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2G Oil return does not match

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Brandonjffrs96

Proven Member
116
22
Nov 2, 2019
Bronson, Michigan
Posting for a buddy:
I have a 99 Gsx. Installed a TD05H turbo and the oil return does not match up. The flange is too big for the new turbo. Has anyone ran into this and what is the solution?

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The 2g style oil return is different. It only works for the t25, if you use a 14b, 16g etc.. You need to use a 1g oil return line or if you have a carbide bit you can widen out the holes on your current 2g oil return so you can get the bolts in. And do not turn the car on oil will spill out, even though it is just a return it still has some pressure and needs a good seal.
 
The 2g style oil return is different. It only works for the t25, if you use a 14b, 16g etc.. You need to use a 1g oil return line or if you have a carbide bit you can widen out the holes on your current 2g oil return so you can get the bolts in. And do not turn the car on oil will spill out, even though it is just a return it still has some pressure and needs a good seal.
Thank you brotha
 
If you can source a better fitting return line easily, go for it. Personally I had to also modify the stock T25 return to fit a genuine e16g. It was fairly easy like mentioned. Drill out the holes towards the center until you can just about snug both bolts. And if you end up having issue with aligning the whole line, cut out the straight section and put something like an AC line hose. The AC lines have reinforced rubber but also have a very strong inner layer which oil cannot penetrate. That's why it works so great in places like this. Personally I used a piece from a Galant's AC lines since it perfectly matched the diameter of the return line. Yeah it's a hack job, but if done right you'll be leak free and you don't have to go searching for parts.

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Use the stock 2g drain. Just slot the bolt holes that go to the turbo and you’ll be set.
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I had that set up a while back and i did everything to prevent a leak. I settled with industrial hydraulic 3/4 ID hose and had access to a hydraulic fitting press. Made my own custom stainless fittings so the only spots that could leak were right on the turbo or right on the oil pan. The whole passage for the oil was 3/4". I probably spent too much time on it but I was sick of the intermittent oil leaks.
 
On every DSM I ever had, I always purchased the -10 AN bung for whatever turbo I was running and then welded a -10 AN bung into the pan. For line, I would use normal -10 AN fittings (like a 45 degree and a straight) that were not the push-lock type. I never had any leaks going that route. Ever.
 
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