2006 BRM head swap

[bustacrab]

Ok, so in another thread I posted a huge issue that I had and took the car to a dealer. Dealer basically tracked the problem down for me and wanted $6200 to replace the head. This is something I can do myself. I've rebuilt engines in the past. Just not a volkswagen engine.

So, My question is, If I am swapping the head because there is an issue with the head itself, Other than the obvious head gasket. What else do I need to make this head swap easy and as painless as possible? I have any tool needed at my disposal unless it's a VW special tool.

Does anyone know of a good write up with pictures for this as well?

Thank you in advance.

 

[CARTMATT]

You will need vw timing tools, and triple square sockets. Contact frank06 for parts, youll need to look at old gasket for him to send correct one. Why is old head bad? He may be able to fix.

 

[bustacrab]

The issue with the head is that on one or two cylinders, the injectors have warn their ports into an egg shape and are letting the compression drop because they aren't completely sealing into the port anymore.

 

[Ol'Rattler]

Call Frank Irving (Franko6) directly. No more needs to be said...................

 

[bustacrab]

Ok I'll give him a call today and see what he thinks.

 

[2bitthugs]

You will also need new TTY head bolts.

 

[texanTDI]

Add this failure to the BRM list. Wow, "egg shaped"? what else can go wrong with our cars? Another thing for me to worry about. Man I miss my 1998 ALH.

 

[nord]

Sometimes we worry and over-think. Just remember that for every problem described here there are many cars and owners that never experience these same issues.

For all we complain about dealers and their techs we also need to remember that they're the same. Many vehicles out there. Various issues, but probably not enough to generally cause much alarm at any particular dealer over any one thing.

And, of course, the general level of competence amongst techs who often can't describe exactly how a diesel differs from a gasoline engine. Or for that matter exactly how a gasoline engine works.

There's more of course. And that's why many here find it best to go to gentlemen who understand our diesels and have a reputation worth more to them than profit.

 

[CARTMATT]

Sometimes we worry and over-think. Just remember that for every problem described here there are many cars and owners that never experience these same issues.


Crazy how people act like your a small percent of a single known VW failure! I must have very bad luck! My car had failed cam, EGR, wiring harness, turbo actuator, air bag wires, alternator pulley, paint, bad ac, fan motor, trunk latch, at who knows what I forgot. On a car 6 years old with under 200k on it. So when DMF started to rattle, I got the hint! Most these issues arent if, but when! All happened from 150k up, so if traded off at 145k, would thought best car ever.

 

[runonbeer]

The issue with the head is that on one or two cylinders, the injectors have warn their ports into an egg shape and are letting the compression drop because they aren't completely sealing into the port anymore.

Sounds like a load of BS. A worn out cam will give low compression numbers. Take the cam out and post some pics for us.

 

[bustacrab]

Dude, working on getting the cam out right now. I have the car out at Jon's Auto here in Marysville. He's one of our Trusted TDI guys. The cam is smoked. One of my lifters has a hole in it.
I have a couple of pictures. I'll try to get them up ASAP. I'll have more after the cam is actually out.

What recourse if any do I have against the dealer? The ripped me off about $1,000.

Sounds like a load of BS. A worn out cam will give low compression numbers. Take the cam out and post some pics for us.

 

[nord]

One thing I can say... This bunch of keyboard cowboys here seem to be far ahead of the supposed dealer techs. Imagine that!

 

[runonbeer]

I bet you also have a MAF code.

PD cams are kind of a bummer but it really isn't a big deal to change. The parts are pretty inexpensive compared to what they were a few years ago before the aftermarket stepped in.

 

[runonbeer]

One thing I can say... This bunch of keyboard cowboys here seem to be far ahead of the supposed dealer techs. Imagine that!

I spend far more time with my hands on TDI engines than on a keyboard.

 

[nord]

Runonbeer... It wasn't intended as an insult. You along with many of us spend time at the keyboard. We first gain knowledge by working on these vehicles, then we willingly share it. After all, you could be the best TDI tech in the country, then walk away at 5 pm. But you don't!

I'd say a pretty high compliment when one considers what we share for no charge versus what many dealers charge huge sums of money for and still usually get it wrong.

Kudos to you and all the good folks who put professionalism ahead of a dollar.

