Hello all! First TDI owner!

[325_Guy]

Man, this has been such a humbling and learning experience lol.

I hope you don't get discouraged. Those head bolts bite the best of us. I've done more than a few BRM camshaft changes and the last one I did I pulled four head bolts before I realized my error. Thankfully it was on my own car! New head bolts and I was back on the road.

As for the vendors you listed, any of those three are solid. Especially for ID Parts and Cascade German, they both contribute a lot to the TDI community so I view my own purchases from those folks as giving back in a way.

FCP Euro offers lifetime part replacement which extends to consumables, which if you're going to keep your TDI for a long time may pay you back as well.

 

[bc1550]

What are you guys' favorite websites to buy parts from?

I know of these:

IDParts
FCPEuro
Cascade German

I like Cascade German because they are fairly local to me and they have given me great service. I also like FCP because their prices are pretty good, and they give a lifetime warranty on nearly every single thing they sell (which is why I got my BRM camshaft from them).

While you're replacing the head gasket, you might want to change the coolant flange and tandem pump gasket too.

 

[novusB]

I like Cascade German because they are fairly local to me and they have given me great service. I also like FCP because their prices are pretty good, and they give a lifetime warranty on nearly every single thing they sell (which is why I got my BRM camshaft from them).

While you're replacing the head gasket, you might want to change the coolant flange and tandem pump gasket too.

I'm trying to find a new head gasket to buy, on cascade I have 3 options to choose from and I have no idea how to choose.

https://www.cascadegerman.com/product/038103383brm/


1-Hole(038103383BL/DE)
2-Hole(038103383BM/DF)
3-Hole(038103383DG)

*EDIT*

I found on some images, that the physical gasket itself will have either 1, 2, or 3 punched holes in the gasket indicating gasket thickness. I guess I'll have to remove my old gasket first and see what thickness is currently on there before ordering a new one.

 

[Rx7145]

I'm trying to find a new head gasket to buy, on cascade I have 3 options to choose from and I have no idea how to choose.

https://www.cascadegerman.com/product/038103383brm/


1-Hole(038103383BL/DE)
2-Hole(038103383BM/DF)
3-Hole(038103383DG)

*EDIT*

I found on some images, that the physical gasket itself will have either 1, 2, or 3 punched holes in the gasket indicating gasket thickness. I guess I'll have to remove my old gasket first and see what thickness is currently on there before ordering a new one.

you should be able to see the holes with the gasket installed.

 

[novusB]

I am going to ASSUME this is a 1-hole gasket, but I cannot tell. Also, 200k miles and I don't think this head gasket has ever been replaced LMAO!

Would anyone mind taking a second look and confirming how many hole gasket this is?

https://drive.google.com/file/d/1KGMJX-G5XgRpLuGUhKcvNHo9gAF7FSMJ/view?usp=sharing

https://drive.google.com/file/d/1CWeOSazvYaZsDoa-IqmnnW3fE5nfDbcB/view?usp=sharing

Thank you!

 

[Rx7145]

Looks like a three hole to me.

 

[turbodieseldyke]

The holes should be round. The 3 holes you're seeing are cylindrical. Mine has those same 3 cylindrical holes plus 2 rounds ones to the right, which makes mine a 2-hole.

novus, you need to clean that area off and get a better look. Old toothbrush, brake cleaner, anything.

 

[novusB]

The holes should be round. The 3 holes you're seeing seem to be cylindrical. Mine has those same 3 cylindrical holes plus 2 rounds ones to the right.

novus, you need to clean that area off and get a better look. Old toothbrush, brake cleaner, anything.

Roger, let me go grab some from the shed and try to clean the area. I see one round hole to the right, but yeah should clean to verify.

 

[novusB]

If you had guessed it was a 2 hole you'd be absolutely right. LMAO

Thank you so much for the recommendation turbo, I didn't want to spray anything like that onto my engine, but brake cleaner does evaporate lol

https://drive.google.com/file/d/10vmXEElAagMuQ_4CoZaFjwoGCvNwsOP3/view?usp=sharing

 

[novusB]

I finally got my camshaft out and my hydraulic lifters out as well.

Because of my novice mistake I now need to remove my head and replace my head bolts and head gasket.

