What gaskets do I need (W123, 617.952)?

[Jeremy5848]

If I can ever find a spare trap cat from a 1985 300D-T CA car (still looking!) and have a test pipe made at a muffler shop, I'll pull that side of the engine apart and clean things up. Before I get to that point, I want to have new seals and gaskets ready. What will I need?

I have Brian's kit so I'll be able to seal off the EGR port. The trap cat test pipe will not have an EGR port so nothing to seal there.

Side note: My engine compartment has always had black soot all over it, especially on the right (passenger) side. At first I thought it was just a "diesel thing" (inexperienced as I am). When the '87 came to our house and didn't have that problem, I realized that something was wrong. Turns out the flex pipe from the trap cat to the EGR valve was cracked (transversely) and almost broken. It's now patched until I can make it go away entirely.

I should not have to pull either of the manifolds. The turbo will have to come off, as well as the air cleaner and all of the various pipes and hoses. The trap cat can then be pulled from above and the test pipe put in its place.

It looks like there must be an o-ring seal between the turbo outlet and the intake manifold -- can someone confirm?

Are there gaskets on the ends of the trap cat? Any seals on the oil lines to/from the turbo?

Anything else?

Jeremy

Just get a Manifold mounting kit. That should have the manifold gasket and all the turbo's oil/exhaust gaskets.

[Jeremy5848]

Originally Posted by ForcedInduction

Just get a Manifold mounting kit. That should have the manifold gasket and all the turbo's oil/exhaust gaskets.

Thanks for the suggestion. I can't find such a kit listed in FastLane or other parts places; did you have a specific item in mind?

Is the Exhaust Manifold to Header Pipe seal in the federal engine the same as the seal between the exhaust manifold and the trap cat in the California version?

Originally Posted by Jeremy5848

Thanks for the suggestion. I can't find such a kit listed in FastLane or other parts places; did you have a specific item in mind?

Is the Exhaust Manifold to Header Pipe seal in the federal engine the same as the seal between the exhaust manifold and the trap cat in the California version?

Sorry, that should have been turbo mounting kit. LINK

On the OM603, it's just a cone and socket seal, nothing else is in there AFAIK.

[lietuviai]

Originally Posted by Jeremy5848

Thanks for the suggestion. I can't find such a kit listed in FastLane or other parts places; did you have a specific item in mind?

Is the Exhaust Manifold to Header Pipe seal in the federal engine the same as the seal between the exhaust manifold and the trap cat in the California version?

No. I have both manifold versions in my garage. IIRC, there was no gasket between the trap and manifold. I no longer have the trap but when I removed it from the manifold I don't remember seeing one. If there should be a gasket it would have three bolt mounting holes.

[linguica]

Originally Posted by lietuviai

No. I have both manifold versions in my garage. IIRC, there was no gasket between the trap and manifold. I no longer have the trap but when I removed it from the manifold I don't remember seeing one. If there should be a gasket it would have three bolt mounting holes.

Ditto...no gasket between ex. man. and trap/cat. Cat. to turbo is the same as Fed.(part of the mounting kit referenced by FI). Only thing that you may need that is not in the kit is a second oring for the "coupling" between the turbo and the intake man. There is one included in the kit. If both are in bad shape, you can order just the oring but I will have to get you that part # unless someone else here has it handy. I am on break from yardwork right now

Mark

[linguica]

Intake Manifold oring is part # is 0049975448

[Jeremy5848]

Originally Posted by linguica

Intake Manifold oring is part # is 0049975448

So there are two o-rings to seal that junction? Both of mine must be bad, then, because it leaks there (a little oil and maybe also a bit of diesel soot from the soon-to-be-replaced EGR).

What about the "Ball type exhaust seal ring between exhaust manifold and header pipe," part number H4002-71861 in the FastLane catalog? No indication whether it is for a normally aspirated engine or for a turbocharged engine, whether federal or California.

[linguica]

Originally Posted by Jeremy5848

So there are two o-rings to seal that junction? Both of mine must be bad, then, because it leaks there (a little oil and maybe also a bit of diesel soot from the soon-to-be-replaced EGR).

What about the "Ball type exhaust seal ring between exhaust manifold and header pipe," part number H4002-71861 in the FastLane catalog? No indication whether it is for a normally aspirated engine or for a turbocharged engine, whether federal or California.

Yes...2 orings there; and only 1 in kit. They will wear from vibration if nothing else. If 1 or both are bad, you will see oil in that area (from blowby).

The H4002-71861 is pressed into the bracket that Down pipe connects to. Doubtful that you will need to replace that.