I had the same problem with my first 240D, the thread is buried on the forum somewhere. My current ones air cleaner had completely sheared off all three mountings. The front rubber mount had sheared in half. The other two had actually stripped the threads out of the mounting points on the intake manifold. So. To work...


First task was to clean the area sufficiently that I wasn't completely covered in crude oil. The intake manifold was up to a quarter of an inch thick with caked on oil in places. I started scrubbing with Purple power and a very stiff bristle brush. It was a miserable job. In this pic you can see the front half of the manifold still covered in the stuff.


But eventually I got it clean enough that I was happy to work in the are without getting filthy.


First I enlarged this hole with an 8mm tap.


The result looked good so...


In goes the 6mm thread insert.


New thread insert in place.


This one was a problem. The mounting screw had enlarged the hole in a oval shape and eventually bounced around on the outside of the manifold so much it had started to make a new indentation as you can see in this pic. It was difficult tapping the hole even with the 8mm tap because of the oval nature of the hole, but eventually it got enough purchase that it seemed to go ok. The thread insert seems to have fit in there decently.


The three mounts in place. The front one didn't need to have any work done to the threads fortunately. As the mount itself had sheared in half I simply removed the remmnants of the old mount and installed a new one. Because of the oval nature of the outside hole and the damage to the aluminum in that area I used a heat shield for a Turbo 300D application to act as a sort of washer and spread the load across that area.


Gasket in place. Unfortunately this was a URO part and I had a devil of a time getting it to fit correctly. Took several tries to get the air cleaner housing to fit on there without pushing the gasket off on one side of the other.


The re-circulation pipe back in place.


Air cleaner housing mounted. It took me a couple of days with Purple Power and a brush and towels to get all the oil off of this and clean it up. Both inside and outside.


Almost done.


Filter in place.


Done. I'll keep an eye on the job for a while, especially the outboard mounting point, but based on the success I had with my last 240D's repair I'm confident this should hold for a long time.

- Peter.

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2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S

That`s a nice DIY fix and pictures. very detailed.

I have a 80 240D with almost 375K, got it 5 years ago as it was just turning 306K miles.
I haven`t had this problem, as it seems to stay tight. Ours looks almost identical to your set up.

Now you need to polish out the Aluminum Filter cover. I did ours, and it looks amazing.

Charlie

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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

Once I get the whole engine bay properly cleaned. I'll see about trying some polishing and detailing. But there's a lot of stuff needs doing before I get there. And of course there's lots of non car related projects as well. Life and work getting in the way of important stuff like 240D's as it will.

- Peter.

__________________
2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S

Good work.

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83 SD

84 CD

X2

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Actually it appears someone used purple power cleaner on it...and well its now etched...purple power cleaner is a big no no on these engines as it eats aluminum...

WARNING: Do not use Purple Power near Aluminum - FFCars.com : Factory Five Racing Discussion Forum

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Yes, PP etches aluminum. I don't care in this instance. It was more important to me to get the quarter inch coke/crude/coal off of the area than have it looking concourse. I had used Simple green which was too week even in concentrated form, and even tried pumice containing hand cleaner and elbow grease. But non of it worked and so I went for the vicious stuff.

- Peter.

__________________
2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S

Its up to you, but I seen you also used it on upholstery, carpet and what ever else it can be sprayed on...this stuff is horrible and needs neutralizing as it can continue to eat the products...fyi it doesn't just etch...it eats..

Have you ever thought of using steam? Transmission fluid? Gunk Upholstery cleaner? Citrus cleaner? Kerosene? Gasoline? There are a million safe things to use to clean items...I am stating this because I don't want other to use your "idea" of clean and destroy their car....as it has been done in the past...

Like uro parts......the cheapest degreaser on the shelf of walmart is not always the best idea...

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Ive noticed with the old style degreasers in a can, the foam type will etch aluminum. The liquid will not.

True they all have their problems some worse then others.

My issues with the liquid and it seems to be common sense but people lack this.

Is that the liquid like purple power is more likely to seep/run into gaskets thus getting absorbed and spread onto the flat surfaces of intake/exhaust manifolds, heads, thermostat housing and other areas. Then you are not able to wash it away thus it sits on the surfaces causing pits that you are unaware of until leaks start. Foam is less likely to do this...

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Yes. That is true. I used a vast amount of water to wash it off. There may be other products that work as well. Simple Green did not. Citrus did not. I have no access to steam cleaners and had to do the work in my garage, so limited time, space and equipment. I have tried using other products on the carpets and such. There may be others that work as well as PP. If so I've not encountered them. And no. I'm not spraying gasoline around my garage. My wife would explode probably shortly before the house would.

- Peter.

__________________
2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S

Ohhhh. I meant the aerosol cans "engine degreaser." Its been a long time. I always use purple power for the floor. Never thought of using it on top.

Im in california, on a ranch I dont own, so i have no choice but to have it steam cleaned. Im particular who i goto after someone didnt cover the breathers....