Do I need to take off my tandem pump to do so? I also need to what, remove my exhaust header bolts, do I need to take my turbo off of the head as well? I bought some permatex optimum max temp gasket maker, is this what I should be putting on my head gasket when it's installed? I have never replaced a head gasket before and don't know exactly what I need. I have a new 2 hole gasket(same as my old gasket) and some new head bolts.

https://drive.google.com/file/d/1V0k-U8pd-1aMfkNhVHlCaL-OnRTa5iv8/view?usp=sharing
https://drive.google.com/file/d/1i1hcren-YRCi989OQ94fvcqtmC-mCO0U/view?usp=sharing
https://drive.google.com/file/d/1CAKCFULxL6Fcv8SRtCJfws_gAK5s0KSO/view?usp=sharing
https://drive.google.com/file/d/1tu7DjOjGl9QZy0JLcjJ2hfUxbdkf2jS1/view?usp=sharing
https://drive.google.com/file/d/1axIiaVr2ncP6LTcT1JCqavWR77PbxW2k/view?usp=sharing
https://drive.google.com/file/d/1Yhv4VxJkHLIBD2DBggrUPJis3WLYZxnp/view?usp=sharing
https://drive.google.com/file/d/1F-_nWTprYNW1Zum1rwMXYL6dWd_hVHaM/view?usp=sharing
https://drive.google.com/file/d/1yeME2SLyhPKcQdJqZfkHUZ65B-3pUd2K/view?usp=sharing
https://drive.google.com/file/d/1K-yHH63klJVaGhPRfakGDf2CaFOOqpTv/view?usp=sharing
https://drive.google.com/file/d/1PdQkERE7mtdUK5YVTyzup_yvGGKWdvRv/view?usp=sharing
https://drive.google.com/file/d/1jKT34FJ6K9gUSjt4ijyFIYegnOXLmcSP/view?usp=sharing
https://drive.google.com/file/d/1U7I22wfxdb8UzoP0Udf9Cul9IiPcQEmV/view?usp=sharing
https://drive.google.com/file/d/1d3n3AxSTgGKgbW7-BPJ7HyNB5PrHyXtk/view?usp=sharing

 

[turbodieseldyke]

Do I need to take off my tandem pump to do so?

Nope

remove my exhaust header bolts, do I need to take my turbo off of the head as well?

Probably

I bought some permatex optimum max temp gasket maker, is this what I should be putting on my head gasket when it's installed?

Absolutely not

 

[novusB]

Absolutely not

What do I need to put on my new head gasket?

 

[turbodieseldyke]

What do I need to put on my new head gasket?

A clean surface on the block and head. That's it.

 

[crockit]

Cant insert a pic I have a 2 hole head gasket? between ij pump and head the gasket sticks out 2 round holes on the left and 1 oval hole on the right. I think I'm right , broke intake lifter on #3 , cam rolled around pieces long enough to gouge out enough aluminum so the head has to come off and repaired/replaced with a new head , Any good places to get a head and gasket with bolts I have a 03 Jetta wagon 1.9 TDI ALH with 637+ k . or should I just put her out to pasture or put old Yeller down for good ! HAA I insert a pic on my profile pic perfect !

 

[bigsexyTDI]

Is there something I am missing on the head gasket replacement? I get that he goofed and pulled the head bolts, and that took the tension off, but he didn't pull the head, so the mating isn't compromised... why not just put the new bolts in and send it?

 

[crockit]

I finally got my camshaft out and my hydraulic lifters out as well.

Because of my novice mistake I now need to remove my head and replace my head bolts and head gasket.

Do I need to take off my tandem pump to do so? I also need to what, remove my exhaust header bolts, do I need to take my turbo off of the head as well? I bought some permatex optimum max temp gasket maker, is this what I should be putting on my head gasket when it's installed? I have never replaced a head gasket before and don't know exactly what I need. I have a new 2 hole gasket(same as my old gasket) and some new head bolts.

https://drive.google.com/file/d/1V0k-U8pd-1aMfkNhVHlCaL-OnRTa5iv8/view?usp=sharing
https://drive.google.com/file/d/1i1hcren-YRCi989OQ94fvcqtmC-mCO0U/view?usp=sharing
https://drive.google.com/file/d/1CAKCFULxL6Fcv8SRtCJfws_gAK5s0KSO/view?usp=sharing
https://drive.google.com/file/d/1tu7DjOjGl9QZy0JLcjJ2hfUxbdkf2jS1/view?usp=sharing
https://drive.google.com/file/d/1axIiaVr2ncP6LTcT1JCqavWR77PbxW2k/view?usp=sharing
https://drive.google.com/file/d/1Yhv4VxJkHLIBD2DBggrUPJis3WLYZxnp/view?usp=sharing
https://drive.google.com/file/d/1F-_nWTprYNW1Zum1rwMXYL6dWd_hVHaM/view?usp=sharing
https://drive.google.com/file/d/1yeME2SLyhPKcQdJqZfkHUZ65B-3pUd2K/view?usp=sharing
https://drive.google.com/file/d/1K-yHH63klJVaGhPRfakGDf2CaFOOqpTv/view?usp=sharing
https://drive.google.com/file/d/1PdQkERE7mtdUK5YVTyzup_yvGGKWdvRv/view?usp=sharing
https://drive.google.com/file/d/1jKT34FJ6K9gUSjt4ijyFIYegnOXLmcSP/view?usp=sharing
https://drive.google.com/file/d/1U7I22wfxdb8UzoP0Udf9Cul9IiPcQEmV/view?usp=sharing
https://drive.google.com/file/d/1d3n3AxSTgGKgbW7-BPJ7HyNB5PrHyXtk/view?usp=sharing

DO YOU NEED a new camshaft bearings and lifter kit I was sold the wrong kit and now can't get DHL to pick it up and send it back

 

[turbodieseldyke]

Is there something I am missing on the head gasket replacement? I get that he goofed and pulled the head bolts, and that took the tension off, but he didn't pull the head, so the mating isn't compromised... why not just put the new bolts in and send it?

