W123 Turbo Air Intake Boot issues
 

Has anyone encountered this problem?

The intake boot on my 300CD Turbo, 1983 was damaged while rebuilding the turbocharger, I ordered a new one (part number 617 098 05 01). Upon receiving it I installed new gaskets in the boot and then tried to install it. The original boot pushed on with some effort, but was not impossible. The new boot simply could not be installed.

I began to inspect the two, both old and new, to discover some significant differences in size and shape. The original boot's large opening at the air cleaner is 74mm diameter and fairly constant as a circle.

The new boot is out of round and more elliptical with a vertical dimension of 76.9 mm (77mm) and an horizontal of 73.4 mm. The rubber gasket reduced the diameter of the boot by 4mm in each direction. The working diameter for the new boot becomes 73mm X 69.4mm.

Perhaps the new boot can be deformed by 1mm in the vertical, but even trying to deform the new boot with a clamp, it was impossible to force it onto the housing.

Pelican informs me that Mercedes is now using a different
manufacturer, and that all the new boots in the warehouse are the same elliptical shape and size.

Has anyone encountered this problem and found a solution? I am returning the new one, but it looks as though there is not a replacement. My next bet is to find a salvaged but sound one.

It can be hard to install those, even when reinstalling an existing hose with a new sealing ring.

Try putting it in hot water first to soften it so it is more pliable, or use a heat gun, and apply a little penetrating oil to lubricate it.

Check your local PNP type salvage yard. the 300D turbo`s and probably the 300SD Turbo is the same. 85 300D and 300SD Kali. are different.




Charlie

I have one for sale. PM me.