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Hello from Kansas! I am working on a 2001 GLS. Well my son and daughter-in-law have had this beetle sitting in the grass for almost 2 years because the oil pressure light comes on. My son took off the pan and cleaned things up but after a few miles the light came back on so it has been sitting.

My wife suggested I fix it to help them out, so here I am. Most cars I have had oil pressure issues with are just the opposite, they are good when the engine is cold, but as it warms up the light starts coming on at idle. This car starts and drives fine for a few miles then the light comes on with the RPM's up, but if you bring the RPM's down the light goes out. Unless the pressure system on this car expects different pressure at various RPM's that makes no sense. Most cars have a dangerous PSI in mind when the light comes on, and increasing the RPM's will get you over that threshold and put the light out.

I noticed a strong chemical smell from the oil, which I suspect is some sort of flush my son used in the oil before he took it apart. I drained the oil and could see black sludge come out in the clean oil as it drained. I removed the pan,the pick up tube, and the plastic cover. Everything looked pretty clean. The pick up tube was clean from end to screen. The oil pan has tons of black sludge particles floating around in it, but it is clean. I pulled the oil pump expecting the passages to be clogged, but it also was clear. What I did find that I do not like is damage to the oil pump gears. I assume the groove is not supposed to be there, and that the rough end on the tooth is supposed to be smooth.

My question is what caused it? Did something fail internally in the pump or engine. Is it damage due to the previous severe clogging? Any ideas?
 

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Is this a 2.0 or 1.8 VW Beetle? If there was sludge in the pan then the improper oil was probably used. Only use VW approved synthetic oil in the Beetle since they did have issues with sludge build up.
Castrol Edge 5W40 is what VW puts into the Beetle if you take it there for an oil change. Other VW approved oils are Mobile One 0W40 and Castrol Edge 0W30. Once sludge is in there it is very difficult to remove.
Not sure what would have caused the oil pump to fail but it seems that is the reason the Oil pressure light comes on.

Here is an oil pump for the 2.0 liter engine:
Volkswagen New Beetle 2.0 > Search > Oil Pump > ES#1876862 Oil Pump - 06A115105B

Here are pumps for the 1.8
OEM / Performance Parts for Audi, BMW, Mercedes Benz, Mini, Porsche & Volkswagen - ECS Tuning

Might as well pick up an new Oil pick up tube while you are at it.

The gears inside should look like this:






Good luck.
 

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Replace the oil pickup. It's only about $20. If you look at it closely you will likely see it is restricted with what appears to be carbon particles. This is a COMMON problem with the 1.8t, basically coking/cooking the oil.

If you think the oil pump needs to be replaced, good time to do this as well.

There will likely be some deposits in the oil pan, but not heavy sludge like you would expect.



You may also need to replace the oil pressure switch as well.

May want to run some AutoRX through the motor once you get is back together.

Then make sure your thermostat is working and plan on a timing belt & water pump replacement before you think you are in the clear.
 

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Thanks for the info. It is a 1.8 Turbo. I need to ask my son what oil he had in it. Whatever cleaner he put in it seemed to have broke lose tons of sludge. I will make sure to put the correct oil in it if a new pump does it.

CB
 

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New oil pump installed and no leaks or oil light on after 6 miles!!! I took the old pump apart and it sure looks like something went through it. Thanks for your inputs!
 
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