Just went through this job myself when I replaced the head gasket and know it's a big task. If you have a couple of extra oil return pipe (orange) o-rings, all the better. I seem to manage to break the o-ring as I try to get the pipe positioned into the block when mounting the turbo and manifold to the head; learned either to have a helper guide the pipe in from underneath and/or use assembly lube on outside of o-ring.

my 245Ti has the original setup with non-watercooled turbo, so no coolant lines to worry about.

Good luck, Robert

Hi again Roadside,
Glad to see you are making good progress. How about making sure the oil return pipe from underside of turbo to block is clear of any obstructions... could be gunked up. For example: when one has a turbo professionally rebuilt, one of the stipulations to keep the rebuild warrantee in effect is that a new oil return pipe be installed too. Also, while the whole turbo/manifold is out it would be a good time to check the hard coolant pipe from the rear of the waterpump to(runs under exh manifold) around the back of the motor that eventually connects by heater hose to a nipple on the drivers side firewall. On one of my cars( can't recall if 240T or 740T ) this pipe was perforated by rust where the mounting bracket was welded to the pipe. Just a couple things I thought of, I'm sure others will chime in.



Best wishes,



Dan