1981/82 Model Vehicles

Breather Modification for 1981/82 Models





1981/82 Model - Kit # 000 043 017 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
3 Clamp N 024 510 3
1 Cap 930 110 256 01
1 Seal 999 701 477 40
1 Gasket Set 060 198 025
1 Hose 931 107 394 02
1 Casket 931 110 152 00

Work Sequence

- Disconnect battery.

- Remove suction/pressure line between turbocharger and intake air 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. (Illustration X) Do not unscrew fuel lines.





- Locate and center punch for hole in center of cylinder head flange near # 1 fuel injector (see arrow - illustration XI)





- Drill 13mm (1/2 in.) diameter hole (Illustration XII)

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 2Oinm bolts (4) . (Illustration XIII) . The connecting tube must face up.

- Reinstall valve cover.





- Cut off old vent hose on turbocharger such that approximately 6Omm of hose remains on adapter. (Illustration XIV)





- Push pipe (5) onto hose and secure with hose clamp (8) (Illustration XV)

- Push foam rubber part (6) over pipe (Illustration XV) - use silicone.

- Push shaped hose (7) onto pipe (5) and install hose clamps (8) . (Illustration XV)





- 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)

- Remove old hose leading to branch on crankcase vent hose and plug opening with an end cap (arrow - illustration XVI) part number 930 110 256 01.

- Install hose clamps.

- Prior to reinstalling mixture control unit, check condition of rubber boot 931 110 138 04; replace if necessary.

- 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 kit) between oil separator and air filter.

- Reinstall air cleaner.

- Reconnect battery.

- Start engine, check for leaks, then check idle speed and CO.