Nothing short of removing the oil pan itself and resealing it is going to stop the oil leaks.  Do not bother buying a Mazda OEM gasket, you don't need it.  Use a good-quality RTV as your sealant.

1. Remove the black, plastic engine floor pan.
2. Drain the oil.
3. Remove the aluminum engine mount located in the middle of the oil pan.
   You might want to secure the engine by utilizing an engine hoist to keep the engine from falling.
4. Remove the 21 10mm bolts that secure the edge of the oil pan flange.
5. If the oil pan is still stuck to the engine, use a chisel (preferred) or flathead screwdriver and tap at the corners to separate the oil pan from the engine.
6. Once the oil pan drops, be careful of any oil that is still in the oil pan.
7. Clean the sealing surfaces on the oil pan and the engine very carefully.
   This is to ensure a clean surface for the RTV sealant.
8. Cover the oil pan flange surface thoroughly with RTV, making sure to encircle all the bolt holes, including the large ones for the engine mount.
9. Replace the pan and tighten the oil pan bolts to Mazda spec of 96 inch-lbs (which is 8ft-lbs).
10. Reinstall the aluminum engine mount and tighten the three 17mm bolts to the Mazda service manual spec of 40 ft-lbs.

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If stubborn oil leaks from the oil pan flange don't stop, make sure the oil pan flange is flat.  As an alternate method of sealing the oil pan, Judge Ito on NoPistons.COM recommends dimpling the mating surfaces before mounting the oil pan to the engine.  This helps keep the silicone RTV in place.
http://www.nopistons.com/forums/index.php?showtopic=30113





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09/05/2004