Sump Gasket Replacement Woes - Hole In Block

[fuji 0]

Hi, decided to tackle a leaking sump gasket over the weekend as noticed one of the bolts (underneath nos. 1 cylinder) was missing, although strangely no oil was leeking from this area. Managed to get the sump off O.K. and also the spacer plate but while removing the old paper gasket from the engine block a piece of metal came away from the thread where the missing bolt should have been. Obviously with the bolt missing, over time corrosion has attacked the threaded hole causing the metal around it to disintigrate. I am now left with a hole about 3mm deep. It seems that the sump bolts in this area (2) screw into the top of the nos 1 main bearing cap.

Can I replace the main bearing cap without having to change anything else or would the new bearing cap not be matched to the crankshaft?

Can I fill the hole with a metal filler and not bother refitting the missing bolt as these are torqued to a very low tension and there are enogh to effect a good seal with RTV?

Just wondering what my options are.

Thanks in advance.

[welshpug 1,657]

by number 1 do you mean timing belt end? in which case that is an alloy plate bolted on separately and simply carries the crank seal.

 

just a note - if what I said above is correct about the location, peugeot number from the flywheel end, timing belt is at number 4 piston end

[Tom Fenton 1,542]

A picture would help us.

 

I would personally look to repair the threaded hole with a helicoil, then everything is as it should be.

[fuji 0]

A picture would help us.

 

I would personally look to repair the threaded hole with a helicoil, then everything is as it should be.

 

 

The hole is at the cam belt end of the engine block , i'll post some pictures later but as far as I can see the thread is in the top of the bearing cap which the sump and spacer plate screw in to.

[Tom Fenton 1,542]

The sump does not bolt to the main cap at that cambelt end, it does at the flywheel end, but not the cambelt end. As Welshpug says, at the cambelt end it is an alloy housing that carries the crank seal.

This all assumes we are talking about an XU 1.6/1.9 GTI engine?

Anyway, if it is into this housing, you could either drill/tap to M8, or helicoil back to M7.

That is assuming I've understood correctly, and it is the thread that is u/s?

[fuji 0]

Thanks for the responses but it would help if I gave you the correct location. The hole is at the flywheel end so I think this is the bearing cap it's drilled in to. I have attached some pictures. Can I replace the cap with a new one or should i try to fill? Any advice appreciated.

Thanks again.

 

 

 

http://s440.photobucket.com/albums/qq123/f...mview=slideshow

[Tom Fenton 1,542]

At the flywheel end it does go into the brg cap. These are line bored to each block and are not interchangeable. As said before, carefully helicoil it and then you are back to standard.

[fuji 0]

Tom, thanks for the response - I accept i may be able to helicoil the original thread but it will still leave me with a hole that is about 3mm deep that runs across the block mating surface. How do I get a good seal when re-fitting the sandwich plate?

Cheers.

[sub205 5]

why not cleaning and using fluid metal so fix it?

 

thats what i would try.