2000 VW MK4 Golf TDI Dip Stick Tube Repair

Project 23 - 2000 MK4 Golf TDI Dip Stick Tube Repair

Epoxy Repair

A common problem on the Golf TDI is a broken dip stick tube. Most TDI's the TDI Guy has serviced over five (5) years old have a weak or broken dip stick tube. Over a period of time, due to the elements, the plastic dip stick tube snaps at the filler tube of the crankcase.

There are two (2) options to fix this problem -  (1) Repair with a fast drying epoxy, and two (2) Replace the dip stick tube with a new VW replacement part. There are not many parts that you can buy at the VW parts center for less than $10.00. The actual cost of this part is $8.88.

While diesel fuel has spiked to almost $4.50 a gallon, the TDI Guy chose to attempt to repair the dip stick tube with a fast drying two (2) part epoxy. It will save a trip across town to the VW parts center.

The steps that the TDI Guy used to temporarily repair the dip stick tube are as follows:

Note

This repair is only temporary. The dip stick tube should be replaced at your convenience.

    
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  With the hood lever, raise the hood

  
      

    
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  Using a 1/4-inch square drive ratchet and 1/4-inch 10mm socket remove three (3) bolts and hose (EGR valve) that secures the top engine cover.

  
      

    
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  Remove the upper engine cover.

  
      

    
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  Remove the broken dip stick tube and dip stick from the Project Car TDI.

  
      

    
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  Thoroughly clean the dip stick tube with PPG DX330 wax and grease remover of all old oil and dirt.

  
      

    
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  Use 80-grit sandpaper to rough up the jagged edges of the broken plastic tube.

  
      

    
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  This step will provide good adhesion of epoxy to the plastic dip stick tube.

  
      

    
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  Clean the oil filler tube with PPG DX330 wax and grease remover.

  
      

    
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  Rough up the jagged edges of the filler tube with 80-grit sandpaper.

  
      

    
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  Join the roughed up dip stick tube and line up the jagged edges to the edges of the filler tube.

  
      

    
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  Mix up a small dab of resin (A) and hardener (B) on a mixing board and stir thoroughly.

  
      

    
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  Using the fingers, walk a bead of epoxy around the circumference of the dip stick tube.

  
      

    
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  Apply pressure with the fingers to the dip stick tube for one (1) minute or until the epoxy has taken a set.

  
      

    
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  After fifteen (15) minutes, mix up another small dab of epoxy and apply a second bead around the dip stick tube.

  
      

Warning

Place epoxy bead on the outside of the dip stick tube where it joins to the oil filler tube. Coating the walls on the inside of the oil filler tube with epoxy is a "NO-NO". It would be very difficult to remove the old dip stick tube for a replacement without damaging the oil filler tube connected to the crankcase.

    
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  Let the epoxy repair cure for eight (8) hours. Figure 23-1 shows the epoxy repair that has cured and installed on the Project Car TDI.

  
      

Figure 23-1 TDI Dip Stick Tube Repaired With Epoxy

Finishing Up

    
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  Install the upper engine cover.

  
      

    
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  Check engine oil for proper level.

  
      

    
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  Start the engine let run for two (2) minutes.

  
      

    
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  Check for oil leaks around the repaired dip stick tube area.

  
      

    
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  Close the hood.

  
      

    
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  Road test the Project Car TDI.

  
      

Tools and Materials

    
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  PPG DX330 wax and grease remover

  
      

    
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  80-grit sandpaper

  
      

    
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  Two part epoxy

  
      

    
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  Mixing board

  
      

    
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  Plastic spreader