there anything that I might have messed up on the install that would cause this leak to open up 6 months later? If it was something I did or didn't do, I don't want to mess it up again.

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1984 300D 193.5k miles
ASTM-certified B100 bio when able

When I removed intake Manifold one of the Studs came out with the Nut. I was surprised to find that the part of the Stud that threads into the Cylinder Head has only about 4 full threads on it. So they are not an item that you would want to tighten a lot.

I saw a non-Mercedes manual that had a torque for the Manifold Bolts but cannot remember which manual or how much.

I am curious to see what the cause of the problem is as I reused my old Manifold gasket (I coated it with Copper Kote) and have had no problems with it.

Not related to Mercedes but I have twice had an experiences (on 2 different vehicles) where exhaust manifolds would not go back on easily.
The reason seemed to be that after they were removed from the Engine (no longer held down by bolts) they warped.
On the last set (from a Chevy V-6 that were off of the Engine for more than 6 monts) they were warped enough that they also need to be resurfaced.
It might be a good idea to check the Manifold surfaces with a straight edge to see if they are all still flat and lined up with each other.

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84 300D, 82 Volvo 244Gl Diesel

Whenever I post a problem, I like to post a solution.

My exhaust leak was not at the manifold. I recently adjusted valves and installed a braided stainless steel turbo oil line. To gain some room I unbolted the ALDA line and the bracket above it which holds the trans dipstick in place. Evidently, I didn't tighten the ALDA line back up after I was done. I found the line and the bolt wedged against the firewall with a a big, oily stain surrounding it. I can't believe the bolt was still there, but it was. I drove it about 100 miles in that condition.

A couple 20 cent washers and all is well again.

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1984 300D 193.5k miles
ASTM-certified B100 bio when able