Replacing my oil pan

[Bdub]

My oil pan was rusty as hell, so I decided I was going to replace it. I got a new OEM one about a year ago. I was waiting for the right time to do this project. So, recently I just happened to have a leaky steering rack line. Take the steering rack out and think "gee, one more step and I can get the crossmember out and the oil pan will be a breeze!" I should have learned from previous ventures, nothing is easy on this damn rusty northeast vehicle.

So, anyways, I managed to get my old oilpan off. Come to find out, there was a small pinhole on the side of it, not sure why, it was in a very random spot. Leaking nonetheless. Once I scrape the old RTV off the bottom of the block, I go to test fit my new oilpan up on the engine so I can map a way to not get the RTV all over everything. Can't do it. I am having a bitch of a time getting the pan to seat. The oilcooler is in the way on one side, and the dipstick tube hits the exhaust on the other. The fucking oil cooler is making it really hard due to a hard line sticking out just enough to muck things up. It's just awkward enough to where there isn't a way to just pop it on.

Taking the headers off really isn't an option...rust is my biggest fear. The last thing I need is something else to just snap due to corrosion. SO, I'm wondering anyone with a 91 w/ the oil cooler manage to get their oil pan on without having to take the exhaust headers off? I'm getting pretty frustrated.

[Legacy777]

When I ordered a new oil pan I had some similar fitment issues. My main issue was due to the oil pickup tube and the extra baffle plate. They hit and I had to bend the baffle plate a bit to get things to fit. I'm not sure if that's the same problem as what you're experiencing or not. It may be, and the oil cooler issue just might be a byproduct of it.

Here's some pics of my "modified" oil pan.
http://www.main.experiencetherave.com/s ... /ej22t/15/

[Bdub]

After reading up on some newer oil pan replacements, I see the oil pickup tube is the main cause of the problem. I may just do a little modifying myself to get it to fit it into place properly. Thanks.

[Legacy777]

Sounds good. Let us know how it turns out.


Kind of off topic.....how do you like you 07 2.5i 5mt? I've been half-heartedly looking for an 05-07 2.5i wagon 5mt, and a couple gems have slipped by me, but wondering how you like yours.

[Bdub]

So, I slightly bent one of the openings to see if it would make a difference. It did, perhaps I didn't go far enough to make it larger. I really wasn't spending much time on it, just curious if it would make a difference. I can still see that the oil cooler hard line, and the exhaust are perfectly aligned to where I cannot just squeak the pan in between. That is what is making it the most difficult.

I love my 07. I bought it brand new, and have never had an issue with it. I have the sedan, and I really wish I purchased a wagon at the time. The 5mt is a nice mix. It isn't a fast car, by any means, but it has enough power to get the job done.

[Bdub]

Okay, spent a little more time opening up the space in the pan, and it fits in there with a lot less effort.
I suppose there is an upside to this.
After taking all the crap off, I can finally replace that oilpan, put in some sti motor mounts I was given, replace the steering rack bushings, replace steering rack pressure line, and put on a new crossmember because I snapped off all but one bolt in the steering rack mounting holes, yay!

[Legacy777]

Glad to hear a little elbow grease got things to fit better.


For your 07, does the rpms drop when you shift gears? I test drove one in Houston earlier this year. It had some idle issues, and when shifter gears the revs acted pretty weird. I ended up passing on that one because it was beat!

[Bdub]

rpms dropping when shifting doesn't seem normal. When my car sits for a few days, it has a crazy high idle when first started.
It takes a couple minutes for it to calm down, and if you drive it without letting the car warmup, the revs are all over the map on the lower gears.
That seems to be a pretty consistent issue, I always see people on LGT.com complaining about it.

[Legacy777]

That's interesting about the idle....