Oil pan changes:
The oil pan on
this kit was previously sealed to the block using RTV silicone as
is done from the factory. Thanks to Dan Dunhem who found
out that Fel Pro had an oil pan gasket part number for the
'93-'97 2.5Ls, I won't have to worry about leaks or the RTV's oil
solubility.
The Fel Pro part number is OS30909 C and cost should be $6-$10 at your local auto parts store.
Originally the oil pan gasket was the only thing I planned to do differently with the oil pan, but once it got here, I changed my mind. It had already been tapped for the oil drain line, but something made me want to change it. Since the photos of it did not turn out, I will simply have to describe the drain tap. As you can see from the inside photo (below), the tap is a brass fitting, that is female-to-female with about 1/4" of length hanging out on the outside. Now, a block-off fitting (basically a bolt to plug it) was inserted into it and was then drilled through. This added enough length to the fitting to allow the 1/2" drain line from the turbo to be slipped over the entire thing and clamped down....and that's the way it was done.
Somehow having a 1/2" drain line
flowing through a 1/4" hole in the fitting didn't seem to
make much sense so I was headed out to find a better fitting. I
wanted to take the male fitting out so I could match the threads,
but as soon as I put a wrench on it and applied pressure, the
entire fitting popped off the pan. Apparently it was JB Welded
on, not really welded.
So the next thing was to have a fitting welded to it. I took it down to a friend's auto parts shop who, in turn, dropped it off at a welding place that he uses. They are welding on a 5/8" female fitting that I will thread a 45° angle male fitting into with a 1/2" hose barb fitting on the other side. This will increase the flow and make a solid, leak-free connection at the pan.
The pan should be back Monday and on the car by Saturday (damn school and work all week!). Check back for photos of the new fitting next week.