The gasket is a .40 cent part and it seems to be a standard item to be replaced as the car gets older. I have seen others quote over $400 to replace this, so wanted to give my story on replacing this. My how-to:
Sockets -
- 8 mm for the bolts on the bottom of the turbo for the oil return-line
- 5/8 (yeah, that's 5/8 - not metric) wrench (open or closed) for the lower water return line
- long ratchet extensions
Other tools -
8 or 9 " long hog nose pliers to remove the lower clamp on the oil return-line
Parts -
oil return-line gasket
new crush washers for the water return-line
1) remove battery, intake pipe from turbo (you do not have to remove the airbox, just the tube to the turbo)
2) loosen hot-side pipe clamp from turbo
3) loosen/remove the bottom hose from the hot-side pipe that attaches to the intercooler
4) Remove hot-side pipe from turbo - 2 bolts at bottom of the engine close to the oil filter - important - I have a Maxxfab turbo-back exhaust and a wideband controller - I HAD to remove the wideband 02 sensor to get enough clearance to drop the hot-side pipe....pay close attention to this - the hot-side pipe has to move back and then down to get disconnected from the turbo. A quick spray from the top of silicone spray at the hose at the turbo helped to slide this off..
5) I have several combinations of 3/8 and 1/4 ratchet extensions to get to the bolts at the bottom of the turbo for the oil return-line - it's about 2-3 feet of extension needed. Remove the bolts.
6) remove the lower coolant-line bolt (5/8) from the back of the turbo - it's on the bottom back of the center-section and it's the ONLY way I could remove the oil return-line from the turbo - once this is removed, it is CAKE to get the oil return line out (this is the key to getting the oil return line off easily).
7) Get the hog-nose pliers, lift up the heat shielding on the oil-line, and use them to grip and slide up the hose clamp on the line at the engine (you may find it easier to go UP above the clamp and grip and slide it up....depends on angle - the larger pliers are needed to get enough force/grip/leverage on the clamp to get it off - it's a hefty clamp.
8) once the lower clamp is off, move the top of the oil-line towards the back of the engine, and slide the bottom of the oil-line off the standoff on the engine - it was very easy coming off for me.
9) clean old gasket off - after 78k miles, there was only a hard rind of carbon that it took me a good while to scrape off - take your time and do this right. check the bottom of the turbo and get any gasket stuff off there - the turbo side was clean for me. Install new gasket (I used copper gasket spray on both sides...this helped hold the gasket onto the oil-line and made install easier)
10) Reinstall oil line - do NOT forget to reinstall the heat shield around the rubber hose....very important!
11) bolts on bottom of the oil return are 105 in lb, so not much force - I strongly suggest a good torque wrench for this!
12) the water return-line has little clearance for a torque wrench(I did not use a torque-wrench though I try to always use one if I can...) - it's 27 ft. lb. and when you remove the line, try to get a feel for how much force it took to remove and then use good judgement tightening.
Hard part is over....reverse all the other stuff...02 sensor, hot-side pipe, hose to intercooler, turbo intake.
It may seem hard but it's just remove parts, reinstall parts - the hard stuff is ensuring the water return and oil return are installed/torqued properly. I spent at least an hour under the car trying to carefully twist the oil return out of the way of the water line....once I removed the water line, it was a very easy project (so learn from my efforts - take the coolant line off!). This does mean you have to get new crush washers for that line, but that's a few bucks for making this an easy fix (I was fortunate to have ordered those for a different reason so I had them available).
If you want a tip to make it very simple to replace the lower oil gasket once you get the other lines off...pull the Vband and turbo off and just pivot the turbo out.
Instead of trying to weezle your hands in there to get the two 8mm screws. If its pivoted out its takes just a few seconds to tighten them both up.
If you want a tip to make it very simple to replace the lower oil gasket once you get the other lines off...pull the Vband and turbo off and just pivot the turbo out.
Instead of trying to weezle your hands in there to get the two 8mm screws. If its pivoted out its takes just a few seconds to tighten them both up.
Its saves you a ton of hassel, trust me...
Well, why not just remove the turbo compressor cover with the snap ring pliers. The oil return line flange is right there.
Use a 1\4" ratchet, with over 20" of extension, you just need to loose the front bolt & take out the rear. Then pull it towards the rear of the car. Should disconnect, pinch the hose clamp on the bottom of the drain, lift up to take the drain hose out. The gasket might be stuck on the drain pipe 90% of the time.
clean off the car, and use brakleen to make sure it money clean.
Reach up there, hold the gasket on the turbo from the rear, thread the front bolt to hold it on the turbo. Then reinstall. The rear bolt is the easier of the 2 to tighten, but with a swivel on the socket keeps it on the front one.
1) dodge dealer
2) if you go for the mitsu evo part (better gasket), mitsu dealer - don't remember the part #, but I posted about this gasket on the forums.
dealers dont' charge much more than on-line and you don't have shipping for a cheap gasket (unless you're buying a bunch of other stuff as well - then go S&P)
The AutoGuide.com network consists of the largest network of enthusiast-owned enthusiast-operated automotive communities.
AutoGuide.com provides the latest car reviews, auto show coverage, new car prices, and automotive news. The AutoGuide network operates more than 100 automotive forums where our users consult peers for shopping information and advice, and share opinions as a community.
How-To: Turbo Oil-Return Line Gasket
PIE IN THA FACE 
HA HA!!
Linear Mode
