W123 turbo starter removal procedure
 

I just r&r'ed the starter motor in my 83 300D turbo for the second time and took notes of steps taken and tools used so that if I ever have to do it again years down the road, it would save me time. I am documenting it here for my benefit as well as others. There are other ways to do this job using other tools that's documented here with lot's of pics.


My procedure is not picture intensive (only 2) and may not work for you unless you have the same tools.

Here's a crucial tool for loosening and tightening the top bolt. A box GearWrench on a 1/2" long 10 mm allen key cutoff. This is about the lowest profile tool one can come up with to get into the tight spot of the top bolt from above. Others have used a 2 foot long 1/2" drive extension on a ratchet via the transmission tunnel. When I saw how oily and dirty my transmission was, I found this method very unappealing and sought other means. I also do not own long 1/2" drive extensions.
http://i31.photobucket.com/albums/c3...062011_002.jpg

1. Remove tubo to air cleaner plastic elbow pipe. 10 mm clamp bolts, ratchet.

2. Remove air cleaner housing. 10 mm nuts x 3, ratchet

3. Remove battery and tray. 10 mm bolts, ratchet

4. Remove heat shield. 8 mm bolts x 2, ratchet

5. Remove starter bracket. 10 mm bolts x 4, ratchet w 10" extension

6. Remove starter solenoid small wire, #2 stubby phillips

7. Remove starter big wires, 17 mm nut, ratchet

8. Remove upper transmission dipstick mount bolt on inlet manifold, 13 mm box GearWrench. This allows access to the top starter motor bolt from above.

9. Remove top starter ket head bolt with GearWrench and 10 mm allen bit (see pic above). Use a jack and a short length pipe on the GearWrench and push up with the jack to loosen the bolt, alternatively, jack the car up and lower the GearWrench onto the pipe supported on the ground.

10. Remove bottom starter bolt. 3/8 drive 10 mm allen bit on a 3/8 drive ratchet and a 16" pipe for extra leverage.

11. Turn steering wheel all the way to the right for clearance. Starter slides out on top of tie-rod as shown in pic.

http://i31.photobucket.com/albums/c3...062011_001.jpg