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  #1  
Old 06-16-2006, 08:01 AM
HUD HUD is offline
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'87 300td Exhust Manifold Gasket

I have a gasket leak on the exhust manifold that hooks into the turbo charger and I do not know how to go about changing it. It looks like a donut gasket and it is up above. It connects the exhust manifold. It looks like a one inch flex pipe with two clamps. Also, to install this, what other gaskets will I need?

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Old 06-16-2006, 10:26 AM
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Location: Eastern TN
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From what I've heard you can remove the exhaust manifold but leave the turbo in place. Basically you remove the crossover pipe, mixing pipe, turbo feed pipe, maybe the turbo oil feed tube then the exhaust manifold is free of everything else. It doesn't have to come off, just off the head enough to work on the flex section if I understand what you're asking.

The bracket from the bottom of the turbo to the side of the block will suspend the turbo.

Sixto
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Old 06-16-2006, 12:09 PM
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The stub of pipe is 117 142 01 54 described simply as pipe.

The flex section is 117 142 01 59 described as flexible metal tube.

The nice thing about 117 prefix numbers is that these parts are probably shared with the ubiquitous 450, 500 and 560 V8s.

Sixto
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Old 06-16-2006, 12:16 PM
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The gaskets you need will depends on how much comes off. Definitely the exhaust manifold gasket and to be safe the gasket that goes between the turbo oil feel line and the turbo. I reused several times the gasket between the crossover pipe and the intake manifold. A light layer of RTV cured the oil seep. There's also a gasket between the EGR valve and the mixing pipe but you can keep that union intact. Some of these engines seem to grow a solid plate between the EGR valve and mixing pipe over time The big green o-rings in the mixing pipe are so well oiled that they rarely need replacing.

The manual says to use new exhaust manifold nuts. New nuts are copper and are a little ovaled. Might be a shade cheaper to get these nuts at a VW parts counter.

Lots of folks snap the rearmost exhaust manifold stud though I had no trouble with it. Go easy and use lots of penetrant if it resists.

Sixto

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