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Ok here we go....
On this page we will be replacing the turbo return tube grommet and O rings.
And while we are at it lets replace the lower engine oil pan gasket.
Just a little update on this repair....
Its been several weeks and about 3000km and the oil pan is bone dry.
11/05/2008
No5 Allen socket
These are most of the tools you will need.
A set of 3/8 sockets metric.
3/8 Ratchet.
Medium and long 3/8 drive extensions.
3/8 Drive torque wrench
Allen sockets you will actually need the No5
Retrieving pan with a magnet
Parts
Turbo drain grommet
OEM # 617 187 01 85
Turbo drain O ring
OEM # 004 997 53 48 X2
Lower oil pan gasket
OEM # 616 014 01 22
Turbo drain gasket
OEM # 603 187 05 80
Oil filter and brass ring for drain plug and large O ring for oil filter housing.
Ok lets do this!
Oil filter...Remove the two bolts
Set car on ramps and make sure to chalk the rear wheels.
Drain engine oil
Remove oil filter
Don't forget to replace both O rings there cheap and worth replacing.
This is the mess we have to deal with.If you pay close attention you will notice that the previous owner added RTV sealant on each screw and you will see latter on that they even added it to the oil pan gasket for a better seal....NOT
Don't forget to screw your drain plug back on after the pan is empty.
Serious oil leak
Look at the RTV sealant between the lower and upper oil pan.
There are two bolts above the two screws above that need to be held with a 10mm wrench,this is holding a bracket for the low pressure hose of the A/C
You've got 19 of these screws...so don't loose them
Oil pan is cumming off
Second one.
Needs persuasion...With all the RTV Sealer
Finally
What a mess.
Look at how much RTV was applied on each screw.
Remove the old gasket and RTV....
Clean the inside and outside of oil pan with engine cleaner,then hose it down and wipe clean,
Now its time for the turbo drain tube.The top tube has to be unscrewed from above the engine compartment.Remove air filter and use a 1/4 inch ratchet with a 10mm socket to remove both nuts holding the tube in place.Under the turbo!
Wont be long....
Done...Out with the old.Now new O rings and grommet.
Remove excess oil that was leaking from turbo.
Oil pan is clean inside and out,and let to dry in the sun.
New O rings and grommet.The trick to fitting the grommet on the tube is to soak the grommet in boiling hot water for a couple of minutes then pull it right on.Be careful its very hot.
This is how much RTV sealant he had around the old grommet....wow!
Make sure that new gasket fits just fine....
Don't forget the gasket between tube and turbo.
Its time to put it all back together.
Ya...That look's nice doesn't it?
Needs to be torqued at 2.4 ft lbs...No more no less.
Don't forget the large O ring on the oil filter housing.
Now were talking!
Another picture of the amount of RTV on the grommet...
Don't add any of this stuff folks Its really not necessary.
Last but surly not the least....While your hands are still dirty,do your Banjo bolt cleaning.As I previously noted when ever you do your oil and filter replacement,its always a very good idea to clean out your banjo bolt,only takes a few minutes and well worth the effort.
Its located on the right hand side of the engine,just at the end of the exhaust manifold.
Notice the two washers on the bolt,put them back the way they were.Clean this banjo bolt with engine cleaner and rinse well with running water.
Put it all back together and DON"T over tighten this bolt.
Now your done.
Now its time to add your favorite engine oil.
Mine is Shell Rotella T 15w40 7.5 litres to top it all off.
Hope you like the pictorials I did my best and hope it helps.
Best regards to all
Big Dan
