W40 Engine rebuild

[tknott]

Just getting started and wanted to say thanks to all who have posted on these topics in the past. Pulling the engine was made possible from all the great ideas posted here. CPA by trade so the rebuild should be a great learning adventure.

Engine ran fine but leaked oil badly (see picture of my rubber catch basin). Had to suck the oil out of the pan before each use.

Plan to compression test and leak down test the engine this weekend.

First oddity/question.........the manual shows the oil drain plug on the underside of the sump basin.  Mine is on the side (see pic). Any thoughts?


 

[SVJourney]

I like your oil drain! Mine was on the bottom which was a problem as it was not accessible. Somebody probably welded in a more useful drain onto your pan at some point. Look for a welded closed area under the pan?  The other possibility is that it is an aftermarket pan or from another engine (Perkins?).
I permanently installed a banjo fitting and capped hose so I could easily connect my oil drain pump which made oil changes much easier. Even for your setup, this would be a cheap and useful mod.
https://en.wikipedia.org/wiki/Banjo_fitting

Many people have had issues successfully replacing their rear main seal. It seems like half the people that do replace it have leaks afterwards.  I would suggest researching carefully.

Have fun! 

[Ed.]

I've the same plug.. I got it out (hard fight blindly by touch..) and drained oil.. but the question is now what to put there..
I'm in marina on the water and there's no way I can get engine out here.. 
I'd love to replace it with banjo fitting but I'm puzzled what kind of size thread I should be looking for...
---
My measurements:
diamenter: 20.40mm
thread: 14G seems whitworth 55deg..
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Was considering to put there some SAE fitting but the threads are not quite the same as I was hopping.. any ideas what should be looking for?
I wish I could change it before I will install new gearbox.. after that there's no way I can access the drain plug without removing gearbox.. and even that's is pain in the ass to access it..

@tknott what did u use for yours?

Thanks in advance!

[SVJourney]

Ed,
I got my banjo fitting from a marine engine shop in New Zealand.  It was something he had laying around used from another engine. Now that I think about it we may have used a bushing to reduce the thread size.

If you look at your fuel injection pump there are banjo fittings on it, so you just need a slightly larger fitting than that for your oil drain I imagine. Start at a diesel shop? Or a good industrial supply store that does hydraulics?

Wish I could be of more help!

[Ed.]

Thanks SVJourney! Unfortunately to find some mechanic shop around is near to impossible..
Anyway got few from amazon:
1/2" SAE - I was able to screw just 1.5 threads max.. - FAIL
1/2" NPT - better but still not feeling right
1/2" BSP - looks fine.. so plan is to fit hose on it with 2 clamps level it higher to some valve and connect pump afterwards for future change..

NPT vs BSP explained..

[Ruvel]

I happen to be working on the same thing. It's a little easier for me because I have my engine out and taken apart. I just got it figured out, I believe. You can use a 1/2" pipe thread reducer and attach the hose right to it.

I'll be using the hose only from this kit

MPI Oil Drain Kit - 3/4" X 16 Thread Size https://a.co/d/4AQo5i0

[Ruvel]

This is my final set up.

I'm using a Home Depot,
LFA-827 Bushing,
LFA-739 Street Elbow,
and the MPI Easy Drain Oil Kit, part #307-0380 (Any of their 0380 kits will do as the oil pan fitting isn't being used, this one was the cheapest.)