Hi everyone - I have my head all free, ready to come off, but it is stuck on the passanger side. The downpipe (where the intake cross-over attaches) - is fitted over a slimmer pipe which feeds the turbo. It looked like it would just pull off, but it isn't. I think it does not - actually, there is a set of three 4mm allen head bolts that attach this assembly to the passanger side of the head, the top and side came right out, but there is one more underneith the I cannot figure out how to remove. Or am I making this too hard?

Here is a shot - looking forward, towards the front side of the car, from the passanger side of the head, the turbo is below this part.

Charge air goes the other way - from the turbo, up the EGR mixing pipe to the crossover pipe. A 1/4" drive u-joint should get you to the last bolt. Try a wobble tip hex key if the bolt head has an internal hex. Once the bolt is off the mixing pipe should slip off the turbo. There's a similar green o-ring on the turbo outlet flange over which the mixing pipe slips.

Are you lifting the exhaust manifold with the head? If not, are all 12 studs out of the way? If so, did you remove the turbo oil feed line that snakes through the exhaust manifold?

Sixto
87 300D

Hi there, I'm lifting the head without the turbo, leaving the exhaust manifold attached. Do I have to remove the three 4mm bolts if the pipe will just slide off anyway?

That is indeed a difficult bolt to access -- so difficult that when the dealer did the trap cat recall on my '87 300D (they replaced the turbo as part of the recall -- it was damaged) the mechanic didn't put that lower bolt back! It eventually caused a leak and damaged the o-ring. I fixed it myself, no longer trusting them. Anyway, I used a number of socket adapters to create a curved tool that would reach the hidden bolt.

As the pictures show, I used a 3/8" ratchet, extension, and swivel to a 3/8" to 1/4" wobble adapter and finally a 1/4" deep socket. I had to put the socket on the bolt with one hand and then thread the extensions through the space and plug it into the socket -- I couldn't get the entire assembly into place when it was all put together. A PITA but it finally worked.

Jeremy

Attached Thumbnails

   

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

How can you removed an allen head bolt with a socket? Your dealer probably replaced the allen head bolts with a hex bolts.

Normally, the turbo pipe is the first thing to come off for the head job. That is the way I did it. The turbo can be removed or stayed it does not matter. As to removing the bottom bolt, it is bit difficult to get to but not that bad. I used a 1/4" socket set with a 6" extension. I do not think I used an u-joint. You thread it from the bottom., there is a gap there to thread it thru. Please, please do not bugger up the allen head or else your will be in deep $hit.

__________________
Not MBZ nor A/C trained professional but a die-hard DIY and green engineer. Use the info at your own peril. Picked up 2 Infractions because of disagreements. NOW reversed.

W124 Keyless remote, PM for details. http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/334620-fs-w124-chasis-keyless-remote-%2450-shipped.html

1 X 2006 CDI
1 x 87 300SDL
1 x 87 300D
1 x 87 300TDT wagon
1 x 83 300D
1 x 84 190D ( 5 sp ) - All R134 converted + keyless entry.

My car had hex head bolts, obviously. I didn't think I would have to explain this but . . . presumably the car had been worked on before I got it and the bolts replaced.

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

A long allen key gets in there just fine. IIRC I chopped the head off one and used a 1/4 drive 4mm socket on it.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Good ideas all - I will start tonight when I get home, and weather it kills me or not, I'm getting this head off tonight. For about 5 minutes last night I was ready to light htis whole thing on fire, but the canopy the car is under is attached to my home, so I got over it. I also love the car. Anyone else here ever feel this way?

We all feel that way sometimes. That's why my car has a broken timing belt cover "UMPFH JUST CRANK ON IT HARDER" *snap*

__________________
$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

Woo-Hoooo!!!! Got the darn bolt out using Jeremy5848's advice, had to borrow some 1/4 extensions from my neighbor. After I got th ne bolt out, the hole thing fell into my hands, which kinda surprised m. If it just slids onto the turbo pipe, why couldn't I just lift it off with the head? Hmmmmmm, now that I am thinking about this, it was probably the transmission dip-stick still bing attached to the head that was making me think that this other part was the problem. Dunno, all that matter s now s tha the head is off and I am not bleeding (almost lost my front teeth putting h engine hoist away though.


Thank you to EVERYONE who chimed in with advice, photos and encouragement.