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lucittm lucittm is offline
Manassas, VA
 
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Join Date: Apr 2007
Posts: 1,211
Garage
Bryan,
You are correct in assuming that the crush washer should seal this fitting. The problem is that the oil line and engine case reducer fitting are hollow and can distort under severe wrench torque. Possibly your fittings were over-torqued at one time. The best fix for this is to replace the fittings and torque them to spec (35 Nm or 26 ft-lb).
The engine case reducer is P/N 930-107-705-00 and is $28.00.
The banjo bolt is P/N 930-107-706-00 and is $30.25.
The 14x18mm sealing rings for both sides of the banjo bolt are P/N 900-123-007-30 and are $0.25 each.
The 18x22mm sealing ring under the engine case reducer is P/N 900-123-140-30 and is also $0.25.
The oil line fitting is probably OK, but you can test this by marking-up the contact areas with dykem or black marker and test fitting the bolt with minimal torque. It should take off the marking all the way around the sealing surface of the new crush washers.

You may want to ensure your engine case is flat.

I would also use a tap to chase the threads in the engine case. I believe the thread size is M18x1.5mm, not taper. Use some grease on the tap to catch the metal shavings.

Mark
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1991 964 Polar Silver Metallic Turbo Coupe
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