 

[chudzikb]

I was at a car show in January and talking to the head of service for a VW dealrship, he described this very issue of the wearing of the sealing surfaces in the head by the injectors on a PD engine. I said, what? Now, I hear about it again? Glad it was not your issue, but, it has to be coming from someplace? Anyone else hear of this wearing of the sealing surfaces by the injectors? Service guy said it needs a new head then? I figure Franko6 could figure a fix?

 

[nord]

Logic would seem to dictate that either movement, erosion, or corrosion would be necessary here. Given that the injectors are supposedly held firmly in place and that the seals should never be directly exposed to corrosion, this leaves erosion as about the only option.

But then we're told of the injectors wearing their mounting holes into egg shaped patterns rather than round. This doesn't tend to agree with the erosion theory. This is more a function of physical movement it would seem.

Right now I'm of the opinion that this theory is largely a fantasy.

 

[aja8888]

I was at a car show in January and talking to the head of service for a VW dealrship, he described this very issue of the wearing of the sealing surfaces in the head by the injectors on a PD engine. I said, what? Now, I hear about it again? Glad it was not your issue, but, it has to be coming from someplace? Anyone else hear of this wearing of the sealing surfaces by the injectors? Service guy said it needs a new head then? I figure Franko6 could figure a fix?

Most heads of service at VW dealers, if they are of any value, leave and start their own shops.

 

[runonbeer]

Runonbeer... It wasn't intended as an insult. You along with many of us spend time at the keyboard. We first gain knowledge by working on these vehicles, then we willingly share it. After all, you could be the best TDI tech in the country, then walk away at 5 pm. But you don't!

I'd say a pretty high compliment when one considers what we share for no charge versus what many dealers charge huge sums of money for and still usually get it wrong.

Kudos to you and all the good folks who put professionalism ahead of a dollar.

Thanks!

 

[runonbeer]

I was at a car show in January and talking to the head of service for a VW dealrship, he described this very issue of the wearing of the sealing surfaces in the head by the injectors on a PD engine. I said, what? Now, I hear about it again? Glad it was not your issue, but, it has to be coming from someplace? Anyone else hear of this wearing of the sealing surfaces by the injectors? Service guy said it needs a new head then? I figure Franko6 could figure a fix?

If the cam they're installing right now doesn't fix the compression problem that we are discussing here then I'll eat my hat.

 

[bustacrab]

First, Jon is certain this will fix it. I am as well. I know a lot about engines. Including rebuilds from the block up. But, I've never worked on a TDI before. Mostly GM, Ford and Jap crap. So, from what he showed me, the cam and lifters are definitely smoked. How do you post pics on here? I have a great one of the lifter with a hole in it.

 

[chudzikb]

If the cam they're installing right now doesn't fix the compression problem that we are discussing here then I'll eat my hat.

I never said I believed him! Actually, I questioned what he was saying to the point of annoying the guy! Imagine that, me annoying some service manager, that made for a very good night...

 

[luke05]

Check the rocker arms too that run the injectors. Mine where broke in my car.

 

[runonbeer]

Check the rocker arms too that run the injectors. Mine where broke in my car.

Yes you always want to check the little plugs in the ends of the rockers. Sometimes they walk out. I put a little peen on the edge of the bore.

 

[jjblbi]

As to the idea of the injector port being worn to an oval: I recently replaced my injector o-rings and seals and definitely saw the finish of the injector worn off the injector. On the side opposite the hold down wedge the dark grey coating was worn through and the injector was shiny. It was the same on all injectorsand almost exactly 180 degrees opposite the bolted side. Given the injectors are much harder than the aluminum head it is easy to believe the port could oval especially if the injector is a little loose.

 

[aja8888]

If the injector was "a little loose" you would have no compression (or very little) and a loud hiss, or a big mess on your hands. Injectors must be held very tight in the head to perform properly.

 

[bustacrab]

Does anyone know a way to file a complaint against the dealership?

 

[bustacrab]

I just wanted to close out this thread and say thank you to those of you that actually contributed something useful. The issue was the cam and lifters. John Hamilton from John's Auto Care here in Marysville, Ohio did all of the work post dealership. He is a fantastic guy who knows his TDI's inside and out. He installed a BEW cam with new lifters, did the timimng belt and water pump, and did all the seals. I got out the door at his place for just over $2k. I would suggest him to anyone who needs a specialized mechanic for an issue with their TDI.