My brothers' 92 760 turbo wagon has had a loud exhaust leak since he bought it from some motorheads in Houston. Somehow it has passed two inspections like this. These guys said that they had taken the turbo unit apart and it was in good shape. Well, yes, it does work fine...but leaks. Apparently they didn't completely assemble the turbo unit before installing it back in the car! Between the front part of the turbo body which houses the inlet turbine, and the rear part which connects to the exhaust manifold, there is a thick metal washer or ring. Looking at the Haynes diagram, this ring is supposed to be a complete ring, I guess this is a seal. However it is loose on this turbo, and the entire upper half (180 degrees) is not there. I don't know if they cut it, broke it off, or if it is supposed to be split into two halves...and only the lower half was put in. Also, there are four bolts (or maybe six) that do not go all the way through the turbo, they go only through this washer between the two main halves of the turbo and secure into the rear part. Well, there is only ONE installed.... the three (or five) others are not there! So I told my brother, well this has got to be where you exhaust leak is, its not on the exhaust manifold or exhaust pipe. We thought about just stuffing the cracks where it is leaking with JB Weld....nope, some sharp-eyed inspector might see that, and that is illegal. And besides, if he ever wants to get the job right, then the cracks or bolt holes filled with JB Weld are a problem. So he knows he is going to have to remove the turbo to fix the botched installation. What we need to know is if there is a source for this metal washer? Its circular on the inside ID, but on the outer ID, the upper half (that is missing) looks like it is elongated, and the end of the elongation, it's bent towards the rear at 90 degrees. Also he would like to know what size are these bolts? 13 MM? and how long/thread pitch? He would like to have the parts on hand before removing the turbo. Haven't had any luck finding a junked 760 turbo through the salvage yards here. Well gladly pay $$$ to get these parts.
Thanks, Geronimo