August 28, 2005 --

Ben Swann -KFOX Morning News Anchor/Reporter

It can cost thousands to repair or replace an engine damaged by sludge. Our auto experts report that almost 5-million vehicles have engines that are prone to this problem and carmakers aren't always inclined to reimburse you if your engine is damaged.

Brian McNeilly drives a 1999 Volkswagen Passat. One day he lost oil pressure while he was driving.

Brian McNeilly-Passat Owner: "I've always been taught, shut the car off. So I shut the car off and got it to the dealership."

Brian was told sludge in the engine had caused the problem. Consumer Reports' Cliff Weathers says sludge can do real damage.

Cliff Weathers-Consumer Reports: "Sludge forms after long exposure to high heat, and after a while the oil oxidizes and breaks down and forms a thick, muddy-like substance that can block vital engine passages."

Engines that aren't properly maintained can develop sludge. But Consumer Reports says certain engines in vehicles from five different automakers appear more prone to the problem. The automakers are Audi, Chrysler, Saab, Toyota, and Volkswagen. And Consumer Reports says car owners should be aware, automakers have resisted covering repair costs.

Cliff Weathers-Consumer Reports: "Manufacturers were slow to offer the repair and replacement programs. Now all of them do, except for Chrysler. However, they put the burden of proof on the owner, so you have to keep a thorough accounting of your maintenance records."

And Brian learned even that may not be enough. When he first complained, his carmaker suggested the records he provided were for a different car because they listed his license plate number rather than the car's VIN number.

Consumer Reports says if you have an at-risk car, there are steps you can take to protect your engine. First, you can use synthetic oil. Synthetics don't break down easily, even under harsh conditions. Or go by the "extreme use" schedule in your owner's manual for oil changes. Finally, save all of your maintenance records, just in case. Consumer Reports says if your engine does develop sludge, be persistent with the dealer and the manufacturer.

Brian McNeilly-Passat Owner: "I probably had no less than 20 phone conversations with different people."

Ultimately the manufacturer paid for the necessary repairs to get Brian back on the road. One other note, Consumer Reports says while Chrysler does not currently offer a repair and replacement program for engine damaged by sludge, the automaker says it is handling sludge complaints on an individual basis.

For more helpful consumer information, visit *Consumer Reports on the web.

http://www.consumerreports.org/

*Consumer Reports is a fee based website. Many of the articles require a subscription.