Genuine Mercedes-Benz 300TD Turbocharger

Mercedes-Benz 300TD Turbocharger Parts and Q&A

• Turbocharger
  002-096-92-99-80
  Q: How to remove and install a turbocharger on Mercedes-Benz 300TD?

  A:

  Unhook the negative battery pipe and take off the air cleaner and bracket assembly and the turbocharger air intake hone. Disassemble turbocharger oil pipe at turbocharger (bonded with two bolts) and dismount turbocharger heat shield. Before removal, spray penetrant oil onto all attaching turbocharger threads in an attaching nut and a bolt. Unscrew the exhaust pipe flange nuts, and lift the pipe off using the studs and getting them open is not a problem with penetrating oil. Then unscrew two bolts that hold the flexible strap fixation to the coupling place and drop out completely the straps. Take out the two bolts connecting the flange collar, bend the flange collar, and extract it through the flexible coupling that can be then cut free of the turbo unit. Unthread the four retaining nuts of the turbochargers using an open-end wrench but there are difficult to reach in a narrow space. Unjoin the turbocharger plus oil return pipe and raise the assembly off the engine with the oil line clear. Take out the fitting between the turbocharger and the intake manual, paying attention to its installation sideways, and clean up the flange gasket of the exhaust manifold in addition to the contact points of the manifold and the turbocharger. Install a new flange gasket in the raised bead side facing the exhaust monument, install the manifold fitting, then the turbocharger, then the retaining nuts, using new O-rings on turbocharger-to-intake manifold fitting, tighten nuts properly and install. Flexible coupling is reinstalled, the exhaust pipe fitted, all nuts and bolts tightened and then the heat shield is fitted. When a new turbocharger has been provided, about 1/4 pt (1/8 liter) of clean engine oil should be poured into the opening of the oil pipe, thereupon the bolts should be placed in position, with the oil pipe and the new gasket, and the bolts tightened. Lastly is fitting the air cleaner assembly, attaching the battery cable, then starting the engine and checking it against leaks.