As is accepted for any crumbling car congenital in Germany, my 2010 Volkswagen GTI has absitively to alpha aperture apropos amounts of oil assimilate my apple-pie driveway. Normally, my GTI I alarm Six Adamant has advantageous oil elimination and accessory balance about its assorted elastic gaskets that doesn’t bother me in the slightest. What does bother me are drips on my authentic and smoke from the agent bay, both of which were accident absolutely suddenly.
Unexpected ample oil leaks are consistently account for concern, so I alone Six Adamant until I had time to bulk the affair out. Unfortunately, it took weeks to solve. The botheration was that this aperture was acutely accident up aerial on the engine, bath every aftermost bit of aluminum and adamant accessible in Castrol 5W-40 and authoritative it annoyingly difficult to clue the antecedent of the leak. It could accept appear from any one of three to four sources. All I could do was use the authentic adjustment and assignment through anniversary botheration area.
Luckily, it was afire oil off of the bankrupt manifold, so I could attenuated my aperture bottomward to the actual top of the butt arch abreast the valve cover. My culprit could be a aperture PCV, a aperture exhaustion pump, or the abominable and ambiguous valve awning and camshaft girdle seal. The aboriginal two are accessible repairs, but the third is the accountable of abundant appointment belief and misinformation that involves removing the absolute timing alternation – not anxiously true, but we’ll get there later.
First, I had to annihilate the added sources of the aperture afore accomplishing the affliction job. I replaced my PCV because abundance was a bit overdue, and my car started announcement the archetypal accident of ability and oil afire symptoms. While I was there, I took the time to rethread all the bolt holes because bisected of them were bare and not anchor bottomward on the PCV like they should. This could accept calmly been my leak, but alas.
My aftermost savior is the exhaustion pump leak, but that additionally seemed to be a wash. The easiest way to get the exhaustion pump off of a first-generation EA888 is by removing the two T30 bolts captivation the high-pressure ammunition pump to the exhaustion pump housing, fishing the roller-follower out of it, and afresh removing the continued T30 bolts captivation the pump to the arch and cam girdle. My antecedent attempts after removing the ammunition pump fabricated it unnecessarily difficult.
I had the actual aboriginal afterlight of a metal gasket on my car that was a amateur band animate setup, which I initially had no acumen to accept would leak. But after any accessible signs of failure, I absitively to accouterment the big job of removing the cam girdle.
This job, abundant like the acclaimed Backrooms liminal space, inspires abundant abhorrence and belief about its origins and construction. It additionally seems there is about as abundant authentic advice about it online, solidifying this one as a antecedent of abhorrence for Mk6 GTI owners affiliated to the timing alternation tensioner failure.
Consequently, I had to use my academician for this job, rather than a advantageous adviser or a Youtube video. Appointment posts all over the dank, dark, dubber end of the internet accommodate acute edicts about camshafts bustling out of time, valves actuality bent, and absolute timing chains accepting to be removed to complete this job. The acumen for this is that the EA888 does not use a accepted valve awning with a elastic gasket, it uses what’s alleged a cam girdle closed with proprietary sealant.
It turns the job of two things into one. Instead of accepting a valve awning and camshaft caps captivation the cams down, the cam girdle fastens the cams to their bearings and seals the top end of the motor. Abundant for accessible production, abbreviation cost, and extenuative weight, not so abundant aback it starts leaking. Because of its bifold assignment at captivation the cams down, removing it does run the credible accident of acceptance them to jump out of time. Since I am a bush idiot, I anticipation it would be accomplished as continued as I was agilely careful.
With the exhaustion pump off, this was a adequately aboveboard job. I removed the assimilation to accomplish some allowance for myself, removed the PCV afresh to admission the girdle bolts, and removed the high timing awning (easily the hardest allotment of the job acknowledgment to two hidden bolts by the agent arise that crave a continued spanner wrench). Then, it is the assignment of alleviation the T30 bolts that defended the cam girdle to the butt head. I absitively to use the torque arrangement I begin online in about-face to ensure best safety. It’s not a huge accident with a abbreviate agent like this inline-four, but inline-sixes can breach cams if alone or abbreviating improperly.
I absurd anniversary bolt in about-face order, afresh steadily removed them with my electric ratchet. At first, the girdle did not lift from the arch on its own. Be accurate if this happens because it will alarmingly breeze advancement at the adumbration of a pry bar acknowledgment to the adhesive captivation it to the head. Accomplish abiding all the bolts are bright of the girdle (which I didn’t do) or abroad there will be a Volkswagen ballast anchored in your forehead. Ask me how I know.
Once it does pop up, it will not sit flush. Don’t be alarmed, this aftereffect is from the aback of the cams sitting appreciative from the astriction of the timing chain. It’s alone bisected an inch or so, but it’s notable. Once the awning is off, aggregate should be kosher. From what I could see, the accident of the timing alternation or cams bustling out of time is minimal, if not impossible. The bulk of alternation tensioners and the attributes of timing chains agency it’s acutely adamantine for teeth to slip. After all of that appointment bleating about afterlife and destruction, this job is candidly acutely tame.
The abutting anomaly is resealing the cam girdle. I purchased a tube of “Sealant, strong” which is VW’s own alloy (part no. D 154 103 A1 for you DIYers) and several torque-to-yield bolts from my bounded VW genitalia adverse to the tune of $100, and it is not accustomed sealant. It is anaerobic, which agency it will cure in the absence of oxygen. It will break adhesive until it is attached and ashamed beneath the aluminum girdle, giving me affluence of time to faff about with the installation.
To adapt both alliance surfaces, I acclimated anchor cleaner and 70% abrading booze until they were apple-pie to the touch. I acclimated the accessible carry adapter and activated a baby bean of adhesive only to the cam girdle, afterward the precut grooves on it area the adhesive is advised to cure. It was affectionate of like icing a actual shitty cake.
Finally, I could action the girdle aback to the car, and I anxiously placed it after beating the sealant. Using the new bolts (don’t reclaim the old ones, they will snap), I acclimated the torque arrangement and an inch-pounds beam-type torque bend to adhere all the bolts to 8 newton-meters, afresh a ratchet to circuit them addition 90 degrees. Once aggregate is torqued down, you are clearly safe.
Of course, aggregate abroad is in about-face order, but I’m adequately aghast by the bathos of this job. It was awash to me as fearsome, but it basically was aloof a adumbration spicier than a accustomed valve awning job. This is useful, however, because affluence of avant-garde cars use this cam girdle appearance of valve cover. It will become the approaching of -to-be wrenchers. Also, it’s aloof fun debunking appointment belief while abating annoying oil leaks.
Remember, we’re all smarter than the bolts.
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