I had a terrible experience during last months' service of my Polo TDI.
I gave it for the routine annual service at EVM Passenger Cars, Trivandrum on 30th August for 6th annual service. The car did not have any issues and it was just supposed to be a routine annual service. All services of the car had been done to date at EVM Trivandrum dealership.The car is driven absolutely very well without any underbody or external damage.
The service advisor (SA1) attended my car at 9:15 and took notes for the regular service. I left the service centre by 9:40. At around 10:30 SA1 calls me and says that the oil sump drain thread is loose and the newly added oil is leaking. He said that the thread of the oil sump drain may not be fitting with the new drain plug. I was very surprised since the vehicle is in top condition and there is no oil leak ever observed.
I asked specifically how the oil sump drain plug can leak. He first said it is a 2012 “old” model and the new plug may not be fitting properly. I asked him to check with the older oil plug and he said that too was leaking. I told him that I cannot understand how a perfectly sealed oil sump drain plug suddenly became loose.
He then stated that this is a wear and tear issue. I firmly stated that this is not a wear and tear or running repair issue. The drain bolt would have been opened 6 times by EVM Trivandrum dealership mechanics in the last 6 years. How can screwing/unscrewing the oil drain bolt 6 times cause a thread damage in the oil sump ?
He did not give a clear answer on how this damage to thread is possible. He then tried to tell me that its an aluminium engine block and this happens! I can't believe he is telling such a absurd justification. Aluminium engine blocks are used in all cars and the only way a damage is possible is by human negligence. I am sure Volkswagen does not build shoddy engine blocks.
I told him that it is very evident that such damage is possible only by a cross thread or higher torque applied while tightening the bolt. This is clearly due to a novice mechanic causing damage by incorrect tool usage.
I asked him for the solution. He told that only option to fix is to replace the oil sump. That is a cost of nearly 18,000/-

I said I will not be bearing any cost to fix something broken by the dealer. I asked him to check if this can be replaced by goodwill or any other means. He said he will get back to me.
SA1 called me later in the evening asking if they can fix it by taking it to a lathe!! I said Absolutely not. I am not going to allow any kind of shoddy temporary work on my car and that too outside the workshop on an engine part. He said he will get back to me.
I got a call the next day morning from another SA - SA2. He started telling me that I had given my car for service the day before and there is a problem with the oil sump and that has to be replaced. He went on to state that the car has had body work repair done due to multiple accident damages and there were underbody damages due to accidents. He stated that the leak was possibly due to the accident damages !
I had the shock of my life since my car has never ever had an accident (touch wood). There are only very minor paint scratches (not even visible) and the car has always been driven really very well. I asked him to double confirm the vehicle registration number. He replied that he checked and it was correct. I said I am absolutely sure there is never a body work done. He said he will get back to me in 5 minutes.
I along with a friend went directly to EVM Trivandrum service centre and I demanded that the car be raised on the fork lift to see what the damage is.There was absolutely no damage in any part of the under body. Attached is the picture of the oil leak at the bolt. You can see there is not even a scratch around.
SA2 said that he made a mistake and mixed up the papers from another car !! He was joined by the Service Manager - SM who also said that it was their mistake. He confirmed that my car never had any accidental damage and they mixed up. I spent 2hrs of my working time due to oversight by two senior staff of EVM?
I am absolutely horrified that EVM Trivandrum tried to pass it on to me as an accidental repair. It is a clear foul play. If it was some other customer, they would have believed this absurd story.
SM told me that they will fix it. He said the normal process is for taking it to a lathe and drilling the thread again. I said I am not sure how long that will last. He assured that such a process will be leak free and he would guarantee that. I said I do not believe that taking it to the lathe and fixing is a standard approved process by Volkswagen. He said it is. I told him and SA2 that I can accept any fix as long as it has the approval of Volkswagen.
There was no calls from the dealer for a couple of days. In the meantime I checked with my friends at other dealerships and they confirmed that this damage is possible mostly by cross threading. They assured me that fixing the thread is quite normal.
After couple of days SA1 calls me again and said that they will fix it by correcting the thread. This essentially meant that they will remove the oil sump, take it to a lathe, correct the thread and remount by applying the sealant. The CRM sent me an email beating around the bush stating they ordered parts and will fix as per VW norms

and they will take care of any related issues. I replied stating my understanding of their fix and that they would be responsible for future issues around the oil drain plug.
Finally got my car back after a week and feeling quite jittery ever since with the thought my car in a pool of oil

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I did not get the service invoice until a couple of weeks of follow up. They had to find a way to work around the bill amount pertaining to the fix (sealant, lathe and labor). I also had to persist to get a remark added to the job card about this thread correction.
