I read through the 617 turbo return tube wiki today before I replaced the seals on mine, and discovered that the method of putting the pipes in place in the wiki is a very unwise way to do it.

The wiki recommends attaching hose clamps to the pipe to use to pry against to "shove" the pipe down into the seal. The correct way of doing it is way easier.

-Clean up pipe.
-Put on new O-rings
-Lube lower o-ring and the flange seal with some oil
-Slip flange seal over the tube so the end with the o-ring is all the way through
-Place pipe into opening on the engine, gently press into place, assist the flange seal into the opening with your fingers (easy) That's it!
-Pull lower pipe at an angle and shove the upper pipe into place
-Press the two pieces together
-Insert new paper gasket at upper pipe
-Fasten pipe to turbo

Done


No prying required.

To get it out I used a 1/2" drive extension up through the hole (yes I removed the oil pan, this is highly recommended so you can clean out the opening and prevent junk/old seal chunks from falling into the pan) and pounded it out.

If MB intended you to have to forcefully shove the pipe in place it would say so. In reality it takes very little force and is quite easy. My turbo return tube is now completely dry!

It is a lot harder to get out than in. Cutting/chipping away the old flange seal is necessary to get it free enough to come out.

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