[Mk2] [Turbo] REV3 Sump removal

[fzr400]

Hi Guys,

Im trying to remove my rev 3 sump, but struggling to get it off the gearbox end, is there a hidden bold or do i have to slit the box off the block, it is loose at the pulley end but wont budge

your help would be much appreciated

thanks
jon

[Lewis Jay]

There is a bolt tucked underneath the bracket from engine to gearbox at that end, just have a look around.

If there are no bolts left in, it will just need a good yank to get it off as they use sealer on them and its quite tough.

[fzr400]

thanks lewis,

ive found the 2 sunken in 10mm bolts, and the two 14mm bolts that go into the box, will try againand take another look

thanks jon

[fzr400]

ive found two allen bolts behind the rubber bung as well, but it is still stuck at the gearbox end

anyone know if this is possible with the engine in?

by the way this is for the rev 3 and not 1 or 2, which i know are easier !!
thanks
jon

[Chris]

It is possible to do it in situe. I had to get a scraper and hammer it round to release the sealer. It's bloody good stuff!!

[liamc]

I did this a weeks ago on my rev3 na to change the oil pump. The 2 allen bolts are the only ones that are hidden. The rest can be seen if you have a good look. Don't forget the 3 or 4 around the rubber bung that run horizontaly into the bell housing. After that its probably just the sealant keeping it together.

You can get the sump off without removing the exhaust mid-section, but you wouldn't be able to get it back on while keeping your fresh sealant in place.

[fzr400]

thanks guys gonna try again at the weekend, I can lever the sump from the oil filter end and it moves ok, but you know that feeling when you have left a bolt and the sump will snap a corner off !!

but thanks again glad to hear, I have undone all the above

cheers
Jon

[diycinema]

It's a real pain to get off even with the engine out.

You have to take the oil pan off first, there are about 3 or 4 bolts holding the sump on under that. Then there are loads dotted around the edge of the sump. Like has been pointed out already there are two at the flywheel end hidden under the rubber cover.

There are also a couple of plugs which help line it up when you put it back. These are near the transmission end. I found they were pretty stiff to break loose but there is a cutout you can get a lever into.

Once it breaks free it should come off easily.

Here's a few pics from my rebuild which might help:

[fzr400]

Thanks you are a star, now I know there are dowels, I need to lever a bit more, as I said one end is free, but it is the flywheel end that is stuck,

can I ask in the pic (2nd down) with the dowells on, there is a bolt hole horizontally to the dowell on the right, is this a bolt hole for the sump, as Id never be able to get this out with the gearbox in

thanks for the info

Jon

[diycinema]

Hmm, the only bolts on the far edge near the dowls are the two near the flywheel inside the transmission casing, then there are the two recessed into the deep holes.

[fzr400]

thanks guys for all you help here, done it with a scrapper hammer and some levers

however I found one bigend shell got so hot due to lack of oil it had spun and locked onto the other

James at 3S is assisting with a new engine

thanks again

Jon