How to remove the intake/exhaust manifolds with turbo - PeachParts Mercedes-Benz Forum

gregp1962 · #1 02-14-2019, 10:03 PM

1984 OM617 with turbo.

I have all of the manifold bolts off and the exhaust manifold is about 1/2 in from the head. Of course, the intake manifold is very loose. But, the exhaust manifold won't budge any more than about a half inch. Are there any hidden bolts under the exhaust manifold? How does the accordion tube come off?

I did a search and didn't find anything on this.

vwnate1 · #2 02-14-2019, 11:03 PM

The accordion tube is help on by band clamps at each end.....

There's also a support bracket one one end of the turbo's cast iron flange....

gregp1962 · #3 02-14-2019, 11:49 PM

I have the bands off the accordion tube. But, the accordion tube doesn't just slip off. It feels like there is a hidden bolt underneath the manifold somewhere.

Alec300SD · #4 02-15-2019, 12:00 AM

Quote:

Originally Posted by gregp1962

1984 OM617 with turbo.

I have all of the manifold bolts off and the exhaust manifold is about 1/2 in from the head. Of course, the intake manifold is very loose. But, the exhaust manifold won't budge any more than about a half inch. Are there any hidden bolts under the exhaust manifold? How does the accordion tube come off?

I did a search and didn't find anything on this.

I find it is easier to leave the accordion pipe in place and remove the downpipe instead.

First, remove the U-bolt from the bracket securing the downpipe to tramsmission bellhousing.
Then, remove the three nuts on the triangular exhaust flange that attaches the top of the downpipe to the exhaust fitting
(located between the downpipe and the accordion pipe).

The flex fitting of the downpipe lets you detatch it from the turbo.

Then you can easily pull the turbo and exhaust manifold as a unit.

The V-band clamps (Marman clamps) can then be removed to free the accordion pipe...without damaging the accordion pipe,
nor damaging the hidden cylindrical pipe that lives inside the accordion pipe.

gregp1962 · #5 02-15-2019, 12:04 AM

Thanks Alec. I am a bit worried about rounding the nuts holding the triangular bracket on. Have you had a problem with that? They look like they might be copper. How far down is the U bolt bracket? So, far I haven't had to jack up the car.

Alec300SD · #6 02-15-2019, 12:13 AM

The nutc are probably ovalized copper lock nuts, use a 6 point socket to remove them.
12mm IIRC.

The U-clamp is at the bottom of the S-shaped downpipe...about 10 inches off the ground.
The U-clamp nuts are 13mm IIRC.

gregp1962 · #7 02-16-2019, 04:48 PM

OK, I got the bolts off the triangular exhaust flange and the down pipe is loose. The I was able to pull everything far enough away that I got the intake manifold off. Still can't lift the exhaust manifold and turbo assembly up even a little bit. There is so much oil it's hard to see what's holding it in place underneath. Is it possible that it is just so heavy that I can't lift the exhaust/turbo assembly? Is some sort of lift required? Does the oil drain tube also hold it in place? I thought that just lifts out from the oil pan.

Diseasel300 · #8 02-16-2019, 05:54 PM

The manifold and turbo will be heavy. The turbo alone probably weighs a good 15 pounds. Remember that this is cast iron you're dealing with. The turbo drain has O-rings on it, if they've been there a while, they could be very "stuck" and need some encouragement to let go. Not sure about the 617, but the 603 has a bracket that supports the underside of the turbo that needs to be unbolted before you can lift it out.

ROLLGUY · #9 02-16-2019, 11:02 PM

There is another bracket that is bolted to the bottom of the manifold at the top, and on the motor mount arm at the bottom. It also holds the air cleaner drain tube.

gregp1962 · #10 02-17-2019, 01:06 AM

Would one need a lift to get the exhaust manifold and turbo out?

Maximan1 · #11 02-17-2019, 01:39 AM

Quote:

Originally Posted by gregp1962

Would one need a lift to get the exhaust manifold and turbo out?

No, but as mentioned in previous posts, it is a heavy assembly. Comparable to lifting an aluminum head from a 4 cyl engine. Not super heavy, but difficult because the weight is far from your body.

gregp1962 · #12 02-17-2019, 08:45 PM

Quote:

Originally Posted by ROLLGUY

There is another bracket that is bolted to the bottom of the manifold at the top, and on the motor mount arm at the bottom. It also holds the air cleaner drain tube.

I'll be working on it again in the morning. Does anyone have a picture of a bracket that ROLLGUY is referring to? Wow, you wouldn't believe the amount of oil under this engine.

Maximan1 · #13 02-17-2019, 09:44 PM

Quote:

Originally Posted by gregp1962

I'll be working on it again in the morning. Does anyone have a picture of a bracket that ROLLGUY is referring to? Wow, you wouldn't believe the amount of oil under this engine.

The bracket should come up from the motor mount arm on the passenger side. It is possible that it is missing.

Diesels are dirty. Especially high mileage engines. I scraped off tons of oily buildup from my OM617 block and had it hot tanked twice before it was clean enough for paint.

Alec300SD · #14 02-17-2019, 11:31 PM

The exhaust manifold has an attachment point at the bottom of the T-3 turbo mount.

The exhaust manifold stay (bracket) is attached with a 17mm nut and a 17mm bolt to the above mentioned portion of the exhaust manifold.
(Number 47, 53, and 50 in the attached EPC drawing).

It is hard to photograph.
You need two 17mm wrenches to remove it.
Postion your wrenches by feel.
Hold the wrench on the fastener furthest from the engine, and turn the wrench on the fastener closest to the engine.

Remove that nut and bolt!
Then turbo and exhaust manifold can be pivoted away from the engine, and then lifted up and out of the engine bay

Maximan1 · #15 02-17-2019, 11:34 PM

Interesting, my '82 manifold does not have that attachment point IIRC.