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Thread: Mk5 2.0L TDI Sump replacement

  1. #1
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    Mk5 2.0L TDI Sump replacement

    Howdy all

    Long time between posts, but back to ask a few questions before turning a wrench in anger.

    I have a 2.0L TDI (BKD engine) with a cracked sump. I have a new one being couriered today and have searched for a few days on DIY tutorials and hints and cannot find a single thing.

    I have decent mech knowledge and ramps and tools. Given this, does anyone know if it is a plug-n-play type thing or will i run into dramas and issues?

    thanks all
    Dyldo
    MY02 Bora V6 4Mo|Matte Black plastidip|VTDA|R32 Exhaust|R32 dampers and springs|TT pedals|R32 steering wheel|17" 8L S3 rims|R32 sways|Blue Haldex|EBC reds

  2. #2
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    Mk5 2.0L TDI Sump replacement-img_0067-jpg

    This guy is on passenger side of oil pan, and by my reckoning I need to remove the bell-housing to get to it?
    MY02 Bora V6 4Mo|Matte Black plastidip|VTDA|R32 Exhaust|R32 dampers and springs|TT pedals|R32 steering wheel|17" 8L S3 rims|R32 sways|Blue Haldex|EBC reds

  3. #3
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    You need to buy a long 5mm Allen key socket with a ball end. You will need to turn the motor over by hand to position the flywheel so the cutouts in it line up with each bolt to assist with removal.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  4. #4
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    Quote Originally Posted by Umai Naa!! View Post
    You need to buy a long 5mm Allen key socket with a ball end. You will need to turn the motor over by hand to position the flywheel so the cutouts in it line up with each bolt to assist with removal.
    is it gasket in a tube or a real one?
    '07 Touareg V6 TDI with air suspension
    '98 Mk3 Cabriolet 2.0 8V
    '99 A4 Quattro 1.8T

  5. #5
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    Quote Originally Posted by Umai Naa!! View Post
    You need to buy a long 5mm Allen key socket with a ball end. You will need to turn the motor over by hand to position the flywheel so the cutouts in it line up with each bolt to assist with removal.
    How would you turn the motor by hand?
    And why would the flywheel be exposed at all?
    MY02 Bora V6 4Mo|Matte Black plastidip|VTDA|R32 Exhaust|R32 dampers and springs|TT pedals|R32 steering wheel|17" 8L S3 rims|R32 sways|Blue Haldex|EBC reds

  6. #6
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    Quote Originally Posted by gldgti View Post
    is it gasket in a tube or a real one?
    Gasket goo on these.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  7. #7
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    Quote Originally Posted by Dyldo View Post
    How would you turn the motor by hand?
    And why would the flywheel be exposed at all?
    The cutouts are on the back side of the flywheel. They allow a more direct shot at the bolt.

    You turn the motor over by hand with a breaker bar and 19mm socket on the crankshaft bolt.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  8. #8
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    is the crank bolt accessible whilst i am under the car on ramps?
    MY02 Bora V6 4Mo|Matte Black plastidip|VTDA|R32 Exhaust|R32 dampers and springs|TT pedals|R32 steering wheel|17" 8L S3 rims|R32 sways|Blue Haldex|EBC reds

  9. #9
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    Yeah, easy enough to get at.

    It'll be easy once you remove the lower inner guard liner. It's right there.
    '07 Transporter 1.9 TDI
    '01 Beetle 2.0

  10. #10
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    Can i just flick the ignition over by small amounts to get the cutout lined up?

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