Well I had to drop the pan to replace the turbo drain tube (super PITA - at some point I'll post pics / tips on that job). Though I got that leak fixed, I created a new one - the oil pan now leaks.

I used a new gasket and thought everything was a clean as could be - but, nope - drip drip drip.

I ordered a new pan, gasket and hardware and went about changing it this weekend. Well, as I unwrapped the new oil pan I found out that it was bent at the lip. CRAP! Called all 4 MB dealers in DFW and no one had one and I had already drained the oil and dropped the pan - CRAP!

Well before I did the turbo oil drain tube,. the pan hadn't been the source of any leaks so I gambled on the oil pan with just a new gasket. I torqued to 10nm all way round - leaked immediately. Torque the side with the leak was to 12nm (scared to go higher as those 5mm hex bolts don't look that stout). But, right now, it looks like it's still leaking. I guess I'll rig some towel / rag / diaper as to not make a mess on the bottom of the car and get the dealer to order another pan and gasket. CRAP! That and I'm going through $40 worth of Mobil 1 every change!

So - what am I doing wrong? This time I buffed the mating surface on the bottom of the engine with a little super fine steel wool and carb cleaner in case of residue. The surface is super glass smooth to the touch. I even got a SK micrometer 1/4" torque wrench that is good to .2nm and did a criss cross (opposite side) pattern. The pan was perfectly clean. I'm putting these gaskets on DRY. The leak is on the back side like before.

Should I:
(a) get a new pan, gasket and try again?
(b) do these gaskets expand some? Any chance it will stop leaking? (I know - fat chance)
(c) new pan, gasket and some kind of permatex sealant? If so - which one?

http://www.permatex.com/products/automotive/automotive_gasketing/gasket_sealants/auto_Permatex_High_Tack_Spray-A-Gasket_Sealant.htm

http://www.permatex.com/products/automotive/automotive_gasketing/gasket_sealants/Permatex_Super_High_Tack_Gasket_Sealant.htm

thanks!

__________________
~shell
As of 2/2010:
2001 CLK55 0o\=*=/o0
13.6 @ 106mph
10K mi
1984 300SD
260K mi and going and going...
97 S600
46K miles
1991 Sentra SE-R (extremely dorked with)
www.se-r.net