1980 Model Vehicles
Breather Modifications for 1980 Models
1980 Model - Kit # 000 043 016 00
This kit contains the following parts:
1 End Plate 931 104 041 00
1 Gasket 059 127 311 A
2 Washer N 011 525 13
2 Screw N 014 710 3
1 Pipe 931 107 219 01
1 Hose 477 209 303
1 Hose 931 110 181 00
1 Gasket Set 060 198 025
1 Oil Pipe 931 107 108 08
1 Hose N 020 363 1
4 Clamp N 024 510 3
4 Seal Ring N 013 816 1
2 Seal Ring 900 123 008 30
1 Seal N 043 815 2
1 0-Ring 999 701 621 40
1 Hose 931 107 394 02
1 Seal Ring N 013 821 2
1 Gasket 931 110 152 00
Work Sequence
- Disconnect battery.
- Remove suction/pressure line between turbo charger and intake sensor.
- Cover opening of pressure line with clean cloth.
- Remove valve cover.
- Disconnect fuel lines at injectors.
- Remove upper and lower section of air cleaner.
- Disconnect mixture control unit including lower section and lay aside; do this by unscrewing hexagon nuts and removing dust cover and vent hose from oil separator on lower section. Do not unscrew fuel lines.
- Locate and center punch for hole in center of cylinder head flange near # 1 fuel injector (see arrow - illustration III.)
- Drill l3mm (1/2 in.) diameter hole. (Illustration IV)
Caution:
To prevent shavings from getting inside of engine, coat engine flange area and drill bit with grease or use shop vacuum cleaner for suction of shavings during drilling.
- Install end plate (1) with gasket (2) washer (3) and 8 X 2Omm bolts (4) . (Illustration V) The connecting tube must face up.
- Reinstall valve cover.
- Lift vehicle.
- Drain oil.
- Disconnect oil lines at oil filter housing (Illustration VI)
- Remove oil filter with filter housing.
- Remove oil return line from turbocharger to oil pan.
- Remove lower bolt connecting the turbocharger.
- Install new oil return line (9) part number 931 107 108 08 (Illustration VII) , connect at turbocharger by reinstalling lower turbocharger connecting bolt - torque to 20 Nm.
- Clean oil filter housing and reinstall - use new 0-ring.
- Reconnect oil lines.
- Lower vehicle.
- Push foam rubber part (6) (Illustration VIII) over pipe - use silicone.
- Connect breather pipe, part number 931 107 219 01 (5) using nose N 020 363.1 and shaped hose. (Illustration VIII)
- Install hose clamps (8) as per illustration VIII.
- Prior to reinstalling mixture control unit, check condition of rubber boot 931 110 138 04; replace if necessary.
- Check breather hose between oil separator and crankcase for proper routing. In the event of a necessary replacement use hose 931 107 169 00 and 931 107 169 00 together with tube 931 107 389 00. (See Illustration XVI)
- Reinstall mixture control unit, ensure proper position of dust cover.
- Reconnect fuel lines at injectors.
- Reinstall suction/pressure line.
- Install new hose 931 107 394 02 (from list) between oil separator and air filter.
- Reinstall air cleaner.
- Refill engine oil.
- Reconnect battery.
- Start engine, check for leaks, then check idle speed and CO.