I've got a 1999 (T) 1.4 16v Polo that leaks oil sufficiently onto the undertray that it eventually drips off that onto the drive making a mess. I've finally had enough of this and plan to fix it. I'm fairly sure I've narrowed it down to being the sump seal that is leaking.

My question(s):

1) I have a reasonable set of hex keys and am not a complete mechanical numpty - is it possible to get the sump off / on without having to remove exhaust etc?

2) It looks to be some sort of sealant rather than a gasket. Is this correct? If it is is there any recommended sealant to use?

3) Is this job much more than drain oil, get sump off, clean the surfaces, re-seal (with whatever sealant), sump back on, refill with oil?

Would appreciate any advice, thoughts, warning etc!

Thanks

Sqwim

pretty sure you'll have to drop the exhaust down and also disconnect the inner mount of the long driveshaft, you certainly do on a mk3 polo anyway. It's covered in the haynes manual.

On a mk3 it's an actual gasket, I'd be surprised if mk4s were just sealant. I tend to put a layer of blue hymolar on the sump itself and then the gasket and then bolt to the block to help them to seal. You've got it right though, make sure the mating faces are as clean as possible.

you may have to undo one driveshaft from the box aswell if there the same as mk2/3 as you cant get to a couple of the bolts

luke

that's what I meant, disconnect the long driveshaft from the box. Don't think my brain was working properly this morning....

Bugger, I was hoping it would be simpler than that!

Exhaust I can figure out I'm sure. I've never taken a driveshaft off before though, is there much to it?

Haynes manual - they never bothered with one for the 1.4 16v engine I thought, I've spent time looking, in fact I think I even emailed Haynes and got a reply in the negative!

Thanks

stuff like the sump is the same on 8v ones too. undoing the driveshaft is just a case of unbolting 6 8mm spline bolts.

Well I've acheived the some total of nothing today as, after two trips to Halfords (one for a longer extension to my socket set and another to try an find an 8mm spline key), I've not managed to get the driveshaft off as I don't have and couldn't find the aforementioned spline key (I thought I had one!). So, I've had to put everything back together and I'll try again another day (raining today and garage so full of crap that the boot was sticking out so couldn't even just shut the garage door and hope to get it done tomorrow!).

Anway, what I'm after is advice as to where to buy an 8mm spline key for the driveshaft bolts? I've tried Halfords and two other local auto shops but no joy.

Also, once these spline bolts are out, how easy is it to actually disengage the drive shaft? Is it just a case of wiggling it about and out it comes? Can I do it without taking the wheel etc off?

Thanks for and advice.

Cheers

Sqwim

Ah, also (I nearly forgot!), I noticed while I was under there that the charlatans who replaced the water pump a few months ago neglected to attach the cam belt cover properly - they've left the lower bolt off and the cover flaps around and is being gradually chewed up by the alternator belt.

I think it's an M8x28 hex bolt - can anyone confirm or, more importantly, let me know whether I need to go to VW for this or might be able to get one from somewhere else (cheaper!).

Oh, and I'm still interested in where you get the 8mm spline key from too as I had another fruitless search for one today.

Cheers

Sqwim

mk4s have no gasket, just sealant! check etka theres no gasket listed

gofasterpinch, yes, you're right - I have £11.50's worth of white, high temp silicone sealant from VolksSpares. I wonder whether it's any different to the high temp sealant you get for sticking oven doors back in, but more expensive?!!

I'm going to cheekily take this opportunity to bump this up a bit as I'm still stuck on the 8mm spline key and M8x28 hex bolt sourcing....!

Anyone?!

Hello again folks, I've now sourced a set of spline keys (and have also got the M6x25 bolt for the lower cam belt cover fixing). So, this weekend I am going to (hopefully not just attempt) to get the offside driveshaft off so that I can get to the sump.

I've never taken a driveshaft off before so have a few questions:

1) I'm assuming the car should be up on axle stands rather than just ramps. Is this correct?

2) Do I need to take the wheel off and then undo anything at that end of the shaft just to get the shaft out of the gearbox?

3) Should I expect leakage of gear oil at all? In fact, do I need to drain the gearbox?!

4) Once out and the sump replaced, am I likely to have any problems getting it back in?

5) Anything else to be aware of?!

Much obliged for any advice / assistance that can be offered!

Cheers

Sqwim

Edited 21 November, 200817 yr by Sqwim

Yes,the driveshaft will just come away from the gearbox flange (the joint has enough telescopic movement in it for this),you just use a cable-tie or bit of string to hold it out of your way (when you bolt it back up,the bolts must be torqued to 45nm).

Empty the engine oil..

You'll need to remove the little D-shaped plate where the sump meets the gearbox,as there are two more sump bolts behind it (you'll have to turn the flywheel to get to them,as it has cut-outs in it for access).

With the sump off,de-grease both surfaces before liberally smearing the sealant onto the sump. You dont want to block any of the bolt holes,as you want to avoid getting it into the threads in the engine block.

Once happy,carefully offer the sump up onto the block,gently press onto it,and screw the bolts in - starting with the four corners. Dont torque the bolts up yet,just nip them finger-tip tight.

Now i gave the seal the time of 'overnight' to cure before giving them an extra quarter turn in the morning.

What the official way of doing it is,i dont know,but that worked for me.

Thanks MikeyMK - I've been thwarted thouhg as he spline key set I bought from Halfords which was supposed to have a 8mm spline key doesn't... it has two 10mm spline keys instead! Back to Halfords we go and I'll have another bash tomorrow!

Cheers