evoIII 16g : Filing the oil return line

[DSMvroom]

After searching for "file" "return" "oil" "size" etc. and combinations of said words, I have been unsuccessful at finding an answer to my question :

What size file do I need to buy? I would like to have the file before I put the car up on jackstands since at that point I don't have a car to use to go to the store.

Also, is the flange pretty soft? How long will it take to file the holes to the correct distance? (This is more just plain curiosity)

TIA

 

[daren_p]

If you have one of the new turbo side oil return bolts handy, take a look at it as thats pretty much the size of file you will need. Basically you want a round file that starts from a point & then maybe measures about 1/4" at the widest point. The filing shouldn't take very long at all, maybe a couple min.

 

[ZmanIV]

Go get a round chainsaw sharpening file I think it is smaller than a 1/4 inch and go to town on the holes. The metal is not really all that hard just mild steel I think. Check the spacing against the gasket and scribe a line, then r4emove all the extra metal.
Be carefull not to stress the return line or you can break it.

 

[daren_p]

Go get a round chainsaw sharpening file I think it is smaller than a 1/4 inch and go to town on the holes. The metal is not really all that hard just mild steel I think. Check the spacing against the gasket and scribe a line, then r4emove all the extra metal.
Be carefull not to stress the return line or you can break it.

Exactly, thats why I said a round file that starts at a point then increases to maybe a 1/4" . The file I used literally started at a fine sharp point and increased in diameter to about 1/4". If you get a file that is a cyliner shape and 1/4" in diameter for the whole length of the file it will be too big.

 

[Boiler2]

A small dremel bit will work also ... and much faster I might add. The file does work well but if you have the Dremel already, go that route.

 

[DSMvroom]

hrm, i do have a dremmel. I'll check out some dremmel bits at Home Depot when I wake up later. Otherwise, thanks for the tip on the file that gradually gets larger in diameter. I didn't even realize those things existed.

 

[DSMvroom]

So the filing went OK with the help of those who responded, but the bolt holes in the evoIII are smaller than the t25?? What size/length do I need for these two? And why is it not mentioned anywhere on vfaq??

Also, I've somehow stripped my oil feed fitting at the filter housing despite using a 11mm flare wrench that i had to hammer on! I dunno what to do about this . . . That and the o2 sensor won't budge either and it is half stripped.

EDIT : I looked at the stuff that came with my install kit (from SBR) and it gave me new bolts for the return line, but they are the same size as the ones that came off the t25! Gah!

 

[larsrya8]

I thought the bolt holes where only closer on the turbo side of the return line. Just use the gaskets to figure out what you need to do to have the new bolts work on the new turbo.

As for the O2 sensor; I couldn't get mine off either. I used the correct socket and everything. For the turbo install all I did was trim the heat shield and unplug the oxygen sensor. There's no need to remove the sensor.

I don't know what you're going to do about the stripped oil feed line. Mine wasn't nearly as difficult to get off. I didn't even use a flare wrench. Did you soak it with rediculous amounts of penetrating oil? I did...

 

[daren_p]

I thought the bolt holes where only closer on the turbo side of the return line. Just use the gaskets to figure out what you need to do to have the new bolts work on the new turbo.

Yes the bolt holes are only different on the turbo side of the oil drain but he is actually talking about the bolt size, not the spacing & he is correct the t25 and 16g use a different sized bolt to connect the drian line to the center section but off the top off my head I don't know the size.

As for the stripped oil feed line how bad is it? When I did mine I used a snapon flaire wrench, which have much thicker heads compared to reg wrenches & I didn't have any issues. Have you tried heating it? If its completely stripped I would think you will have to resort to vise grips, unless anyone has any better ideas?

 

[DSMvroom]

Well the oil feed looks like it won't be an issue because the SBR kit came with a fitting that goes directly into the oil filter housing. So I just took off the original fitting that the feed line threads into (in process twisting the line and breaking it completely, but i'm not worried since I won't be using it).

Only problem left is the o2 housing. I'll pick up with this tomorrow and if the enormous amounts of PB I used today don't help it, then I'll just disconnect the o2 and if I need to, dremmel the heat shielf. I would like to use the o2 dump I have but I won't if I can't get the sensor free.

If anyone can get me help on those return bolts, turbo side, that would be much appreciated.