Today was a bad day.

[NO_H2O]

You might have to get the head bolts from VW if Impex dosn't have them. VW uses lots of stretch bolts (the green ones). I got my bolt drivers (triple-square) from NAPA when I did the TDI.
Be sure to replace the stretch bolts. I have seen some nasty pix of boken stretch bolt aftermath on the TDI forum (mostly from the reused engine mount bolts breaking while driving).

[yetibone]

VERDICT:

All eight exhaust valves bent, $448, three intake valves in No. 1 cylinder bent, $78, hell knows what the guides look like piston crowns are OK.

I determined that replacing the valves myself is outside of the limits of the tools at my disposal, and I would rather do it once, do it right, and NEVER have to do it again (to this car, anyways), so the head went to the machine shop this afternoon.

[ShApE]

sorry man that sucks, but hey, u learned a good lesson even though what u went through was total crap. hopefully everything turns out ok.

[yetibone]

...Yeah, I learned a lesson,

Don't trust the man at the parts counter


I'll be celebrating Memorial Day putting it back together instead of seeing Rush play in Charlotte.

[zen]

let me know how the show is. they are hitting ATL 8/1. really looking forward to it again.

[yetibone]

Originally Posted by yetibone

...I'll be celebrating Memorial Day putting it back together instead of seeing Rush play in Charlotte.

...I would if I could, but I can't, so... I won't.

[yetibone]

UPDATE: Got the Passat back together and running. worked late last night to do everything but the final torque steps on the head. One of the exhaust manifold to turbo bolts kept galling up threads, so I had to take the manifold back off, and chase threads into the turbo exhaust inlet. Installing the timing belt with the *NEW AND IMPROVED* tensioner was tough. The belt was just long enough to fit. Had to get the last two head bolts, and some Mobil 1 this morning to finish the job.

The engine sounded like a pea thrasher until the tappets pumped up. I let it idle fast for 5 minutes or so with plain water in the cooling system to flush any gasket funk away, and to observer the belt, tensioner, and pulleys for problems. after getting up to temp, the valve noise went away .

D&F'ed the cooling system, changed the oil and filter, put the covers, and accessory belts back on, and drove home

This was the most expensive timing belt job I have done to date.

[NO_H2O]

Glad to hear you got it back together. I know what you mean by the belt having a tight fit, the TDI is a tight fit too