Engine replaced, leaking oil, dented oil pan (was: How much is toomuch oil?)

Original thread at [url]http://tinyurl.com/bn5kp[/url],
and [url]http://tinyurl.com/ayf7j[/url] before that.

History: My original engine (97 tercel, 120,000km or 75,000 miles)
sprung an oil leak and I burned it out. A used engine of similar
mileage was put in, and it burned oil in well in excess of what my
mechanic thought reasonable, as well as exuding a lung-aggravating
scentless fume. It has been replaced by a 2nd used engine of similar
mileage, along with a new rear main seal. Prior to this 2nd
replacement, the 1st used engine also leaked at the rear main seal,
enough to leave oil drops on the gound, and the oil smell was
overpowering. Replacing the oil pan gasket seemed to reduced the oil
fumes significantly; it didn't reduce the oil loss, and the scentless
aggravating fume was still present.

The mechanic put in the 2nd engine because of the oil loss in the 1st
one; I was more interested in getting rid of the aggravating fumes,
which makes it impossible to drive without all windows down (bad in
winter, rainy days, and hot days). The 2nd used engine doesn't lose
oil at a significant rate, but there is an overpowering oil smell
similar to that in the 1st used engine before the oil pan gasket was
replaced. As well, there are oil drops on the ground. I had my 1st
look underneath today, and saw some seepage at the rear main seal, and
minor seepage at the front mail seal. The rear main seal is
supposedly new. There is also 2-inch diameter dent in the oil pan, at
the corner (so it bulges inward instead of outward). There is surface
rust on the dent.

There is no significant oil loss in the 2nd engine, but I'm concerned
about the impact from breathing the fumes from seeping oil on hot
engine surface. Whenever I work out, I cough vigorously, and fellow
exercisers remark (jokingly) that its from all my smoking (I don't
smoke). I have been told that changing the rear & front main seals
involve significant work. What is reasonable to expect of my
mechanic, considering that the rear main seal is new, and it still
leaks? I don't want to be unreasonable, but neither do I want to
continue breathing the fumes. I can't tell whether the scentless
aggravating fume has been eliminated when the overpowering oil fume is
present. (It is also possible that the "scentless" aggravating fume
in the 1st engine is really due to the a much smaller amount of engine
oil smouldering compared to before the oil pan gasket was replaced).

What about the 2-inch dent in the oil pan? Is it it a minor issue to
replace oil pan whent the rusty dent rusts through? Is it OK to
ignore the possibility that the engine might have some other problem
due to such an impact? Is it reasonable that I was not informed about
this rather dramatic dent?

Thanks for your experienced opinions.

Tercel Owner wrote:[color=blue]
> Original thread at [url]http://tinyurl.com/bn5kp[/url],
> and [url]http://tinyurl.com/ayf7j[/url] before that.
>
> History: My original engine (97 tercel, 120,000km or 75,000 miles)
> sprung an oil leak and I burned it out. A used engine of similar
> mileage was put in, and it burned oil in well in excess of what my
> mechanic thought reasonable, as well as exuding a lung-aggravating
> scentless fume. It has been replaced by a 2nd used engine of similar
> mileage, along with a new rear main seal. Prior to this 2nd
> replacement, the 1st used engine also leaked at the rear main seal,
> enough to leave oil drops on the gound, and the oil smell was
> overpowering. Replacing the oil pan gasket seemed to reduced the oil
> fumes significantly; it didn't reduce the oil loss, and the scentless
> aggravating fume was still present.
>
> The mechanic put in the 2nd engine because of the oil loss in the 1st
> one; I was more interested in getting rid of the aggravating fumes,
> which makes it impossible to drive without all windows down (bad in
> winter, rainy days, and hot days). The 2nd used engine doesn't lose
> oil at a significant rate, but there is an overpowering oil smell
> similar to that in the 1st used engine before the oil pan gasket was
> replaced. As well, there are oil drops on the ground. I had my 1st
> look underneath today, and saw some seepage at the rear main seal, and
> minor seepage at the front mail seal. The rear main seal is
> supposedly new. There is also 2-inch diameter dent in the oil pan, at
> the corner (so it bulges inward instead of outward). There is surface
> rust on the dent.
>
> There is no significant oil loss in the 2nd engine, but I'm concerned
> about the impact from breathing the fumes from seeping oil on hot
> engine surface. Whenever I work out, I cough vigorously, and fellow
> exercisers remark (jokingly) that its from all my smoking (I don't
> smoke). I have been told that changing the rear & front main seals
> involve significant work. What is reasonable to expect of my
> mechanic, considering that the rear main seal is new, and it still
> leaks? I don't want to be unreasonable, but neither do I want to
> continue breathing the fumes. I can't tell whether the scentless
> aggravating fume has been eliminated when the overpowering oil fume is
> present. (It is also possible that the "scentless" aggravating fume
> in the 1st engine is really due to the a much smaller amount of engine
> oil smouldering compared to before the oil pan gasket was replaced).
>
> What about the 2-inch dent in the oil pan? Is it it a minor issue to
> replace oil pan whent the rusty dent rusts through? Is it OK to
> ignore the possibility that the engine might have some other problem
> due to such an impact? Is it reasonable that I was not informed about
> this rather dramatic dent?
>
> Thanks for your experienced opinions.[/color]

I'm not sure if this changes the assessment of the situation, but in
addition to the front and rear main seals, the oil pan plug also seeps.

Is the oil leaking from the rusted spot or from the gasket? If oil is
leaking from oil pan due to a rusted hole, the entire pan can be replaced
or try some epoxy like J-B weld on the leak.
If leaking due to warped pan, entire pan may need to be replaced.
There is normally copper or alumin washer on oil pan plug that need to be
replaced. Looks like you need to find the source of the other leaks.
Check valve cover for oil leak, there is a gasket that is on the cover and
a spark plug grommet that can cause oil to weep down the engine and hit the
exhast manifold and cause smoking.
I don't think a leak from oil pan can cause smoking, unless it is leaking
on the exhaust manifold or pipe.
Check the distributor for oil leaks, there is o-ring on the shaft that
require periodic replacing. Real seal replacement can be costly.
There are some engine additive and high mileage oil that is suppose to
recondition the seals.