In the thick of teardown

[Durt D1ver]

Well, I have a coolant leak. It's either the valley pan, or the headgasket. So, time to tear it down. Last night I got the plenum, and the DS rocker cover off. I Hate SAI. Removing those pipes from the head is a major PIA. And then removing the plenum because of the SAI Bracket and heater pipe being on the stud in the plenum didn't help either, but I finally wrested it off.

Now to my question: Is any oil in the intakes normal?


On the other hand, the rockers look relatively clean, no sludge or buildups. I've run mobil1 TDI since 23k when I bought the truck, It's just shy of 50k now.

 

[jeffro0502]

Yes a some oil would be normal. But what sucks is you having to do this at 50K, hope this solves your problem.

 

[jymmiejamz]

The pipe are easier to get off if you remove one of the exhaust manifold studs so that you can put a wrench on the part that is threaded into the head. I think it is an 18 mm, and the SAI pipes are 27mm.

To get the studs out of the plenum use a flat punch/chisel and fuck up the threads on it so the nut will remove the stud. Then replace them with 6mm bolts when you put it back together.

 

[adriatic04]

help me clarify, oil and coolant can leak from the valley gasket, correct?

 

[OFFROVER]

That is correct.

 

[adriatic04]

and where does it usually show signs, rear? I wish I could determine if my intake is leaking, hard to spot.

 

[OFFROVER]

Usually runs down the back and around the bell housing.

 

[Durt D1ver]

Well, the good news is it wasn't the valley pan.
Bad news is: Headgasket.

 

[adriatic04]

how difficult is doing just the valley? what is the potential to really screw something up? I think mine is leaking from the valley.

 

[pdogg]

I got down to just before the valley last spring when mine was hemorrhaging fluid. It turned out to be the heater core pipe, where it enters the upper manifold. There's quite a few bits to come off before you get that far, but nothing especially difficult... take your time, take photos as you go so yo can remember when stuff goes.

So now mine is weeping again at the rear on both sides and I'm hoping it's just the lower intake manifold (valley)... I already have the gaskets..

 

[Durt D1ver]

Passenger side head off.

Is it OK to reuse the SAI adapters? Also, I hate the stupid corrugated plastic sai tubing, It broke like a waterboarded taliban.

 

[Cozy41EF]

I did the valley gasket last spring, was leaking both sides rear. Was about 6 hours to get it apart and clean, 4 hours to go back together. I used a gasket kit from AB, very complete, great quality.

 

[Durt D1ver]

Got both heads off. Now just waiting for some funds to clear in paypal, so I can send it to Will T. Heads will be going to the machine shop in the morning. Pulling it off, it's obvious where the HG was leaking. Now just to get all the parts, and button it back up.


Drivers side:

 

[Dallas]

Good post and thanks for the pics, how many hours have you got into the head removal?

 

[Durt D1ver]

It took me probably about 8-10 hours just to get the heads off. Without the SAI Issues, probably under 6 hours. I took my time, and was searching dweb whenever I got stuck for suggestions. It's nice having my laptop w/rave in the garage.

 

[adriatic04]

so the valley gasket alone is probably half the time already? I am thinking I need to tackle the valley, I have a small fear of going for the heads with my limited prior knowledge and skill set.

The bulk of my "soaking" is on the tranny bellhousing. Guessing the valley is the culprit, the leak/soak seems to be fairly light.

 

[Durt D1ver]

so the valley gasket alone is probably half the time already? I am thinking I need to tackle the valley, I have a small fear of going for the heads with my limited prior knowledge and skill set.

The bulk of my "soaking" is on the tranny bellhousing. Guessing the valley is the culprit, the leak/soak seems to be fairly light.

Getting to the valley pan is like like 85% of the job.