Pajero Owners Club of South Africa

2002 3.5 V6 DGI 75W... engine 6g74

A continuation of other of my threads followed by some great advice has lead me to remove my sump by lowering diff, remove crossmember, remove starter, lift engine etc... The most ridiculous way of removing a sump I have ever seen... my land rover is easier than this.

However, after removing all the bolts the sump REFUSES to come of... its as if its stuck on with superglue...

At the rear section are two bolt holes in the corners where the manual says to screw on a bolt which then tightens again the main engine block and forces the sump off.... tried that on one corner and the corner broke off...!!! main sump still OK but i don't really want to try on the other corner.

Do not want to take the engine out.

My sump is the one piece sump, part number 500995

It seems firmly stuck at the back where the 4 bolts attach to the flywheel end (bolts removed).... but is "loose" at the front towards the radiator as I can get a small screw driver in and slightly wiggle and pry.

I don't really want to force this as aluminium may crack etc... and space to work in is very tight.

Does anyone have any ideas how to free the sump from the block when it seems its just the old sealant holding it there??

Thanks again mightily for help.

Make very sure all the bolts are out. The best way is to take a new narrow and thin flat paint scraper (like from the hardware store to scrape off paint - a new one is still nice and stiff - if you can't find one use an old knife) and carefully find the easiest point of entry at some/ any place between the sump and the block. This is the most difficult critical part. Some times it is so tight you have to use two or three scrapers and tap them in slowly / carefully side by side. You usually have to work it / tap it slowly / carefully with a small hammer, a little bit at a time. If you force it it will break the sump. Once you have got one scraper to go through between the sump and the block you have won. Now slowly carefully work it from there all the way round. Whatever you use, you must try and not damage / gouge the surface of the sump. Sometimes a few scratches are unavoidable. Sandpaper / file them smooth. When you replace the sump, clean both areas with thinners, use a new tube of silicone sealer that gives a nice long worm on the one surface. Put the two surfaces together in one smooth movement without manouring and fit at least two securing bolts immediately. Then do the rest of the bolts.

peterpot wrote: Put the two surfaces together in one smooth movement without manouring and fit at least two securing bolts immediately. Then do the rest of the bolts.

Put four studs of the correct thread (temporarily) in close to the corners, to guide the fitment.
Once you have a few bolts in, remove the studs.