I think I've messed up!

[Algypan]

So today was a lovely day, a great day for the motorcycle... but instead I chose to spend the day rolling around under the T5... again. Haha

Anyway, today I decided to swap out the oil cooler, oil pressure switch and fix the suspected leak from the sump gasket. I also thought it would be good to take off the oil pickup(?) and inspect it. It was packed with tiny metal shards and pieces of plastic. Not great I know, however after cleaning it, putting it back on, re-sealing the sump and putting it back, I think I put the pickup pipe the wrong way round? Is this possible? It's facing down and for the life of me I cannot remember if it was facing up or down when I took it off like a wally.

Also while I'm on the subject, the sump gasket seal came unstuck a couple of times while I was trying to put it back on and bolt it back up. Will this be an issue do you think?

 

[BuilderJay]

Where bouts do you live in Kent?
If you need a mobile mechanic I use TW Walter’s from Gravesend.
Comes to you and gets hes hands dirty rather than yours! He owns a T6 too!
If you want he’s number lemme know.

 

[Rabonitez]

@Algypan how easy was removing the sump? Looks like a few difficult to access 10mm bolts by the gearbox/flywheel

 

[DaveD]

I also thought it would be good to take off the oil pickup(?) and inspect it. It was packed with tiny metal shards and pieces of plastic.

I might be inclined to further investigate that before refitting the sump, but I'm not a mechanic.

 

[Algypan]

@Algypan how easy was removing the sump? Looks like a few difficult to access 10mm bolts by the gearbox/flywheel

It's just 10mm socket for the majority of the bolts and I think there is 2 that need to be accessed with a hex ball tool/socket as the angle of them if using a straight edge hex would just round it off. I cannot remember if i was a 5mm or 6mm, but I used a hex ball socket piece on one of those little wobble sockets and that worked a treat. The only agg I had was trying to get the hex piece back out. For some reason it would not release after the bolt was tightened and it spends it's time rattling around occassionally until the day it finaly falls off with vibration... I hope

 

[Algypan]

I might be inclined to further investigate that before refitting the sump, but I'm not a mechanic.

I'll be honest, I wouldn't even know where to begin looking or what to look for with something like that.

 

[DaveD]

I'll be honest, I wouldn't even know where to begin looking or what to look for with something like that.

Although I'm not a mechanic I'm going to stick my neck out and say that metal shards that are visible to the naked eye, and bits of plastic, in the oil pick up strainer certainly point to a problem.
Was it running OK before you removed the sump?

 

[Rabonitez]

It's just 10mm socket for the majority of the bolts and I think there is 2 that need to be accessed with a hex ball tool/socket as the angle of them if using a straight edge hex would just round it off. I cannot remember if i was a 5mm or 6mm, but I used a hex ball socket piece on one of those little wobble sockets and that worked a treat. The only agg I had was trying to get the hex piece back out. For some reason it would not release after the bolt was tightened and it spends it's time rattling around occassionally until the day it finaly falls off with vibration... I hope

Many thanks for the advice. Can I ask what sealant you used when refitting?

 

[Phil_j89]

Pick up pointing downwards is correct.

 

[Algypan]

Many thanks for the advice. Can I ask what sealant you used when refitting?

I used a small tube of Dirko HT. It was about £5 from a motor factors. It's really nice and easy to apply a bead and heat resistant.

My advice would be to try and remove the most awkward bolt from the sump first before attempting the others. I went arse about face and left it til last, and as not impressed. Haha!

 

[Algypan]

Although I'm not a mechanic I'm going to stick my neck out and say that metal shards that are visible to the naked eye, and bits of plastic, in the oil pick up strainer certainly point to a problem.
Was it running OK before you removed the sump?

Yea it ran fine, just a heavy oil leak from somewhere that was hard to diagnose. That's why I replaced boost hose seals/ clips, rocker cover gasket, oil pressure/ cooler and resealed the sump. It did have a compression issue last year and that resulted in a new head gasket being fitted, as well as waterpump and timing belt. Could the shards be a result of that initial problem before it was replaced? I am not mechanically minded to be honest, so it's very hard for me to understand how stuff gets somewhere in an engine.

 

[DaveD]

Yea it ran fine, just a heavy oil leak from somewhere that was hard to diagnose. That's why I replaced boost hose seals/ clips, rocker cover gasket, oil pressure/ cooler and resealed the sump. It did have a compression issue last year and that resulted in a new head gasket being fitted, as well as waterpump and timing belt. Could the shards be a result of that initial problem before it was replaced? I am not mechanically minded to be honest, so it's very hard for me to understand how stuff gets somewhere in an engine.

Yes, hopefully the debris is from issues that were dealt with.

 

[Marco24]

Finding an odd piece of machining swarf or non metallic debris trapped in the oil strainer isn't unusual to find, particularly if someone has had the engine apart in the past. That's the job of the 'rock catcher' gauze used on the strainer. It should also face downwards, and although I'm not too familiar with this VW engine I would be surprised if you could fit it any other way.
The fact you said it was "packed" with metal shards is more worrying. Did you note if they were bright and shiny, magnetic etc? It all helps to work out where the particles originated from.
I would at the very least flush the engine with new oil and change the filter. Cut open the old filter to see if it is also packed with debris. If it is then it's time to ask an experienced engine mechanic for a more in depth diagnosis, including checking the main and big end bearings.

 

[DXX]

@Algypan does you T5 have belt, chain or gear timing drive?

 

[Algypan]

@Algypan does you T5 have belt, chain or gear timing drive?

Belt I believe. When I took the plastic timing cover off, it looked exactly like my other previous VW cars and they were belt. It's a 2004 1.9 5 speed if that helps.

 

[Algypan]

Finding an odd piece of machining swarf or non metallic debris trapped in the oil strainer isn't unusual to find, particularly if someone has had the engine apart in the past. That's the job of the 'rock catcher' gauze used on the strainer. It should also face downwards, and although I'm not too familiar with this VW engine I would be surprised if you could fit it any other way.
The fact you said it was "packed" with metal shards is more worrying. Did you note if they were bright and shiny, magnetic etc? It all helps to work out where the particles originated from.
I would at the very least flush the engine with new oil and change the filter. Cut open the old filter to see if it is also packed with debris. If it is then it's time to ask an experienced engine mechanic for a more in depth diagnosis, including checking the main and big end bearings.

I used a flat blade screwdriver that had a magnetic tip to ruffle the filings out of the mesh and it seemed to stick to the end of the screwdriver. Also, I did make this discovery while I was changing the Sump gasket and oil cooler, so I did swap out the oil and filter for fresh anyway. I also gave the inside of the sump a thorough clean with degreaser aswell before refitting.

Also, I don't know if it's any use but I also replaced the rocker cover gasket and everything looked very clean there and I couldn't see any filings there.