Tapping An Oil Pan For Turbo: The Ultimate Guide

Tapping an oil pan for a turbo is a procedure that involves drilling and tapping a hole in the oil pan to accommodate the return oil line from the turbo. While the ideal approach is to remove the oil pan from the engine, it is possible to perform the tapping while the pan is still on the car. The main concern during the process is preventing metal shavings from falling into the oil pan and engine, which can be mitigated by using grease, vacuuming, or pressurizing the crankcase. Some people also choose to weld a bung onto the pan and tap it with a punch, which can help avoid metal shavings altogether. Overall, while it is a complex process, many car enthusiasts choose to tap their oil pans for turbos as a cost-effective way to boost their vehicle's performance.

Removing the oil pan

If you decide to remove the oil pan without taking out the engine, there are a few steps you need to follow. First, you will need to raise the engine enough to access the oil pan. This can be done by using a jack to lift the engine until the transmission touches the top of the transmission tunnel. Once the engine is raised, you can remove the oil pan bolts and slide the oil pan out. You may need to turn the crank 180 degrees to clear the oil pan. It is also recommended to remove the exhaust y-pipe, starter, distributor cap, torque converter dust shield, and two motor mount bolts before attempting to remove the oil pan.

Another option for removing the oil pan is to use a cherry picker to hold the engine up. This method involves renting or purchasing a cherry picker, which is a type of engine hoist, and using it to lift the engine enough to access the oil pan. This method may be more stable and secure than using a jack to lift the engine.

It is important to note that removing the oil pan without taking out the engine can be difficult and may require more time and effort than simply removing the engine. There is also a risk of oil pan leaks if the pan is not reinstalled properly.

If you decide to remove the engine before taking out the oil pan, the process will be more involved but may ultimately be easier. You will need to disconnect the engine from all its components, including the harness, hoses, p/s pump, and sensors. Once the engine is disconnected, you can use a hoist or engine stand to remove it from the car. With the engine out of the way, you will have much easier access to the oil pan and can remove it without having to contort yourself under the car.

Whether you choose to remove the oil pan with or without taking out the engine, it is important to take your time and be careful to avoid damaging your car. It is also a good idea to have a helper to assist you with the process.

Avoiding metal shavings

To avoid metal shavings getting into your oil pan when drilling, you must use lots of grease and drill a few millimetres at a time. After drilling a few millimetres, grease the bit, drill, and then wipe off the bit and the hole. Repeat this process until you have drilled the desired depth. After drilling, be sure to change your oil a couple of times in case shavings got into your oil pan.

• Use a 7/8" hole saw to make the oil drain as large as possible. This will help prevent oil from backing up and flowing into the turbo.
• Use a step bit instead of a regular drill bit or a hole bit to reduce the risk of shavings getting into the pan.
• Make sure you have the right-sized step bit. The smallest one should be just over 1/4".
• Use a well-placed grommet or Teflon tape to secure the oil line and prevent leaks.
• Take the time to tap the pan properly. This will save you time and hassle in the long run.
• Consider purchasing a used oil pan, having it tapped, and then putting it on when you install the turbo.

Drilling and tapping

There are two main approaches to drilling and tapping the oil pan: removing the pan or drilling with the pan still attached. Removing the pan is generally recommended as it allows for easier access and reduces the risk of metal shavings contaminating the oil. However, it is also possible to drill and tap the pan while it is still attached, although this requires extra care and attention to avoid any potential issues.

When removing the oil pan, it is important to support the engine with a hoist and unbolt the relevant components, such as the oil pickup, to access the pan. This process typically takes a few hours but provides better access and reduces the risk of contamination.

If you choose to drill and tap the oil pan while it is still attached, there are several precautions you should take. First, use a drill that can run at a slow speed to reduce the risk of generating metal shavings. Second, dip the drill bit into a lubricant, such as lithium grease, before drilling, and wipe the bit frequently to remove any accumulated grease or shavings. Additionally, you can use a vacuum or shop vac to suction out any metal shavings that may be generated during the drilling process. It is also recommended to change the oil multiple times after drilling to ensure any remaining metal shavings are removed.

