Slagtrooper's BX 19 GTi 1993

[Tinkley]

There are two differerent 'Operational Return Harnesses' aka Oil Leak Back Harness aka Small Octopus or Squid. The change occurred at BX Factory No 5147 I believe. Make sure you get the right one.

You will find data on this in the Parts List in *PDF format but also in the technical stuff on this Forum. The change happened in year terms about 1992.

Octopus are all the same throughout model life as far as I am aware.

[Slagtrooper]

All our GTi's are after this ORGA. So, all of them with three hoses down instead of two. Now i'm more sure what harness i have to do.
Thank you, Tinkley!

[Slagtrooper]

Little, but important up's:

. Nozzle for the rigid hose heading to the filter box
. Left passenger handle ( AKA "Puta que o pariu" - Brazilian Portuguese of "Holy s***" )
. Shield for holding and protecting the pump/filter rubber flange (Pretty happy to have found this)



And the dance goes on...

[Slagtrooper]

Stuck again. Before going to buy the silicon hoses, found something strange.

Did a diagram showing how bad is the situation...Is a modified diagram form the 1st models. Is exactly like that.



I'm suspecting wrong installation. Specially in the G area (Security valve And ACC).
Security valve sends a hose directly to the T in the LHM cap. Acc sends this to the T too. Is this right? in the diagrams, security valve sends its leak to the octopus in other t piece together with ACC.

And the T piece on the cap?

Operational return is damaged.
Obviously jerryrigged, it goes directly to the FDV. Two hoses for the correctors, ok...And a large diameter going to the PAS, as i asked earlier.

Doubts, doubts, doubts

[Slagtrooper]

I think i found the problem:

That's my diagram, i used the PAS version.



As my ORGA says, after 5168 - Three hoses version on the operational return.
When i uninstalled, the bigger hose was from the PA. So, see "Doesn't have that 2"

In the "X" near "AV" on the diagram, i had this:





Only need to do a DECENT hose.

I stuck in the rear returns, because it went directly to the octopus, instead of that T part with the "Doesn't have that 1"
And when i saw it better, i found that:



Second circle down - No hose! So this part will be back like the diagram: One more mender, one more little hose. Third operational hose goes there in the rigid tube.

Next, the "doesnt have 3". Security valve is like that:



(i disconnected the tube in this photo, it goes to the cap)

Accumulator is like that:



And they end like this:



In the diagram, SV and ACC joins in a T mender and goes to the octopus. I will do that too.

Almost all doubts resolved, it remains one:

From what part comes that breather that ends in the Y on the reservoir cap?

I'm doing this for the sake of sharing and creating good karma with this car, it need that

Removed the brake harness too, now i will make everything new! But when i pulled it out, it dropped some old ATF oil. Even if i complete the hoses, i will first disassembole the hydraulic parts, clean one by one and reinstall everything. Then filling it with LHM. Rising the car repairs 50% of it. So i think it's better making a good overhaul before of it.

Intriguing fact:



In the documents, its 1993, but that ORGA says feb 1991! That's strange, specially about the different colors.

[citsncycles]

It may have hug around a while before being sold. My recently aquired AX was built in January '91 but wasn't registered until May '92. It's believed it also ended up in a different country than originally intended.

There are XM's over here that were registered more than 2 years after they were built!

[Slagtrooper]

Maybe it came in a CKD state and assembled in Uruguay, maybe something like that.
Almost finishing all the returns, finally i found out how i have to do them. For sure when i finish it, i will post in a cake recipe way.

Only for comparison:

Stealer prices - Operational return: 88,60 £, Octopus: 103,49 £, Brake return: 39,85 £, Rubber "T" Sleeve: 8,84 £

That's the main reason why i stuck to DIY.

[Slagtrooper]

Done full diagram. Bought LHM (5L), hoses and some quick fit joints. Still incomplete, missing some parts...But it's happening!

[David]

I made a octopus in the same was as your doing, (only mine was rubber fuel hoses). Make sure they clip on the front height corrector securely, as these were difficult for me to get (& keep) on.

The metal pipe you have pictured is a operational return & must be connected to the octopus, NOT the top of the LHM tank.The steering rack leak off, however, does connect to the top of the LHM tank (from what I remember its the only thing that connects to the tank top).

From what I remember, there are 3 circuits inside the octopus. 2 are oil returns & the 3rd is a breather pipe, but I would have to look again to be sure.

If you get stuck, then I'll have a look at mine & tell you where the pipes go.

Good luck.

[Slagtrooper]

And another drama ends here...Minor, but important update:

I found the OEM dipstick! Brand new one, from july 14'!

And i found that my engine is with low oil, nothing like finding the correct dipstick. I'm lucky that i let the engine idle only for a couple of hours


( OEM, new, sealed package)


(Left: New. Right: Old)


(Left: New. Right: Old)


(Left: Dipstick that i bought for doing the Autobox stick, but i don't need it anymore [cause i found the OEM one too, as i posted earlier], Right: New)

Only need to buy 5 liters of 15W50 now. Semi Synthetic is good for it?

Happiness ensues

[MULLEY]

I thought petrols were 10w40? semi is absolutely fine though.

[Slagtrooper]

In my manual, says 15W40 or 15W50...I think that's because our hotter climate.
I was given advices for filling with 20w50, but i'm not comfortable with this idea. I will stick with the OEM advice.

Thanks about the Semi tip!

[MULLEY]

Aha, that makes sense with the slightly different rating

[Slagtrooper]

And now: Removing the Autobox pan.

Did earlier a post about removing torx: http://www.bxclub.co.uk/forum/viewtopic.php?f=2&t=20016

Ended like that:


Special tools on right


Poor bolts


Finally!


And the gran finalle was one hex bolt (3rd, left to right, 1st line) pissing me off to remove it.


End of the line for this filter, as i expected


Happy to see that, i thought that i would see some disc fragments


Clogged



And that's the way it is...

[mat_fenwick]

That filter has lost its newness slightly!