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Old 10-06-2009, 03:46 AM
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Sev Sev is offline
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Join Date: Apr 2007
Posts: 1,441
GOT LUCKY while removing 617 exhaust manifold today

yeah, so i promised a friend i'd get him a turbo exhaust manifold. so i'm at the JY today, unbolting everything needed to get the manifold off. i did the egr, the air cleaner bracket, took the heat shields off--threw all that on the other side of the engine. i get pretty much all the bolts (or so I thought) of the manifold off (wouldn't you know there were two bolts 'hidden' by grease on the front behind the egr tube), when finally i get to the u-shaped bracket that holds the turbo on. one of the two lower bolts just kept turning and turning. finally i used a larger socket wrench and really put some muscle into it, and the head broke off.

i thought i was screwed, but then i realized that the two bolts facing the engine were removed, and that's all i needed to pull the turbo off. got the turbo off, grabbed the intake and yanked it upwards a little, and out came the exhaust manifold.

wouldn't you know MB would put a nut in a sneaky place on the downward angled bracket that holds the air cleaner box? dang those guys.

the other hard to remove nuts were the lower two of the four nuts on the bolts that come out of the manifold and attach to the turbo unit. had to get a long socket wrench down there and use a breaker bar to unbolt them. i can imagine this whole process would be a major PITA if any of the parts were rusted. couldn't imagine what i'd do if one of those four bolts was rusted--i'd prolly take an angle grinder to it or something, lol.
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Old 10-06-2009, 11:13 AM
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Join Date: May 2007
Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
Posts: 9,585
Yep, been there, done that. that brace under the turbo is a special treat.

Welcome to the "I just removed the Turbo, Intake/Exhaust Manifold special Bracket" Club. You get top honors and the Gold star.

I just went through that on a 85TD at PNP. this was a cali car that some one replaced the Trap with a piece of pipe. that dang thing had 2 braces supporting it. there was so much grease and gunk down below the turbo, it was hard to see the extra bolts added.

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 10-06-2009, 12:13 PM
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Join Date: Mar 2006
Location: Mount Holly, NC
Posts: 26,208
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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