* Directly into the oil pan: This is often the simplest and most effective method. You'll need to drill and tap a hole in the oil pan (ideally in a low-lying area at the bottom of the pan, away from any baffles or structural supports) to accept the fitting for the return line. Ensure the area is clean and free of debris before drilling. You'll also want to use a fitting and sealant appropriate for oil temperatures and pressures. Many use a bung that is welded into the oil pan for this purpose, providing a more robust solution.
* Into the existing oil pan drain back plug: Some people replace the drain plug with a larger fitting that accommodates both the oil drain and the return line. This is only feasible if the existing drain plug location is suitable, offering a low point in the pan for effective draining.
* Using a pre-made oil pan with a return fitting: Several aftermarket companies offer oil pans specifically designed for turbocharged applications. These typically include a pre-tapped fitting for the oil return line, simplifying the installation process.
Crucial Considerations:
* Lowest Point: The return line should enter the oil pan at the lowest possible point to minimize oil pooling and maximize drainage. Poor drainage can lead to oil starvation and turbo failure.
* Clearance: Ensure the line has ample clearance from other components to avoid damage or interference.
* Proper Sizing: The return line must have a sufficient internal diameter to handle the volume of oil returning from the turbo without causing excessive backpressure. Too small a line can result in high oil temperatures and potentially damage the turbocharger.
* Slope: The return line should have a gentle downward slope towards the oil pan to facilitate proper drainage. Avoid sharp bends or kinks that could restrict flow.
* Seals: Use high-quality fittings and sealant to prevent leaks. Oil leaks can cause serious damage to the engine and environment.
Before undertaking this modification: It is strongly recommended to consult with experienced mechanics or individuals who have successfully performed this modification on a 2.2 Cavalier. Improper installation can lead to engine damage. Also, check your local laws regarding modifications to vehicles.
