Club 80-90 Forums

Well it had to happen the first proper breakdown..After a bad hill start in the van this morning where my foot slipped of the clutch pedal, I managed to brake two of three bolts that fix the engine mount onto the right of my 1.6td to the engine block itself (cast iron)..One of the bolts was missing completely and the remaining two have snapped/broken the casing on the engine block. The snapped bolt maybe be able to be drilled out(even then the surface of the casing is damaged) but the other has come out completely from the broken casing leaving only a couple of mm of thread in the block.. Any ideas of the best way of fixing this

Thanks for reading
Mark

if you want a project, Nij is selling a tdi for 150 quid mate
and theres a thread unfolding all about how to do it on alternate engines

I dont know how to fix that except a new block, id dread to weld on there.

As weldore said, I have a VW Golf 1.9 TDi if your interested?

Nij wrote:I dont know how to fix that except a new block, id dread to weld on there.

As weldore said, I have a VW Golf 1.9 TDi if your interested?

Thanks for the sugestion..I was hoping on something slightly less radical..

Mark

id say your looking at a replacement Mark

search your local ads or scrappies for another engine same as yours

weldore wrote:id say your looking at a replacement Mark

search your local ads or scrappies for another engine same as yours

B u g g e r...pardon my language..

if one of the three had worked its way out then without having a 3 point contact the other two would have put stress on the block over time leading to this ...if anyone else has any idea's to fix this it would be great but being a load bearing area and it being cast its doubtful mate

Whats wrong with drilling through the block? and running a tap through..then use a nut and bolt?

dave friday wrote:Whats wrong with drilling through the block? and running a tap through..then use a nut and bolt?

But how thick is the block and will I drill into any oil galleries???

I had similar on mine, jack and plywood to support the sump + removed mount. I bought a cheap right angled drill for the job, centre punched then drilled the broken bolt (blind bolt holes obviously so careful!) . opened it out to about 3mm, then I got lucky with a high quality easy out and lots of plus gas. I borrowed Aidans time sert kit, hand drilled out the old threads with the tommy barand drill bit with cutting fluid. Then flushed with wd40 + a magnet to remove the swarf, (M10) timesert went in, job done. Access wasn't that great, I think I did 2 of mine but one just had the damaged threads not a snapped bolt, but it looks like your engine casing is damaged too, not sure how much thread depth you have left to play with there. if the engine is good might be worth giving it a try.

Bugger Mark , that is not good , I'd give what bob says a go , but tapping the block could cause oil pressure problems amongst other things

the other way maybe get a plate made up that attaches to else where on the block and then to the mount , its been a long time since i saw a naked block so can't say were you'd be able to mount the plate

weldore wrote:
Post details
Re: Broken Engine mounting...

Post by weldore » Wed Apr 18, 2012 9:53 pm
if one of the three had worked its way out then without having a 3 point contact the other two would have put stress on the block over time leading to this

yup , i'd go with that

Mark there's https://club8090.co.uk/forum./viewtopic. ... 8607999751 , in Stoke which maybe worth a punt

Sorry mate and good luck

Mark

Hacksawbob wrote:I had similar on mine, jack and plywood to support the sump + removed mount. I bought a cheap right angled drill for the job, centre punched then drilled the broken bolt (blind bolt holes obviously so careful!) . opened it out to about 3mm, then I got lucky with a high quality easy out and lots of plus gas. I borrowed Aidans time sert kit, hand drilled out the old threads with the tommy barand drill bit with cutting fluid. Then flushed with wd40 + a magnet to remove the swarf, (M10) timesert went in, job done. Access wasn't that great, I think I did 2 of mine but one just had the damaged threads not a snapped bolt, but it looks like your engine casing is damaged too, not sure how much thread depth you have left to play with there. if the engine is good might be worth giving it a try.

Ta Bob for the suggestions..The worst one(top left ) has only 3mm of thread left the bottom one has most of the thread but a damaged mating surface and a snapped bolt in it and the third has no damage as someone never put the bolt in last time the engine was taken out So it has been holding on two bolts for several years

Mark

It's only 100kg bouncing around back there two bolts will hold it mine was the same one snapped bolt left in situ, the other two put under strain, I took mine into have the timing belt changed, the guy saw the accident in progress and suggested I see to it pronto. Just out of interest when it did go, did the left hand mount and gbox keep the engine up or did it drop to the ground?

Sure I have seen some crazy engine mounting stuff on the samba, seen an under the sump arrangement. Maybe a talented tame welder could re engineer the carrier to use different engine mounting holes?

Good idea bob...something using the original engine bars and mounts...get rid of the cast arms and replace with a box section carriage that runs from one side of the engine to the other picking up different bolt holes.that would be the best bet

Hacksawbob wrote:It's only 100kg bouncing around back there two bolts will hold it mine was the same one snapped bolt left in situ, the other two put under strain, I took mine into have the timing belt changed, the guy saw the accident in progress and suggested I see to it pronto. Just out of interest when it did go, did the left hand mount and gbox keep the engine up or did it drop to the ground?

Sure I have seen some crazy engine mounting stuff on the samba, seen an under the sump arrangement. Maybe a talented tame welder could re engineer the carrier to use different engine mounting holes?

The left hand side mount held it up and I didn't notice until I got to my dads house 2 miles away and got out and had a look


Mark