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Pelican Technical Article:

Boost Sensor Replacement

Steve Vernon

Time:

20 min

Tab:

$70

Talent:

*

Tools:

27mm wrench or deep socket

Applicable Models:

Mercedes-Benz 300TD (1979-85)

Parts Required:

Boost sender

Hot Tip:

Work on a cool car

Performance Gain:

Working boost gauge

Complementary Modification:

Diesel purge

The Mercedes Turbo diesels have a rather intricate fuel, pressure and boost system. One of those components is the Boost sender or sensor located on the top of the intake manifold. This sensor reads the intake manifold and in an over boost situation sends a signal to the overload valve to vent some pressure before it reaches the ALDA. While this is an important sensor and it does have a few other functions, if you have an automatic transmission then in reality these cars do not usually suffer from over boost, at least not at this stage of their lives.

If you have just overhauled your turbo you may want to inspect or replace this sensor.

Over the years your car may have been serviced by multiple people including previous owners and this can lead to parts replaced with different size fasteners and hardware. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Our vehicle may vary slightly from yours as Mercedes redesigned systems and sub-system as the models developed over the years. If something is different on your vehicle please let us know and share your info to help other users. If you have any questions or comments or even a different procedure you would like to share please leave it below and please leave your vehicle information.

The boost sensor is located on the intake manifold on the right side of the motor (red arrow).
Figure 1

The boost sensor is located on the intake manifold on the right side of the motor (red arrow).

The sensor is located on the intake manifold between the turbo plumbing and the valve cover (red arrow).
Figure 2

The sensor is located on the intake manifold between the turbo plumbing and the valve cover (red arrow). Make sure the engine is cool to touch before working on it.

Remove the wiring connection from the top of the sensor.
Figure 3

Remove the wiring connection from the top of the sensor.

Figure 4

It is a bit of a tight fit for a 27mm wrench so you can use a 27mm deep socket, just use care because the electrical connector comes out of the top and you do not want to damage the new one when installing

The new sensor simply screws into the intake manifold.
Figure 5

The new sensor simply screws into the intake manifold. Make sure you start the sensor by hand and it is threading well before putting a wrench on it. Installation is the reverse of removal.

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Page last updated: Tue 9/19/2017 03:18:28 AM