And now, back to the reason my Golf has been up on jack stands for the last 10 days.
Actually, if I had just done the TB (it is just shy of 300k miles, so it seemed to be a good time) then I would have been done in 1 long day and the garage would have been clear. Mostly.
Instead, I decided that my wife's NB (see post #8261 above) became more critical and did that instead.
So I'm back to the original purpose. Also, since it has nearly 300k miles after all, I decided that maybe a new oil pump chain, tensioner, and front crank seal would be good, particularly since it had every appearance that it might be leaking oil.
I tried to remove the oil pan first of all. There is 1 bolt that was glued in place just a little too well (back there by the rear main seal), and there are only 2 ways to get it off at this point: 1) drop the transaxle so I can get a combination wrench on there, or 2) break the oil pan. Neither of these seemed like something I want to do. #1 is too labor intensive, and #2 is yet more $$, and if you read post #8261 above and figured out how much more I spent on the front end of Nubee than I had planned, then you'd figure that yet another c-note just didn't need to leave my wallet just now. Not to mention the fact that I might get sent out of town for the next 3 years and it would be difficult to find the extra week I'd need to go that direction (long story, don't ask).
So.
When I was stopped from dropping the pan I rationalized that maybe I could just get away with doing the tensioner and the chain would be OK. But I'd need some kind of access, so if I could get the oil seal out, then I could stick some kind of pointy thing (small screwdriver, pick, whatever) in and see if the oil pump chain was in fact worn and something would need to be done whether my wallet was too thin or not.
I don't know how many of you have ever tried to pull that oil seal without pulling the seal carrier first. It is <bleep>ing difficult. There is something about those thin bands around the outside of the seal. The seal will install with barely more than finger pressure, but pull it out? Yeah, right. You will end up learning new swear words even if you make them up yourself and it still won't come. So just pull out that carrier and then you can pound the crap out of that seal from the backside. While the manual says you have to drop the oil pan first, really you just need to remove the 4 oil pan bolts along the front edge of the oil pan, remove the other 6 bolts around the carrier, then you can pry the carrier out. Just slide it forward so you don't scrape or otherwise scratch or abuse the crankshaft at that band where the oil seal will ride, and you are good to go. (Yes, I'm assuming you already have gone through the headache of removing the toothed timing belt pulley on the crank, which is its own non-trivial task.)
Now you can refresh the seal and check the oil pump chain. Mine showed no wear at all. And the tensioner looks like it was installed new last year. Seriously, a tiny bit of wear, but another 300k miles will be a piece of cake at this wear rate. And in the end, the oil seal wasn't leaking. So I had to pat the oil pan and apologize for ever doubting my trusty Golf.
I also had to check the alternator pulley as it seemed to be seized, but when it wouldn't budge I rechecked and it is working OK after all. Strange.
Anyway, tomorrow I'll reinstall the crank TB pulley, mount up the brace across the hood, suspend the engine, and get on with finishing up this extended TB job. Definitely it will be the longest I have ever taken to do a TB job.
Cheers,
PH