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Old 08-08-2013, 12:39 PM
Join Date: Jul 2012
Location: Port Saint Lucie, FL
Posts: 24
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.

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Old 08-08-2013, 12:45 PM
Zacharias's Avatar
Not so amused
Join Date: Apr 2010
Location: West Quebec
Posts: 4,025
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.

2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

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Old 08-08-2013, 03:23 PM
Registered User
Join Date: May 2007
Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
Posts: 9,628
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.

there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works
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Old 08-08-2013, 10:23 PM
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Join Date: Oct 2012
Location: Chelmsford, Massachusetts
Posts: 4,373
I have one for sale. PM me.

"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."
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