There are relatively few threads about this repair. I am in the process of replacing mine on my '85 300sd due to fumes in the cabin, the sound of a leak in that area and an oil leak. I did not remove the turbocharger entirely but only its lower support bracket. It took a huge amount of fussing to get the manifolds removed and reinstalled. It seemed like I could not get the manifolds to clear the studs in the block and almost had to loosen the exhaust mounting bolts (if I had a lift, I would have done so). In addition, more than one stud came out of the block with the nut seized on it. For anyone who is attempting to do this repair, it is a huge PITA and hope your search finds this post before embarking on it. It never ceases to amaze me how there can be so little space to work in a car so large. This may have been a repair I should have saved for my mechanic....

Brian

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Brian
'94 E420 - 99K
'12 C300 4 Matic

Previously owned:
'06 CLK 500K Cabriolet
'85 300SD (Old Smokey)
2002 Boxster
2002 C320 (The five-pointed star Mercedes)
1993 300E 3.2 (Dealership's cash cow)
1979 300SD (Chrome beauty)
1983 300D (Old faithful)
1983 240D (Right lane cruiser)
1977 240D (Miracle of bondo)

It is IMO easier if you don't skip STEP#8 from the FSM.

#8. Unscrew fastening nuts for intake/exhaust, remove manifold assembly with turbocharger.

STEP#9 from the FSM is very important.

#9. CLEAN intake/exhaust manifold, check flange surfaces with a straight edge, and refinish on a surface plate if required.

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ASE Master Mechanic
asemastermechanic@juno.com

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

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