SunderKraut600

Greetings.

My friends S600 had a coolant leak on the driver side turbo oil/coolant line, he replaced gasket and reassembled the unit.

All seemed well for about 10 minutes of running before the engine hissed and popped at the gasket and it dumped all the oil.

He’s determined the issue was the orange o-ring around the coolant line was improperly fitted causing a bad seal.

Can someone please show me the proper way to re assemble these lines. Thanks in advanced

Astro14

The two bolt flange is the oil line. Has a graphite/paper gasket. It goes on the bottom.

The single bolt flange is the coolant line. Has an orange o-ring with square cross section.

Oil line bolts/mates up first. Then coolant line on top.

No magic here: clean, flat mating surfaces for the oil line. Clean seating surfaces for the o-ring. The portion of the turbo housing outside the o-ring can get rusty. Make sure that the o-ring doesn't get damaged/pinched on installation. A touch of sil-glyde or other silicone grease will help with seating/sealing the o-ring. The oil gasket needs nothing.

Getting a E8 wrench on the bolts is difficult because of all the lines/hoses/etc. in the way. I bought an 1/4" drive E8 socket just to fit that set of bolts. Otherwise, it's an E8 box wrench, and you're getting 1/6 of a turn at a time and it takes forever. A 3/8" drive E8 is too big to fit.

Welwynnick

What Astro says, but a few more comments.
The water goes in the bottom and out the top.
The oil goes in the top and out the bottom.
The oil connections are usually reliable.
The water inlet below is usually reliable.
The water outlet on top usually causes the problems because water accumulates in the fitting around the O-ring.
The water fitting O-rings are actually round, but get squashed over time.
It's not an easy job, best to use 1/4" tools. I actually sawed and ground my sockets down to fit in the space.

Nick