Sump Gasket Problems...

**Super-DA9** · 20-08-2011 01:07 AM

ok so disaster once again. FML.

got brand new genuine p72 oil pan, new gasket.

cleaned the sh*t out of the block surface with brake cleaner, scraper, rag.

using no sealer, put all the bolts in finger tight in order, then went round the tightening procedure many, many times with little tweaks until I got all the bolts perfect, torque set to 12NM.

the gasket had a nice even squeeze the whole way around the pan where I could see, not protruding from the pan more than about 1mm.

http://i582.photobucket.com/albums/s...nder/photo.jpg

filled the car up with oil, came back an hour later and checked it, perfect. started it for a bit, came back another hour later to find a nice fkn fat leak on ONE corner where the block meets the clutch housing.

http://i582.photobucket.com/albums/s...er/photo-5.jpg

http://i582.photobucket.com/albums/s...er/photo-4.jpg

http://i582.photobucket.com/albums/s...er/photo-2.jpg

I seriously cannot figure out what could cause this big a leak when I'm pretty certain I did everything exactly right, and the rest of the pan seems to have a perfect seal.

this has got me so down right now, so any help would be really appreciated....

(images are linked because they are too high resolution.)

**DC2-PWR** · 20-08-2011 08:17 AM

Drain the oil, take the sump out, and try again

focus on tightning it on where the leak is comming from more

had the same problem last night on my mates dc2r, took me 4 attempts but thankfully it was sorted

it sucks

**Super-DA9** · 20-08-2011 11:00 AM

thanks moiz, yeah I will definitely try that today. it's really hard to know what happened because of the flywheel obstructing my vision in that area. hopefully the gasket is re-usable and not broken..

**Super-DA9** · 20-08-2011 08:11 PM

so I discovered the culprit today. the two little metal rings had come off the last gasket and were hiding on the studs next to the flywheel. the fkn things were acting like spacers.. *sigh*

I put everything back the exact same way I did last night. not as happy with the gaskets shaping this time as it's not quite as straight all the way around as I had it the first time, but still up to torque spec and in order with lots of little tweaks.

after lying under the car while it was running for a while I didn't see any leaks, lets hope it stays that way..

I'm still really worried but only time will tell if it'll stay intact.

**TODA AU** · 20-08-2011 08:17 PM

Check the torque on the nuts toward the rear,
From your pics the 2 rear nuts both appear to have less threads protruding than the others.
If the torque is correct, remove the sump & determine the obstruction.

What sump gasket did you use? Was it PR3 or P72?
P72 has metal spacers made into it to prevent crush, PR3 does not.
Or perhaps the old ones are still present around the base of the studs causeing a double-up (& leak)

**Super-DA9** · 20-08-2011 10:51 PM

Originally Posted by TODA AU

Or perhaps the old ones are still present around the base of the studs causeing a double-up (& leak)

thanks adrian, as stated above I discovered it was this. after removing the doubled up rings I went at it again without sealant and torqued it all to spec, and for what I could see with testing it today, it seems to be ok, but time will tell if it will stay fixed. I really hope so, it's a bloody nightmare getting under there and disassembling everything so regularly :S

**dougie_504** · 21-08-2011 12:38 AM

Glad you got it sorted bro. I hope you didn't waste money on a new sump

**TODA AU** · 21-08-2011 09:34 AM

Originally Posted by Super-DA9

thanks adrian, as stated above I discovered it was this. after removing the doubled up rings I went at it again without sealant and torqued it all to spec, and for what I could see with testing it today, it seems to be ok, but time will tell if it will stay fixed. I really hope so, it's a bloody nightmare getting under there and disassembling everything so regularly :S

As they say, the devil is in the detail.
See how take 5 goes...