Hey guys,


So I decided to install a new turbo gasket, new o-rings and a new grommet on my turbo OM617. I was also doing to check valve and the oil pan gasket so the lower pan was removed.

The removal went great, got both pipes out, no issue, got all of the old grommet out of the hole. All seemed well with that.

I went to re-install it and knew I would have a rough time with getting the lower drain tube seated into the grommet and into the engine. First thing I found was that the opening for the grommet was smaller then the tube itself, and that unless I pushed the tube into the grommet a certain way, the grommet would squeeze in and start pushing the O-ring up instead of going over it. So I found a way to get the lower pipe/o-ring started into the top of the grommet, but not all in the grommet which allowed me to push the other end of the grommet into the opening about the sump.

I originally was trying the method from the DIY on here, which consist of putting two hose clamps around the lower tube, and leveraging a screwdriver against a nearby thick piece of metal, and the pipe clamp, to create a downward pressing force. This method worked a little, but the screwdriver kept slipping.

I got frustrated and looked online for others who had done the job. One guy said he used a 10in 3/8 bolt, with 3 washers on each end and a nut to make a simple press. The bolt was fed through the pipe with washers on top, and then washers on bottom, with a nut on the end. The idea being you tighten the nut and it compresses the area between the washers and pushes the pipe into place. Totally makes sense.

So I went with this method. First, I worked the end of the lower pipe into the upper part of the grommet, so that the grommet was just over the lower O-Ring. Then I seated the grommet into the opening above the sump. Since the pipe was less then half-way into it, the grommet was able to seat straight in with little effort. At this point the grommet was seated fully into the opening, and the pipe was in place, tucked into the upper lip on the grommet. At this point, I fed the bolt down through the pipe and got the washers and nut fastened on the bottom. I was very careful to try and make sure the pipe was straight, and then I started turning the nut. The pipe slid down slowly into the grommet, and seemed like it would have no issue. I had lubricated bot the grommet and the end of the pipe with oil as well. yet when I got it low enough, I felt around and realized the grommet got pulled down into the hole in one spot, and upon removing the pipe I found the grommet had gotten mangled and destroyed in the process. So I have to order a new one tomorrow. I've read all of the write ups on this and cant figure out what went wrong. Any ideas? I wanna avoid this happening again. Haha.

Thanks!

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1984 Mercedes-Benz 300D

I had a terrible time removing the old grommet not re-installing the new one. Are you sure all of the old one was removed?

I pushed the grommet on the new lower tube past the place where it needed to sit then installed the tube and pressed the grommet in last by hand. Not a fun job but I got through it.

I used some cheap long 3/8 drive extensions to tap it in. There is a link to a vid showing an easy, one handed way. The trouble with working on old cars is that you only need to do a job once and the first time frequently turns into a pita.

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.

Your order is off a little:
Slip grommet onto lower tube
Drop lower tube into pan hole
Bolt on upper tube, with new orings
Push grommet into pan until seated, with tube"too far in"
Pull lower tube up and over orings until seated. Use hose clamps and lever it UP into place

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James Marriott
2003 Buick Regal
1983 300D (228k, frau Auto)
1996 Suburban K2500 (192k, 6.5 turbo diesel/4WD towmaster 10,000)
www.engineeringworks.biz
1987 300SDL junker 170k
1982 300SD junker, 265k

Haha! Story of my life. I think I saw that vid, the one where the engine is on a stand out of the car, no? I had no idea from that vide that I would have so much trouble.

Oooh, now I feel dumb. If I follow this post correct, I should have slid the grommet to the middle of the tube, where it's narrower, then slid the whole assembly in, seated the grommet, then slid the tube up into place. Well no wonder I destroyed the grommet.

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1984 Mercedes-Benz 300D

Put some generic STP on the Lower O-ring. Don't get any of it on the outer parts of the Grommet lip.
I did it but don't remember the details of how I did it. I think I had trouble stuffing the new Grommet in before I pulled the Tube up; but not an exceptional amount of trouble.

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84 300D, 82 Volvo 244Gl Diesel

Here is a thread Lutztd did and a youtube video, this the Vid you saw?

turbo drain tube install 2 minutes, no tools


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

That's the one. It wasn't hateasy with everything installed. I need to do tit on my new 84SD. Grommet by itself is NLA (I think).

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.