Could anyone out there walk me through the procedure for replacing the intake/exhaust manifold gasket on an '82 240D. I've got a pretty substantial exhaust leak, and I need to replace the gasket. I've searched all over the DIY section, but no luck.

Thanks,
Mike

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

There's not much to it. Remove air filter, unbolt manifolds, replace gasket, bolt manifolds back on, replace air filter.

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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

Thanks. I just wanted to make sure that I wasn't in for any unexpected surprises.

Mike

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

So, basically I just scrape off the old gasket and slap on the new one? Do I need to worry about being careful not to loose any pieces into the intake?

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

Not that hard to do. might want to use some penetrating oil on the studs that hold the manifold to the block. I have good lick with "KROIL", I have PB Blaster, a little better than WD-40.

Also the studs that hold the exhaust to the manifold. If one of these break off from age, rust etc... then..... OK that isn`t going to happen.

Just be glad you don`t have the turbo, oil lines etc .... to contend with.

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

On a 240d this job would qualify as easier than an oil change. You should be in and out in 10 minutes.

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Aquilae non capunt muscas! (Eagles don't hunt flies!)


1979 300SD Black/Black MBtex239000mi
1983 300TD euro-NA. White/Olive Cloth-MBtex 201000mi. Fleet car of the USA embassy in Morocco
1983 240D Labrador Blue/Blue MBtex 161000mi

That's the best news I've heard all day. Who needs a turbo anyway?????

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

Anyone that wants reasonable acceleration!

I suppose, but I never have to worry about speeding tickets - Only if there's a downhill with a swift tail wind!

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

Incidentally, what would be a good brand/type of engine de-funk-er to use to get rid of the grime that's built up where the intake/exhaust manifold bolts up to the head? I suppose I could always pressure wash it, but I don't have access to a pressure washer, and the one at the coin car wash I went to the other day was disappointingly un-powerful.

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

I use Gunk Engine Brite. I wouldn't pressure wash, although I guess on the 240D there's a lot less to harm. I use saran wrap to cover the oil dipstick. Then I spray Gunk on the engine, let it sit for 10-15 minutes, and hose it off using a fairly gentle stream of water or controlled spray from the garden hose. Then just let it run for a few minutes and it will dry off ... just make sure you get all the Gunk rinsed off.

I think I need to replace intake gaskets on my 87 300D but that's probably less fun than the little 240.

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Cool. Thanks. I'm going to go tackle this one here in a few. I've got to run and pick up a few things, but hopefully she'll be up and running again in a few hours.

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks

Today I successfully replaced the intake/exhaust manifold gasket on my 240D. The old gasket was in such bad shape, that when I pulled the manifold, parts of it broke into tiny pieces and fell on the driveway. The bolts on the manifold near the firewall weren't even tight because the gasket had disintegrated so much that most of it was simply no longer there.

After bolting everything back together, I went for a drive around the block. The car was soooo quiet. I can't believe how much of a difference this made. I'm pretty sure that I should have done this several years ago. The loud ticking that the car used to make when pressing hard on the accelerator is complete gone. I am very pleased with the results.

Thanks to everyone for the guidance.

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1982 240D - 292,000 miles and counting
Same family for 33 years
Newly rebuilt Monark injectors
Newly replaced clutch
New Bilstein shocks