The size of the drill bit and tap will depend on the specific application and turbocharger being used. For a T25 turbo, a 1/2" NPT to 5/8" slip-on fitting or a 1/2" NPT to -10AN fitting is typically used, with a drill bit size of 45/64" or 23/32" recommended. However, it is important to consult the instructions or a specialist for the specific turbocharger to ensure the correct sizes are used.

Overall, drilling and tapping the oil pan requires careful planning and execution to avoid any potential issues. It is important to take the necessary precautions to prevent metal shavings from contaminating the oil and to use the correct drill and tap sizes for a secure and proper fit.

Grease and drill bits

Drilling into an oil pan can be a tricky process, and it is important to take precautions to avoid metal shavings from falling into the engine. One way to do this is by using grease and drill bits.

When drilling into an oil pan, it is recommended to use a drill that can be operated at a slow speed to reduce the risk of metal shavings. The drill bit should be dipped into a grease such as lithium grease before drilling. This helps to catch the metal shavings and prevent them from falling into the engine. It is important to wipe off the grease from the drill bit periodically during the drilling process.

Some people also use a vacuum to suck out the metal shavings as they drill, or have a friend hold an air hose into the oil pan to pressurize the crankcase and keep the shavings out. Others choose to weld a bung onto the pan and then tap it with a punch and grease, which leaves no shavings at all.

There are various types of grease that can be used for drilling. Lithium grease is a common choice, but other options include Tap Magic, Boelube, and thread cutting oil. When drilling into aluminum, WD-40 is recommended. It is important to use a cutting oil, not a lubricating oil, as the two have different purposes.

Overall, when drilling into an oil pan, it is important to take precautions to avoid metal shavings from falling into the engine. Using grease and the right drill bits can help ensure a successful and safe drilling process.

Oil changes

When it comes to oil changes, there are a few things to keep in mind, especially if you're planning to tap your oil pan for a turbo. Here are some detailed instructions and tips to guide you through the process:

Oil Pan Tapping Procedure:

• It is recommended to remove the oil pan before drilling and tapping to avoid metal shavings from falling into the engine. This can be a time-consuming process, but it ensures a safer procedure.
• If you decide to tap the oil pan while it's still on the car, use a drill that can run at a slow speed. Dip the drill bit into lithium grease or similar substances to catch the metal shavings. Drill for a few seconds, then wipe off the grease. Repeat this process until you finish drilling.
• After drilling, use a vacuum or a magnetic drain plug to remove any remaining metal shavings from the oil pan. Change the oil a couple of times to ensure that all shavings are removed.
• If you're welding a bung onto the oil pan, apply grease inside the bung or on the tip of the punch to prevent metal shavings.

Choosing an Oil Collector Pan:

When performing oil changes, it's important to have a suitable oil collector pan to prevent spills and messes. Here are some recommendations:

• Wedco pan model W76 is a good option for preventing driveway floods. It can hold over 4 gallons of oil.
• Cut the top off a plastic trash can to use as an oil collector. Look for a trash can with high walls to prevent splashing.
• Old kitty litter containers with screw lids can be used to collect and dispose of oil.
• Some people use old buckets, such as whey protein buckets, to collect oil and then take them to recycling centers or auto parts stores for proper disposal.

Turbo Oil Drain Tips:

• Ensure that the turbo oil drain line is straight and downhill with no obstructions. Avoid kinks or low spots before the sump.
• If you need to connect the turbo oil drain to a modified front cover, consider using a length of hose or adding a bung to the oil pan.
• The turbo oil drain should not drain below the oil level if possible. This is because the oil that comes out of the turbo is frothy and has a larger volume than the oil that went in.
• When drilling a hole in the oil pan for the turbo oil drain, smear the drill bit with grease to catch any metal shavings. Mark the drill bit to prevent drilling too far and hitting the oil pickup. After drilling, use your finger to remove any metal flakes from the hole.

Frequently asked questions