I have slowly been reviving my newest and most favorite hobby, a 85 300D. This site has been the one and only resource for figuring out what is wrong and how to fix it. I love this site and don't know what I would do with out it.

Since owning my car I have

- rebuilt the vacuum pump
- broken into an unopenable trunk
- fixed a vacuum leak so i don' t have to pop the hood to turn it off
- replaced NSS and shifter bushings so I can start in Park
- cleaned window switches so they work

So now, I have diagnosed that the gasket where the turbo meets the engine needs replacing. I have black soot around the area and a high pitched whine/whistle when I am at 2000ish rpms. I intend on getting the turbo gasket "kit" but have read that it is not complete and you need other parts to finish the job.

I guess my question is, what parts beyond the kit are necessary for this job and any recommendations for gasket sealing/dressing? This is my first car with a turbo (or diesel for that matter) so if there are any tricks or helpful antidotes, please let me know.

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85 300D 230K??
96 Passat TDI Wagon 186K

I looked at the turbo mounting kit of the parts section. went out and looked at my engine. only thing I can think of is the 7 copper nuts that hold the manifolds to the block. might have to call Phil, he has them hidden some where. use can reuse the old ones, but I think it best to replace them.
Your going to have to take the turbo and manifolds off in one piece, hard to get to those bottom two nuts on the turbo.
While you are at it clean out the intake manifold.It gets real cruddy inside from the oil and the soot from the EGR. good time to eliminate the EGR.
The turbo drain tube is fun getting lined up and tightened up.

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

The manifold kit I got had only 1 o-ring for the turbo-manifold connection. There are two in there.

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'85 300D Cal 280,000 miles
'14 GLK 350 60000 miles

Great! So an extra o-ring and 7 nuts added to the shopping list.

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85 300D 230K??
96 Passat TDI Wagon 186K

Sounds like your ARV is acting up. Before doing anything, try unplugging the vacuum line to it to deactivate it. Regarding the open vacuum line plug it up with a BB or something so you won't have a vacuum leak. Drive around to test to see if it stops whining.

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1983 123.133 California
- GreaseCar Veg System

The original intake/exhaust manifold gasket has a design weakness that sometimes causes leaks. The gasket is something like two plates of thin metal that sandwich something that looks like it might be asbestos. Over time, the asbestos can blow out a bit. New gaskets are the same construction, but include a thin metal shield around each port that protects the inner asbestos. I found this out because on my 1982 300D, I tracked a minor oil leak to the intake manifold where it joins the head. The oil was blowby to be recycled into the engine, but was leaking a bit from the intake manifold gasket.

You will also find the turbo can be easier to remove while still attached to the exhaust manifold. You don't have to reach those hard-to-get-to four bolts that hold the turbo to the manifold. Once the assembly is off, then you can get to them much easier. Lifting up the whole assembly makes dealing with the turbo oil drain tube much easier also.

So, you may want to get the long one-piece intake/exhaust manifold gasket. You should take the opportunity to replace that rubber grommet where the turbo oil drain goes into the lower block/oil pan. And you'll want to replace the O-rings that go on the sections of the turbo drain tube.

Hope this helps. It made my car a lot drier of oil underneath.

Ken300D

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1982 300D at 351K miles
1984 300SD at 217K miles
1987 300D at 370K miles

I will try disconnecting the vacuum to the AVR and see if i notice a change.

I still think there is an issue with the intake /manifold gasket. It seems to be sticking up a little above where the two meet. I can see the long sandwich looking gasket is sticking up about a quarter of an inch. That didn't seem right to me.

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85 300D 230K??
96 Passat TDI Wagon 186K

The manifold gasket on mine sticks up also, just the way it is designed,
I tried it both ways when I put it on. only goes on one way.

I for got about that ARV on the Turbo. I replaced my turbo with a pre 84.
also all the Cali. Junk. Much better performanc, and milage.

My exhaust manifold must have come off a 78SD, pre EGR . looks much
cleaner. now If I could just find another one.

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

Good! So that is normal for the gasket to stick out. I was afraid it was broken and creeping up somehow. Plus I don't have any reference on what things are supposed to look like. I have seen the blown up illustration showing all the parts but that never seems to be the same as looking under the hood.

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85 300D 230K??
96 Passat TDI Wagon 186K