Golf GT TDI AJM engine Mount breakage

MK 4 GT TDI Golf 2000 W Reg

Has anyone else seen this ??? :1zhelp:

The upper cast engine mounting lug break on the "AJM" engine block, its the rear most bolt on the mounting at the cambelt end.

This puts a 1/3 more load on the two remaining bolts which then fail, causing the engine to drop, wrecking the cam belt tensioner, shearing all three bolts, destroying the plastics and the mounting, if your lucky................:zx11: Good engine but now useless as it can't be used.....:zx11:

VW UK say that they haven't seen this fault, however the more people I talk too, the more this would appear to be a problem.

Local VW's dealers solution is a reconditioned block for ~£1600 + gaskets + fitting etc... Ouch

Gives me a 24 month warranty though........I believe the failure occurs after a cam belt change, which would mean that in most cases the 24 month warranty would have expired!!!! so back to square one if the casting was to go again.

Welding the lug isn't viable (local garage tried that but failed again 3 wks later) re-con engine going in next, facing a bill almost as much as the car is worth!!!!

"DJ"

Quite a common problem.

One on the mounting bolts is very difficult to get to and therefore is not tightened properly during a cambelt change. This in turn leads to failure of the other two.

In extreme cases, it will actually snap off a section of the engine block in which case a new block would be required.

If it is just the lug that accepts the mounting bolt that has snapped off then there is a fix for this by fabricating a bracket. Look on the TDI Club for this fix. There are some detailed drawings and measurements which would allow you or your mechanic to fabricate and fit the fix.

Again, another really terrible bit of design. This really should not happen. but there again, who ever does the work should tighten up the bolts correctly no matter how difficult they are to get on.