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Corsa Sport » Message Board » Help Zone, Modification and ICE Advice » C20XE 5th main cap removal & refitting (Still leaking video added)


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Author C20XE 5th main cap removal & refitting (Still leaking video added)
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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27th Jul 13 at 17:09   View User's Profile U2U Member Reply With Quote
Can anyone tell me how the 5th main cap is removed and how it should be refitted?




[Edited on 11-08-2013 by Mark.W]
monkeytwizzel
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Registered: 10th Aug 11
Location: Chard, Somerset
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27th Jul 13 at 23:24   View User's Profile U2U Member Reply With Quote
Just undo the bolts and give it a wiggle and it will come out,use slight leverage if you need to and best to take off the flywheel because you will need to put some sealant around the cap when you refit it.
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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27th Jul 13 at 23:27   View User's Profile U2U Member Reply With Quote
Doing this with the engine still in the car :/
andy_mk3
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Registered: 18th Dec 11
Location: Peterborough
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28th Jul 13 at 09:46   View User's Profile U2U Member Reply With Quote
Flywheel ought to come off to change the crank seal also
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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28th Jul 13 at 10:07   View User's Profile U2U Member Reply With Quote
Crankseal was done before it went in the car so it is just the cap needs doing.


[Edited on 28-07-2013 by Mark.W]
andy_mk3
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Registered: 18th Dec 11
Location: Peterborough
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28th Jul 13 at 12:20   View User's Profile U2U Member Reply With Quote
You'll have to be careful making sure the seal is located properly when it goes back together then!
Mark.W
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Location: County Durham
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28th Jul 13 at 12:29   View User's Profile U2U Member Reply With Quote
Sod it im leaving it and taking it to the garage,i don't have the know how and patience for this anymore.
andy_mk3
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Registered: 18th Dec 11
Location: Peterborough
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28th Jul 13 at 12:47   View User's Profile U2U Member Reply With Quote
What's up with it anyway?
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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28th Jul 13 at 13:07   View User's Profile U2U Member Reply With Quote
Its pissing out out when the engine is hot and been running on the fly wheel side.This is the 3rd time the sump has been taken off and can't figure out why it's leaking.Im using the 8v rubber gasket & baffle plate with shorter bolts.Tried a different sump dry fitted and sealant applied,new crank shaft oil seal was also fitted.
Darryl H
Organiser: South Central
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Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
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28th Jul 13 at 21:33   View Garage View User's Profile U2U Member Reply With Quote
It's very easy to over tighten the sumps on these. Are you doing it to the correct torque settings

If it hasn't been in the past it's probably warped the sump a bit so it will always leak.

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Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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28th Jul 13 at 23:51   View User's Profile U2U Member Reply With Quote
Sump has always been torque to 11lb as stated in the manual Darryl and i placed my sump a glass table and doesn't seem to be totally level so having it checked tomorrow and a local engineers place.

Il be priceing a steel sump up tomorrow and seeing if i can get the car towed to the garage to have this cap removed and resealed.

[Edited on 28-07-2013 by Mark.W]
Generation
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Registered: 7th Jul 09
Location: Essex
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29th Jul 13 at 07:01   View User's Profile U2U Member Reply With Quote
Has it always done done this since engine was fitted/rebuilt?
Mark.W
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Location: County Durham
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29th Jul 13 at 08:26   View User's Profile U2U Member Reply With Quote
Engine wasn't rebuilt just the usual problematic parts replaced,it did have the old cork type gasket on with alot of sealant.
Generation
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Location: Essex
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29th Jul 13 at 17:37   View User's Profile U2U Member Reply With Quote
I ask as mine was pissing oil out from flyside, and was a grub screw missing soon as ht it pissed out.
Coming problem is the crank seal on that side.

Depends how bad it's "pissing" any videos?
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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29th Jul 13 at 17:46   View User's Profile U2U Member Reply With Quote
It is like a constant drip when hot,i don't have any videos sorry.

It is going into my local garage on Wednesday for the cap to be removed & resealed and they said if it is not sealed well it would cause it to leak badly from there.

I also had my sump checked at a engineer company today and the face of it is not 100% flat and has some gaps in some areas of the sump but not bad enough to cause the leak the way it is.

Also i ordered a new 8v steel sump today to try so will see how that goes.

[Edited on 29-07-2013 by Mark.W]
FlaFFy_91
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Registered: 30th Sep 08
Location: Formby, Merseyside
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29th Jul 13 at 19:37   View Garage View User's Profile U2U Member Reply With Quote
Have you tried replacing the crank seal mate?
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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29th Jul 13 at 21:25   View User's Profile U2U Member Reply With Quote
Crank seal was done before the engine went it bud.
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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11th Aug 13 at 16:46   View User's Profile U2U Member Reply With Quote
Took a quick video of the leak just after a 10min drive.

Seems to be dripping out the bottom of the gearbox more now.

https://www.facebook.com/photo.php?v=10151501585226895&l=934976236923929564
monkeytwizzel
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Registered: 10th Aug 11
Location: Chard, Somerset
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11th Aug 13 at 17:26   View User's Profile U2U Member Reply With Quote
Your going have to check that crank seal for starters bud,You might have a bad seal or damaged it when fitting.Did you check the crank for marks on the area where the seal runs when fitting the new one.I`m guessing that you have had that 5th cap removed,resealed and replaced the sump gaskets and it is still leaking?
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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11th Aug 13 at 17:33   View User's Profile U2U Member Reply With Quote
From what i can remember the crank was fine no marks ect,i think the seal we took out looked like the original gm seal.And iv had the 5th main cap removed and re sealed also the fitted the sump for the 3rd time using different sealants i had it in the garage last Monday and they said they wont know if it is the seal for sure until the box is is off so gonna have to get it done but have to wait until the first week of September to get it in.
Generation
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Registered: 7th Jul 09
Location: Essex
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11th Aug 13 at 18:03   View User's Profile U2U Member Reply With Quote
Bit like mine

http://i121.photobucket.com/albums/o223/markaker/conversion/39AA98AC-01B7-404D-855C-031ACE4CDADB-4825-000001F94707DA1E_zps0ddb0151.mp4
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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11th Aug 13 at 18:06   View User's Profile U2U Member Reply With Quote
Was yours the crank seal?
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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11th Aug 13 at 20:04   View User's Profile U2U Member Reply With Quote
Tbh it doesn't really smell like engine oil.Just been up and took these pics of the cv on the long shaft and is covered in oil,does it look like the shaft is in properly?

https://www.facebook.com/photo.php?fbid=10151501837391895&l=13489c45ba
https://www.facebook.com/photo.php?fbid=10151501837871895&l=f4e76a9edc
https://www.facebook.com/photo.php?fbid=10151501838511895&l=08c951d288
https://www.facebook.com/photo.php?fbid=10151501870466895&l=373da76196
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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12th Aug 13 at 20:13   View User's Profile U2U Member Reply With Quote
Inside of the bell housing does look wet when i shine a torch in.

https://www.facebook.com/photo.php?fbid=10151503566106895&l=8b62c71ebf

Oil drips out this small hole bottom of the bell housing

https://www.facebook.com/photo.php?fbid=10151503565051895&l=448b8e0825
monkeytwizzel
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Registered: 10th Aug 11
Location: Chard, Somerset
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12th Aug 13 at 23:59   View User's Profile U2U Member Reply With Quote
See what you mean,there is a lot of oil coming from somewhere.It looks like engine oil but have you smelt it just to check?
That driveshaft does look odd but i can`t see that would be the reason for leak though.
Get that box out

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