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VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

Does anyone know anything about problems removing the sump on a Golf TDi 1.9? My garage have just called and said two of the bolts have sheared the where they screw in to and to replace that part they'll now have to remove the gearbox. I don't know what to make of what they're sayng to be honest. Any help anyone?

VW Golf TDi 1.9 - Sump Removal Problem - Peter.N.

Very unusual for sump bolts to sheer, they are usually oily! Don't know VW engines but I can't immediately see why you should have to remove the gearbox. Ask them for exact details.

VW Golf TDi 1.9 - Sump Removal Problem - daveyjp

Youtube is your friend.

Possibly the two hidden bolts at the rear of the sump, as shown on this video from 2 minutes in.

https://youtu.be/074GKvD22FM

Not easy to access for removal if they have sheared.

VW Golf TDi 1.9 - Sump Removal Problem - Andrew-T

Possibly the two hidden bolts at the rear of the sump, as shown on this video from 2 minutes in. Not easy to access for removal if they have sheared.

Not easy to notice either ? Perhaps someone applied a spanner and zealously overtightened them. Why would they do that ?

VW Golf TDi 1.9 - Sump Removal Problem - skidpan

Not familiar with the bolts on a VW sump, never worked on one. But on a Ford Kent engine the rear 2 bolts are impossible to remove (and see) with the engine and gearbox in situ. On a Caterham its not unknown for the sump to get damaged (mine has 3" clearance, many have less) and many first timers would remove the obvious bolts and then try removing the sump with the 2 inside the bellhousing still in situ. The really insistent amongst them would then resort to the chisel or screwdriver in the belief that it was the sealant that was stopping it coming off. result was a destroyed sump at best, destroyed rear bolts and damaged block at worst.

Wonder if the sheared bolts on this VW have been caused by a mechanical marvel having all the gear and no idea. Should have gone to spec savers.

On the Caterham the manual told you a simple way to enable removal without splitting the engine and box. Before fitting the sandwich plate between the engine and gearbox make 2 cuts that would enable the lower part to be removed by taking out bolts, then the 2 sump bolts are easy to see and relatively easy to access. All the plate does is prevent road debris entering the bellhousing. One enterprising fellow omitted the plate, he thought he knew better than Ford, big mistake. Cost him a new engine.

VW Golf TDi 1.9 - Sump Removal Problem - John F

I'm wondering why the sump needed to come off?

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

I'm wondering why the sump needed to come off?

I had a slow oil leak and they said I'd cracked the aluminium sump, probably some months age when I went the wrong way into a parking space by going over some raised concrete. Some people have done it in sleeping policemen, so it seems really stupid to use aluminium for the sump.

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

Not familiar with the bolts on a VW sump, never worked on one. But on a Ford Kent engine the rear 2 bolts are impossible to remove (and see) with the engine and gearbox in situ. On a Caterham its not unknown for the sump to get damaged (mine has 3" clearance, many have less) and many first timers would remove the obvious bolts and then try removing the sump with the 2 inside the bellhousing still in situ. The really insistent amongst them would then resort to the chisel or screwdriver in the belief that it was the sealant that was stopping it coming off. result was a destroyed sump at best, destroyed rear bolts and damaged block at worst.

Wonder if the sheared bolts on this VW have been caused by a mechanical marvel having all the gear and no idea. Should have gone to spec savers.

On the Caterham the manual told you a simple way to enable removal without splitting the engine and box. Before fitting the sandwich plate between the engine and gearbox make 2 cuts that would enable the lower part to be removed by taking out bolts, then the 2 sump bolts are easy to see and relatively easy to access. All the plate does is prevent road debris entering the bellhousing. One enterprising fellow omitted the plate, he thought he knew better than Ford, big mistake. Cost him a new engine.

Golf same as Ford kent it seems, and yes it may have been a first-timer. I can't prove it was their fault. They said it's because the car is 17 years old.

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

Possibly the two hidden bolts at the rear of the sump, as shown on this video from 2 minutes in. Not easy to access for removal if they have sheared.

Not easy to notice either ? Perhaps someone applied a spanner and zealously overtightened them. Why would they do that ?

Human error? Or tried to remove with the wrong tool, or pulled the sump without removing them maybe. They say it was a problem with the car being old. I can't prove anything.

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

Youtube is your friend.

Possibly the two hidden bolts at the rear of the sump, as shown on this video from 2 minutes in.

https://youtu.be/074GKvD22FM

Not easy to access for removal if they have sheared.

Helpful video thanks. It is a problem with the two rear bolts. They said it's down to the car being 17 years old, but I suspect someone didn't know there were two hidden bolts to remove and tried to pull the sump off. I've got no way of proving it though.

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

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Edited by Brian Worthington on 19/01/2021 at 16:11

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

Very unusual for sump bolts to sheer, they are usually oily! Don't know VW engines but I can't immediately see why you should have to remove the gearbox. Ask them for exact details.

They said they had a problem removing the two bolts at the rear and that it was probably down to the car being 17 years old. I've got no way of knowing whether it was really their fault (e.g. someone there forgot to remove them and tried to pull the sump out, or they tried to remove them with the wrong tool). There's something damaged where the rear bolts screw in apparently, so they have to take stuff out to get at and replace it.

VW Golf TDi 1.9 - Sump Removal Problem - Andrew-T

<< They said they had a problem removing the two bolts at the rear and that it was probably down to the car being 17 years old >>

17-year-old bolts are quite likely to seize I suppose, and if the block and sump remained leak-free for several years that could well have happened, especially at a joint between steel and alloy.

It sounds like an access problem, which reminds me of one on a 205 GTi many years ago: one of the bolts in the bonnet hinge seized and finally sheared. My local indy had a special Bosch tool with a 90° capability for getting into tricky corners, which solved the access problem. He said it was expensive but had paid for itself very soon after purchase.

VW Golf TDi 1.9 - Sump Removal Problem - Brian Worthington

<< They said they had a problem removing the two bolts at the rear and that it was probably down to the car being 17 years old >>

17-year-old bolts are quite likely to seize I suppose, and if the block and sump remained leak-free for several years that could well have happened, especially at a joint between steel and alloy.

It sounds like an access problem, which reminds me of one on a 205 GTi many years ago: one of the bolts in the bonnet hinge seized and finally sheared. My local indy had a special Bosch tool with a 90° capability for getting into tricky corners, which solved the access problem. He said it was expensive but had paid for itself very soon after purchase.

I called in there this morning for an update. He showed me the old sump with the crack in it (common problem it seems). He showed me a new plate about 5 inches wide he's had to get to replace the one in/near the gearbox that the two rear bolts screw in to. He said there are two plastic washers, one inside each screw hole in the plate, which are damaged and not doing their job properly, so the rear bolts won't tighten properly. Leaving it as-is would probably end up with a worse oil leak than I had before. He said he has to take the gearbox out to put the new plate in. Does that make sense?