The gasket is compromised when you loosen the head bolts. You can get away with it if you pull 1 or 2 bolts, but not all 10.

 

[novusB]

The gasket is compromised when you loosen the head bolts. You can get away with it if you pull 1 or 2 bolts, but not all 10.

Well I initially only loosened 2....... knowing this I wouldn't have removed all of the others......... FFFFMMMMLLLLL

Is there something I am missing on the head gasket replacement? I get that he goofed and pulled the head bolts, and that took the tension off, but he didn't pull the head, so the mating isn't compromised... why not just put the new bolts in and send it?

I also heard that if you pull the head off of the block, there could be some warping on the head surface? I'm not too sure how true this is either.

 

[novusB]

DO YOU NEED a new camshaft bearings and lifter kit I was sold the wrong kit and now can't get DHL to pick it up and send it back

Yep, you need to replace everything, especially since you're already in there to replace your cam. The hydraulic lifters are what go back, usually on the exhaust side of the valves.

 

[Rx7145]

Make sure and blow out the oil and coolant from the head bolt holes before installing them.

 

[novusB]

Apparently I can take my entire head to O reillys and they'll disassemble it and clean it and reassemble it. I'm thinking about doing it, I'm already this deep into all of this lol

 

[turbodieseldyke]

I also heard that if you pull the head off of the block, there could be some warping on the head surface?

It could be warped if it overheated, but the simple act of lifting it up doesn't make them warp.

Apparently I can take my entire head to O reillys and they'll disassemble it and clean it and reassemble it.

Are Jiffy Loob and Firestone too busy to do the job?

Seriously, if Oreilly is doing it themselves, and not farming the job to a machine shop (and marking up the price), they will screw it up. I wouldn't trust a random machine shop with it either. You should describe your problems to Franko6 & ask him if he thinks your head needs to be refreshed.

 

[novusB]

It could be warped if it overheated, but the simple act of lifting it up doesn't make them warp.

Ah okay, I just had to reorder a EGR cooler block off kit. I received one when I bought my EGR delete, and lost it. FML. Figured since I have to pull my head off and my turbo, mine as well finish my EGR delete lol.

 

[325_Guy]

Apparently I can take my entire head to O reillys and they'll disassemble it and clean it and reassemble it. I'm thinking about doing it, I'm already this deep into all of this lol

I strongly suggest not doing that.

 

[crockit]

Can any one give the torque sequence and ft/ lbs for this 1.9 TDI ALH

 

[turbodieseldyke]

Can any one give the torque sequence and ft/ lbs for this 1.9 TDI ALH

The engine we're discussing here is a BRM, very different from yours.

 

[novusB]

I strongly suggest not doing that.

What is your reasoning for not having the heads cleaned? I've talked to 2 other people and they were strongly for doing this.

 

[novusB]

I'm stuck at a crossroad again.

Man, if I would've known this would be such a pain, I definitely would've sold this car lol.

While I have the cam removed, I am trying to finish my initial project of finishing my EGR cooler delete. I finally got some hose clamp pliers and was able to remove the coolant lines to the EGR cooler, I bought a 30mm socket for the axle nut to remove the cv shaft and come to find out the 30mm is way too big. Does anyone know if the cv shaft axle nut is a 27/28mm?

I also need to purchase a socket for the turbo drain return line(i believe that's what it is) to remove the bottom bolt that is holding the EGR cooler in place, does anyone know what the size is either?

Thank you!

 

[AverageAndy]

Does anyone know if the cv shaft axle nut is a 27/28mm?

24mm 12pt

Front Axle Bolt (A5)(Mk6)(Mk7)(NMS) WHT005437 40112 | IDParts.com - Diesel Parts

 

[turbodieseldyke]

30mm is for mk3 and mk4. Mk5 axles use 12pt 24mm or 6pt 27mm. The turbo drain i think is 27mm. You can leave the cooler in place, with the hoses bypassing it, right? If that bolt is the same as the CJAA, the bolt head is too short to get a good grip with a crescent wrench. Stupid.

I understand wanting to just strip it out though. Whoever deleted mine before i bought it, just left the cooler hanging in there with zip ties or i-dunno-what.