Rusted leaking sump

mickdw

I had a small oil leak for the last week and today finally got a chance to look at it.
I was very surprised to find the oil coming from a rusty spot on the sump.
Ive had the car from new audi A5 and it's just turned 7 years old. There is not a mark on it in terms of damage.
Would this be common on vw / audi of this age? I'm stunned tbh and I've ran alot of much older stuff over the years.

mickdw

Sitec wrote: »

What type engine is in it? I thought the sumps were made from aluminum?

1.8tfsi. Certainly not aluminium anyway.

George Dalton

Have seen plenty of them looking a bit crusty on those engines but hadn't seen or heard of one rusting through before!

George Dalton

Sitec wrote: »

What type engine is in it? I thought the sumps were made from aluminum?

Upper section of sump is aluminium. Lower part is steel.

:eek:

It's years since I stuck me head under cars regularly but I've never seen a sump leak due to rust. Id be concerned what state its in ... Is car out of use now until sorted? Presumably it rusted from outside in?

ofcork

Would the anti corrosion warranty cover that,they are normally 10 or more years iirc.

mickdw

ofcork wrote: »

Would the anti corrosion warranty cover that,they are normally 10 or more years iirc.

Was just looking at the wording of that. It clearly states bodywork.

mickdw

Augeo wrote: »

:eek:

It's years since I stuck me head under cars regularly but I've never seen a sump leak due to rust. Id be concerned what state its in ... Is car out of use now until sorted? Presumably it rusted from outside in?

Yep, couple of rust bubbles on outside and one has gone through.
Won't be doing any major running now till I get it fixed.

mickdw

George Dalton wrote: »

Have seen plenty of them looking a bit crusty on those engines but hadn't seen or heard of one rusting through before!

You don't live on the west coast George
How much is a new sump for one of these roughly would you know?

George Dalton

I don't know tbh. Never had to replace one. I wouldn't say they are that expensive though. Maybe €100 or so.

Are you going to change it yourself?

mickdw

George Dalton wrote: »

I don't know tbh. Never had to replace one. I wouldn't say they are that expensive though. Maybe €100 or so.

Are you going to change it yourself?

Well leave it to mate with lift. Doesn't look like there is a whole pile in the way anyway.

George Dalton

It looks easy but there are a few awkward bolts towards the bell housing side where the steering rack is in the way. One in particular is very fiddly IIRC.

I would also recommend taking out the oil level sensor while the sump is still on the engine. If you try to remove the sump with the sensor still fitted you will most likely break it.

mickdw

George Dalton wrote: »

It looks easy but there are a few awkward bolts towards the bell housing side where the steering rack is in the way. One in particular is very fiddly IIRC.

I would also recommend taking out the oil level sensor while the sump is still on the engine. If you try to remove the sump with the sensor still fitted you will most likely break it.

Thanks for the tips.
Nothing is ever as straight forward as imagined.

ofcork

mickdw wrote: »

Thanks for the tips.
Nothing is ever as straight forward as imagined.

Apparently a guy in the UK has an A3 with the same issue.

mickdw

ofcork wrote: »

Apparently a guy in the UK has an A3 with the same issue.

Really. Where do you see that?

ofcork

mickdw wrote: »

Really. Where do you see that?

On a site called AUDI-SPORT.NET

listermint

Any damage to the sum? i.e. scrapes rocks speedbumps.

Would have assumed this to be extremely rare for a 2008.

sky6

Could you not just get a patch welded over it.? Also I wouldn't drive it in the meantime as you will lose crankcase pressure and will lead to engine damage.

mickdw

listermint wrote: »

Any damage to the sum? i.e. scrapes rocks speedbumps.

Would have assumed this to be extremely rare for a 2008.

Nope and that is a first for me. Sump tucked up very nicely out of harms way in this car.
Will stick up a photo in a while.

Edit: Photos



The rusted section in the photo is towards the rear of the car. The cross shape stamped into the sump is on the bottom of the sump.
Its mostly perfect but there are a few areas where the paint has started to crumble leading to this issue I guess.
The second part shows where the part number is marked on the sump and it looks factory fresh which is strange as the number seems to be cut deep into the metal with no paint coating.

mickdw

sky6 wrote: »

Could you not just get a patch welded over it.? Also I wouldn't drive it in the meantime as you will lose crankcase pressure and will lead to engine damage.

Sump ordered. Should have it wednesday.
I wouldnt bother going the patching route. Other sections would rust too Id say.
€100 for the sump so not so bad really.

listermint

Thats insane for a 2008. Pretty shocked at that tbh.

mickdw

I was surprised myself when I saw it.

mickdw

Just to update, got the sump from audi, got it fitted and all is well again.
Inside the sump, the hole was pretty much invisible. The oil was just slowly bleeding through it. I eventually located just a pinhead hole inside, pressed on it with small screwdriver and it went straight through. The wall of the sump was gone to paper in the rusted area.
There is alot of heavy blistering on it looking at it now off the car.