Hello all,

Currently 90% of the way to removing the turbocharger along with intake/exhaust manifold so I can replace the freeze plugs on the passenger side of the block.

However I've become completely stuck. I've removed the 7 manifold stud nuts, and was able to remove only the lower nut on the manifold support bracket (should be enough?), removed turbo oil inlet bolts, etc. etc.

This is the guide I was following: Removal and installation of exhaust manifold

So I've reached the very end, and I simply cannot pull it out. I can get the assembly as much as 1.5" away from the block, and also get the bracket off of it's own stud. I'm not really sure what's going on but it seems to not be clearing the top mounting studs enough to lift the assembly out.

I'm at a loss as to what I'm doing wrong with this. Have any of you done this job before?

Thanks for any tips.

I had the same problem. I ended up taking the turbo off the exhaust manifold so I could take each manifold off separately.

I removed the turbo & exhaust manifold on my 84 300D a few months ago to effect a weld repair of the K-frame. I don't recall any special problems, just normal "wish I had more room for a wrench" issues. I removed the turbo first. Replace the O-rings on the "turbo-to-intake" aluminum spool piece while in there. I used some from a Harbor Freight kit (I recall the "better than buna-N" kit). I didn't have the square turbo-to-exhaust metal gasket in my engine gasket kit, so I ordered one on ebay (~$5, stainless I recall). It is a standard size, but I forgot which one. Several ebay sites show dimensions.

I pulled my turbo first and everything went fine. Never tried it assembled so I don't know if that works. My only "issue" was getting the flex pipe to let go - that sucker fits REALLY tightly. I just kept working with it and finally it let go.

Dan

If I recall correctly, that's what I did too. Don't think I even tried taking off the whole thing at once.

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• 380SL (diesel)
• Corvette C5
• Manx
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• F350 Powerstroke
• Auburn Boattail Speedster replica

Decided to go to work on the turbo as suggested.

Was able to open bracket bolt and three of the four nuts using 17mm wrench with a cheater bar (who knows when the last time these moved were).

So far as I can tell the lower left nut on the turbo/exhaust mate can only be accessed from the under the car, and I can't get enough leverage to crack it (pre-soaked in penetrating oil).

I guess I'll try the big red wrench?

I can hardly believe how difficult this is.

It can be done, if you're lucky. There is a trick I can't remember, but I know it takes a lot of wiggling and the whole intake/exahust/turbo/sonnector comes off as one.

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

Heat is your friend. Forget the penetrating oil. Get the nut as hot as you can.

Remove the exhaust downpipe. That will allow you to get tbe last nut out of the heat shield onbthe manifold above the starter. With manifold nuts off you can then move manifold out and access the lower rear turbo flange nut from above with a 17mm open end. It should be the last one. Then turbo will come out.

Have Fun,
Karl