QuestionQUESTION: how do I remove the sump to inspect the crankshaft bearings as it has developed a knock.
ANSWER: You'll need to remove the lower part of the oil pan (steel portion) to access the two 12mm sump attaching bolts. Once you've removed the sump, then you can remove the upper part (aluminum portion) of the oil pan to access the rod bearings.
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QUESTION: I have done this but the aluminium casing only comes away about 6cms then it seems to be prevented from coming away altogether but I cannot see any obstruction. It will easily go back to the block and come away this 6cms but will not compeletly part from the engine
ANSWER: I'm presuming you've already removed the front exhaust pipe.
One possibility is that the baffle in the oil pan is hanging up on the sump. If you haven't yet removed the sump, the 6cm should be enough for you to access the bolts.
Another possibility is that there isn't quite enough room to clear the subframe and the small lip on the transmission. In this case, you may need to lower the right side of the subframe, or remove the right engine mount and jack the engine, or a combination of the two.
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QUESTION: I've already asked a follow up to the above but in the interim I have found that there is a crescent shaped piece of alloy casting that is in one of the guides for the very long bolts that are at the flywheel end. It seems that this crescent is maybe preventing the complete withdrawal of the casing. Any ideas please.
AnswerI do recall this being somewhat of a tight fit, but I don't recall having this much difficulty without the oil pan obviously striking something.
Have you already removed the steel portion of the pan and also the sump? If not, the sump may be preventing you from sliding the pan fully toward the crank pulley. In fact, have a look there to be sure this isn't the item preventing your removal of the pan. You'll need to move the pan far enough away from the transmission that the crescent shaped area (which is indeed part of the pan) will clear the bell housing. If you cannot get the pan down far enough, the crank pulley may be in your way.
