2002 S40 oil return line replacement

jgilber01 · May 5th, 2014, 22:30

Hi all,

New here! I just got my son a used 2002 S40 and it has a leak from the turbo oil return line. I assume the turbo needs to be removed to access the flange bolts on the line. Can anyone tell me how long it will take to remove and re-install the turbo? My mechanic did a good job troubleshooting this but I want to make sure his estimate is good before I have him do the work.

Any reference you have would be great too! Much appreciated.

Thank you
John

gatos · May 5th, 2014, 22:35

It took me 2 hours to replace a turbo on a 1.9D S40. And I am not a mechanic and had to do it on a car park by the seaside. It would take me another 20-30 minutes on a petrol model, as the heatshield would have to come off, and there are two extra coolant hoses going in/out the turbo, which the 1.9D doesn't have.

However, if you are only changing the turbo return oil pipe, you don't have to remove the whole turbo,.... I think

jgilber01 · May 5th, 2014, 22:40

Thanks Gatos! Does it sound reasonable that the turbo needs to be pulled to access the oil return line flange bolts? I read several threads here and its not clear if its necessary.

gatos · May 5th, 2014, 23:10

Quote:

Originally Posted by jgilber01

Thanks Gatos! Does it sound reasonable that the turbo needs to be pulled to access the oil return line flange bolts? I read several threads here and its not clear if its necessary.

Let me check VIDA and see what is says and I will get back to you. Meanwhile, hopefully another member who has done this on their T4 can shed some more light about it

gatos · May 5th, 2014, 23:55

Is your car a 200BHp T4, or the 165BHp 2.0T? Also, do you have manual or automatic transmission?

gatos · May 6th, 2014, 00:42

See attached pdf with procedure of replacing the turbo. One of the steps BEFORE removing the turbo is to remove the coolant and oil pipes. In other words, if you are just replacing the return oil pipe, the turbo DOES NOT need to come out

Cymro1986 · May 6th, 2014, 00:57

Done a Turbo change recently and sadly unless you have super bendy fingers or bendy tools its a turbo off job.

The 2 screws holding the return pipe are Torx bit and while one is accessible the other is obstructed by the pipe itself, and engine mount its also a very small gap.

also that join bit is a serious headache to refit without dropping it a few times.

Baffler · May 6th, 2014, 01:10

On the T4/2.0T upper oil return pipe the studs are 6mm hex, if I remember correctly, so a 1/4" long extension and a universal joint should suffice. Expect it/them to drop out a few times so patience is a virtue...otherwise an easy task

scottishvolvo · May 6th, 2014, 09:33

I did my turbo on my previous 2.0T, petrol, manual and the return pipe was removed before the turbo itself.

mitchyboy01 · May 6th, 2014, 13:53

I've just fitted new suspension, 6 pot brakes and a serviced my T4 so don't mind DIY, but I put it in today at my mates garage for the oil return to be done. It's one of those awful fiddly jobs I get no satisfaction doing and knowing my luck I'd round off the hex bolts! Will be done with the turbo in situ though, no need to remove it. Much easier on his ramp than on my drive.

May 5th, 2014, 22:30	#1
jgilber01 New Member Last Online: May 5th, 2014 23:24 Join Date: May 2014 Location: Califon	2002 S40 oil return line replacement Hi all, New here! I just got my son a used 2002 S40 and it has a leak from the turbo oil return line. I assume the turbo needs to be removed to access the flange bolts on the line. Can anyone tell me how long it will take to remove and re-install the turbo? My mechanic did a good job troubleshooting this but I want to make sure his estimate is good before I have him do the work. Any reference you have would be great too! Much appreciated. Thank you John

May 5th, 2014, 22:35	#2
gatos Premier Member Last Online: Nov 15th, 2022 21:34 Join Date: Apr 2010 Location: London / Essex	It took me 2 hours to replace a turbo on a 1.9D S40. And I am not a mechanic and had to do it on a car park by the seaside. It would take me another 20-30 minutes on a petrol model, as the heatshield would have to come off, and there are two extra coolant hoses going in/out the turbo, which the 1.9D doesn't have. However, if you are only changing the turbo return oil pipe, you don't have to remove the whole turbo,.... I think __________________ Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba Last edited by gatos; May 5th, 2014 at 22:39.

May 5th, 2014, 22:40	#3
jgilber01 New Member Last Online: May 5th, 2014 23:24 Join Date: May 2014 Location: Califon	Thank you! Thanks Gatos! Does it sound reasonable that the turbo needs to be pulled to access the oil return line flange bolts? I read several threads here and its not clear if its necessary.

May 5th, 2014, 23:55	#5
gatos Premier Member Last Online: Nov 15th, 2022 21:34 Join Date: Apr 2010 Location: London / Essex	Is your car a 200BHp T4, or the 165BHp 2.0T? Also, do you have manual or automatic transmission? __________________ Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba

May 6th, 2014, 00:57	#7
Cymro1986 Member Last Online: May 3rd, 2015 12:32 Join Date: Apr 2013 Location: Carmarthen	Done a Turbo change recently and sadly unless you have super bendy fingers or bendy tools its a turbo off job. The 2 screws holding the return pipe are Torx bit and while one is accessible the other is obstructed by the pipe itself, and engine mount its also a very small gap. also that join bit is a serious headache to refit without dropping it a few times. Last edited by Cymro1986; May 6th, 2014 at 01:00.

May 6th, 2014, 01:10	#8
Baffler Premier Member Last Online: Today 13:55 Join Date: Dec 2002 Location: Co. Limerick, Ireland	On the T4/2.0T upper oil return pipe the studs are 6mm hex, if I remember correctly, so a 1/4" long extension and a universal joint should suffice. Expect it/them to drop out a few times so patience is a virtue...otherwise an easy task __________________ Liam... '96 854 TDI SE, '99 V70 2.5D S, '05 C70 2.0T Collection, '05 S80 2.0T SE, '15 V70 D4 SE Lux Nav.

May 6th, 2014, 09:33	#9
scottishvolvo Premier Member Last Online: Jun 3rd, 2024 20:32 Join Date: Dec 2004 Location: Glasgow	I did my turbo on my previous 2.0T, petrol, manual and the return pipe was removed before the turbo itself. __________________ Chris '98 S40 2.0T..Gone. 2000 S40 2.0 SE Auto and loving it. 2014 V40 Cross Country Please consider registering with the Anthony Nolan Trust, you could save a life.

May 6th, 2014, 13:53	#10
mitchyboy01 Premier Member Last Online: Oct 25th, 2020 06:40 Join Date: Jun 2011 Location: Dover	I've just fitted new suspension, 6 pot brakes and a serviced my T4 so don't mind DIY, but I put it in today at my mates garage for the oil return to be done. It's one of those awful fiddly jobs I get no satisfaction doing and knowing my luck I'd round off the hex bolts! Will be done with the turbo in situ though, no need to remove it. Much easier on his ramp than on my drive. __________________ 855R, Standard, Manual, Black Interior. Nice. Stage 5 Saab 9-3 Aero V6 2.8T. 372bhp. 677nm.

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