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#1
02-09-2008, 01:37 PM
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OM617 Manifold Disassembly Tips?
I'm ready to remove the manifolds, turbo, and trap catalyst from my 1985 300D (W123, OM617, California version) for cleaning and replacing leaking seals. I suspect that the last time this part of the engine was apart was when the trap oxidizer was removed and replaced by the trap catalyst, long before I bought the car, which now has 239,000 miles on the original unrebuilt engine.
Other threads here have mentioned that the nuts on the exhaust manifold studs are sometimes hard to loosen; I'll use plenty of PB Blaster. It's supposed to be easier to remove the turbo and trap cat as a unit and disassemble it on the workbench. (I'll post results with pictures.) Any other things to watch out for? Jeremy
__________________
 "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 
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#2
02-09-2008, 01:46 PM
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a 1/2" drive breaker bar with extension and a universal is your best friend
don't forget to remove the oil feed line.. oh.. its also heavy.. so lay some heavy blankets on the fender in case you drop it or w/e
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#3
02-09-2008, 01:47 PM
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I can't remember where the turbo support bracket is on the Cali cars, but on the federal cars it is below the turbo and bolts to the engine mount arm and is a B%(# to get at and remove.
Make sure you use a 8 point socket on the manifold and turbo bolts to prevent them from rounding off.
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver 1982 300SD - 232K miles - Wife's Daily Driver 1986 560SL - Wife's red speed machine
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#4
02-09-2008, 05:50 PM
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Turbo feed line must be removed..........all the way to the oil filter.
Turbo drain line must be removed from underneath the turbo. As mentioned, if the turbo has the bracket underneath, it's got to be removed to allow the manifolds/turbo to come out. The nut is a real PITA and needs heat to break it loose.
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#5
02-09-2008, 10:00 PM
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Socket to me
Quote:
__________________
"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
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#6
02-10-2008, 12:38 AM
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I just pulled my turbo for rebuilding in December. I didn't think the turbo support bracket was that hard to deal with. I had a much harder time with the turbo drain grommet that I replaced while the turbo was out!
Don't forget to unbolt the air filter drain line from the main support bracket, get that out of the way. The exhaust nuts came off easily for me (but it has always been a California car, no rust).
__________________
84 300DT Puke Yellow. Totalled after 438,000 84 300DT Orient Red. 169,000 (actual mileage may vary) 2002 Explorer EB (wife's)
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#7
02-10-2008, 12:47 AM
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Quote:
__________________
"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
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