A new leak. Never had this before. Have had the entire top of the engine off twice and no leaks but here we go, 5K after reassembly, the engine was DRY and running tops. Then the oil line feeding the turbo starts leaking right at the point where it bolts to the top of the center section of the turbo. No idea why it would just start out of the blue. New gasket when I reassembled 5K miles ago.

I changed the gasket last night however I think oil seeped down while I was reassembling and screwed up my nice clean mating surface and sealant. It leaked the same today. Tonight I disassembled the oil line, blew it out with compressed air and Brakeclean, cleaned to surgical standards, new gasket, sealant and reassembled.

I am waiting until tomorrow to start it so the gasket sealer can set up. Any bets on if it leaks or not? Its a dumb design. Should be braided stainless oil hose and conical seat fittings just like every other turbodiesel I've ever worked on..... PITA. RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

Well, it leaks! Again. Thats four gaskets, no sealant twice, once with Hondabond and once with Permatex. I am taking it apart again tonight to see if the mating surfaces are really true and if they are and it isn't sealing the turbo is getting the inlet NPT tapped and its Aeroquip time.... RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

Update:
Finally got the time to tear into this again. I was able to extract the hard oil line without too much trouble once I figured how to pull on it. Like a Chinese puzzle sometimes.... I checked both mating surfaces, the turbo and the oil line and both are true/flat. Then I really started checking the oil line over very closely with a magnified glasses. I found the problem. The hard line is brazed or silver soldered to the turbo side mounting flange. There is a hairline crack on the underside of the hard line-to-flange union. The crack is just visible when the line is flexed and the flange held fast. Oil weeps from it as you move the pieces. Thats where the oil is coming from. Now I am hoping that these lines are still available new or its off to the boneyard tomorrow. RT

__________________
When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

I have a hairline fracture on the oil line going to the turbo. I was curious if you found a part number for that line, If not how did you fix your issue.

Here is a picture of where my leak is. (click image for a bigger picture)

Some members have made up flexible lines for the turbo oil feed. There was a thread on it in the last couple of months by a member retrofitting a 617 into a Landcruiser.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

If you want to use a braided Steel covered Hose Gasser Speed shops sell the pre-drilled and tapped Flanges.

I am not sure how the Banjo end would be handled. Perhaps the Speed shops sell a Banjo that is also threaded.

However, I do not know of any braided Steel Covered Hose that would last 25+ years like the original tubing did.

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel

Clean up the area around the crack, silver solder it and it's good as new. Reason it cracked was due to vibration. There should be mounts in the middle of the line to dampen vibrations. Were those missing?

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

That is a maybe. Sometimes it is the Steel Tubing that Cracks; not the Silver Solder/Brazing.

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84 300D, 82 Volvo 244Gl Diesel

I do not see a clamp on the line. it is clamped to the air filter bracket, and at the rear of the head. also the line is not lined up with the turbo. it looks like the pipe is bent back from it`s mounting point to the turbo. bending the pipe can kink it, and that could cause it to crack and leak.

W/O one or both clamps, the pipe will vibrate and develope a crack where it is Silver soldered or brazed to the banjo fitting.

I had this happen to me at the lower end at the filter housing. I didn`t replace the bracket and clamp behind the head when I replaced my engine. 4300 miles later it cracked and almost leaked out all my oil.

I removed 2 From the Junk Yard before I found a good one. one had worn through at the clamp behind the head.

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

I did not include the Part Number because my source showed 2 part numbers and one did not reference when I looked up the price.

Depending on who you get it from the a new original tubing is about $150.

So the Steel braided Covered Hose and Fittings could be had for less than $50 if the House used crimped on ends.

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84 300D, 82 Volvo 244Gl Diesel

Well then clean up the steel tubing crack and silver solder it then it's good as new.

If the tube is mounted only at the ends, it acts like a string instrument and vibrates at it's natural frequency and you know what that means.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Perfect timing ! I believe I have a leak in the same general area. Need to investigate today.

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92 500E Silver 66k
82 Porsche 911SC 84K
68 Cadillac ( Gone Now )
03 Suburban Z71 200K
85 300SD 217k From Original Owner ( Dad )