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Thanks for the offer of data and the pictures. When I refitted my upper oil pan (on a non turbo OM617) found it quite easy to align it but then it didn't have this extra cover bit you've got...
...actually I've just had a penny dropping moment - now I can see why not so many people have trouble removing the spacer that sits behind the front seal (crankshaft).
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Now of course you've got to fit the crankshaft seal and the balancer etc...
...have you by any chance got the fly wheel lock?
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