[bryanrex]

Nice work on the oil return tube replacement and documentation! I just replaced the return tubes on my 1979 Euro SC today and it wasn't fun (having never done it before). On my car there are emissions air inlet tubes going into the head, and those tubes plus the heat exchangers (not SSI) render it a nearly impossible task, but it can be done!

On the driver's side you must pry the heat exchanger down with a pry-bar while using a rubber mallet to coax the oil return tube through the small gap. Do not bend the tubes, and do this without the outside oil return tube seals placed or you will probably damage the new seals. Place the outer seals after getting the return tube assembly through the gap (this is also difficult). You don't have to remove the air inlet manifold on the driver's side to get the tubes in, however on the passenger side you will have to remove the air inlet manifold or there is no way to get the tubes in place.

Removing the passenger side air inlet manifold is straight-forward, however due to oxidation I had a hell of a time getting it detached without stripping the fittings. Use a lot of WD-40 or thread penetrator. You must hold the nubs in place otherwise you could strip the aluminum fitting. This was a delicate process!

On the passenger side there is plenty of room to extend the tube once placed using the hose clamp method. I used only one hose clamp on the inner tube, and twisted a flathead screwdriver between the hose clamp and the lip of the outer tube in order to extend it. It extended about a quarter inch at a time and I kept relocating the hose clamp as the tube extended. Once you understand the process the passenger side could be accomplished in less than an hour.

On the driver's side however, extending the tube is next to impossible (due to almost no access). I placed a hose clamp at each end of the return tube, then used vice grips (wedged in place) to hold the side closest to the engine case in its seat. With that side of the tube securely in place, I then used a pry-bar against the heat exchanger to extend the tube using the outer hose clamp. It took about 2 hours, but both finally seated and sealed perfectly. Moving the c-clips into place is simple once the tube is extended properly.

Although I was successful replacing the oil return tubes on a Euro SC, I've heard from several credible sources that it can't be done properly without removing the heat exchangers and the air inlet manifold. It CAN be done, but it requires forcing a lot of pieces in ways they weren't meant to. Do not attempt this on a Euro SC unless you are very patient and inventive. I'll try to upload some reference pics in a bit.