[tks]

Hello, I am a new member to the forum. I have a 2005 VW Passat TDI with 93,000 miles. Just had the timing belt, tensioners, and water pump replaced by VW dealer. Got it home and noticed oil puddle on ground. Found drain plug was stripped. Problem not entirely dealers fault- some mine over the years. Used helix coil repair- still leaks because the drill was not aligned properly. Can I drill out to larger size and repeat helix coil repair or do I get a new oil pan?
tks

 

[Keithuk]

Welcome to the forum. welcometomyturbodies

Well there are some known Known fixes and bulletins for the Passat. They list 01-05 and 05> do you know the engine code?

The later 2.0 GTD TDI had a problem with the sump plug.

All models, 1999→.
Problem
Oil leak from engine oil sump drain plug after replacing engine oil.

Cause
Engine oil sump drain hole or drain plug thread damaged.

Remedy
Drain engine oil.
Thoroughly clean threads on engine oil sump drain hole and drain plug.
Check engine oil sump drain hole and drain plug thread for damage.
Replace component(s) as necessary. Tighten engine oil sump drain plug. Tightening torque: 50 Nm.

You could try and re-helix coil the thread, the problem is as your said getting thread tapped square.

 

[chittychittybangbang]

Take a look through this writeup on how to remove the oil pan - the writeup is for something else but it tells you how to do it.

http://www.myturbodiesel.com/1000q/b5/oil-pump-passat-tdi-replacement.htm

Long story short, you have to lower the subframe. Also, post moved to mk4 technical section.
welcometomyturbodies