Refitting the Sump

Sump mating surfaces, baffle (both sides) MBP and sump-pan needed to be cleaned. The baffle had already been cleaned but was given a polish with the ro-loc bristle brush.
The MPB sump bolt holes are positioned badly in use; they point upwards and allow general muck to drop onto them. Although I had thought these were clean, I discovered this was far from the truth and I had to scrub them out using a pipe-cleaner and carb cleaner spray. At this time it also became apparent that many of the threads were damaged, partially stripped or blocked. All threads were re tapped or chased with an M8 tap. Blind holes were an additional problem because many of the bolts present were shorter than those specified in the parts list. This created a dead space in the end of blind holes which had become full of silicone from the jointing compound. This had to be carefully removed and the holes re threaded using blunt ended taps.

Using a tap to clean and repair threads in sump holes

Mating flange polished

Since some of the bolts were shorter than they should be (by about 0.5 Cm) this had probably placed too much strain on that part of the thread that they did contact. Since this was now potentially damaged I ordered new bolts of the correct length so that there would be more threaded alloy to accept the load.

Once these had arrived I was able to go ahead. I refitted the oil pick up pipe olive and torqued it down.
The sump is sealed to the motor using  a gasket sealant, but there isn't much information on how to do this as the baffle also fits in this position. I decided to apply sealant to both alloy cases, refit the sump baffle and then fit the sump+baffle to the MBP.

Sealant applied to sump, note it is placed as a bead inboard of the bolt holes. 

Sealant applied to MBP, again inboard of bolt holes

I applied sealant around any openings that would be covered by the baffle plate.

 The exact pattern in which sealant should be applied isn't given in the manual- that seems a real omission as there is a multitude of openings in the MBP and Sump and its not clear which should be sealed and which not. Some are (I think) just blind cavities but others communicate and its not clear whether they are oil or water passages and whether they need to be separated from one another by sealant forming an impervious join. I adopted the policy of sealing any cavities that would be closed by the baffle when its in position and the layout I came up with is shown above... fingers crossed!

Sump refitted- position slightly to the rear of the motor, lower and slide forward to engage oil dipstick pipe and allow oil pickup rose to slip though the baffle.

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