Replaced the cam tensioner seal and gasket on 2.8 V6 (shortcut)...long

SoFla 2.7 · 02-10-2005, 11:40 AM

Last weekend, with the help of a veteran VW tech, we replaced the cam tensioner seal on the right (passenger side in the US) cylinder head. Contrary to what everyone (two dealerships and two different indies) said, we did not remove the cams or even moved the cam chain.

One dealer (the same dealership where the guy who helped me worked) quoted a price of $600+parts to replace the seal. One indy quoted $1,100 (but this included timing belt, tensioner, all seals, etc. The job costed me $44.58 in parts (tensioner kit $7 and valve cover gasket $37) and I "took care" of the tech.

I did see a write-up on here (I think?) from some else who may have also done it similarly, so I am not trying to take credit for something that has already been done.

I am not sure if this is a problem that plagues the 2.7T. Does anyone know?

Removing the valve cover is fairly straightforward so I will not go through it here. After removing the valve cover, and disconnecting the fuel and transmission lines that run on top the head, we released the tension on the chain with a "special tool". (Note: this "special" tool is nothing more than a sort of clamp used in shipping a new cam tensioner. The VW tech was kind enough to give it to me.) We then removed the four (three on the back, one between the cams) bolts holding the tensioner down. After some very careful manipulation (and tons of patience) we lifted the thin metal gasket over the two dowells (sp?) and slid it out. We then pushed the half-moon seal out and carefully place the new one in. We then replace the gasket, making sure it was in place with the dowells and bolted the tensioner back down. Putting everything was the reverse of taking it off.

Overall, it took about two hours, of which more than one hour was just fiddling with the actual seals and gaskets (old and new).

I know this write up is not as detailed as other, but I would like it to show that what many consider an expensive job does have a cheaper alternative.

Email me if you want to try it yourself and have questions.

JimR · 02-10-2005, 11:49 AM

And we think we know the root cause of the seals blowing out.

There's also a green vacuum check valve in the vicinity, that also should be replaced.

Read here, then open a new window for the link in this post. You'll need both posts.

SoFla 2.7 · 02-10-2005, 11:53 AM

The link references the Y-pipe on the 2.7T

Eric 2.7 · 02-10-2005, 12:34 PM

the mating surfaces clean. I used quite a few Q tips (numbered and counted of course).

OOOOya · 02-10-2005, 01:11 PM

it's in the same place as the pictures illustrate in the thread that has the watch for scale.

JimR · 02-10-2005, 01:22 PM

Take off the covers, and dig around back there, and you can see it.

JimR · 02-10-2005, 01:24 PM

I really need to do a consolidation thread on this subject, I have a lot of good links. Ijust added yours to the collection.

Click

SoFla 2.7 · 02-10-2005, 01:48 PM

a_o_smith · 02-10-2005, 06:28 PM

Eric 2.7 · 02-11-2005, 04:07 AM

02-10-2005, 11:40 AM	#1
SoFla 2.7 New Member Account #: 69890 Join Date: Feb 2004 Posts: 168	Replaced the cam tensioner seal and gasket on 2.8 V6 (shortcut)...long Last weekend, with the help of a veteran VW tech, we replaced the cam tensioner seal on the right (passenger side in the US) cylinder head. Contrary to what everyone (two dealerships and two different indies) said, we did not remove the cams or even moved the cam chain. One dealer (the same dealership where the guy who helped me worked) quoted a price of $600+parts to replace the seal. One indy quoted $1,100 (but this included timing belt, tensioner, all seals, etc. The job costed me $44.58 in parts (tensioner kit $7 and valve cover gasket $37) and I "took care" of the tech. I did see a write-up on here (I think?) from some else who may have also done it similarly, so I am not trying to take credit for something that has already been done. I am not sure if this is a problem that plagues the 2.7T. Does anyone know? Removing the valve cover is fairly straightforward so I will not go through it here. After removing the valve cover, and disconnecting the fuel and transmission lines that run on top the head, we released the tension on the chain with a "special tool". (Note: this "special" tool is nothing more than a sort of clamp used in shipping a new cam tensioner. The VW tech was kind enough to give it to me.) We then removed the four (three on the back, one between the cams) bolts holding the tensioner down. After some very careful manipulation (and tons of patience) we lifted the thin metal gasket over the two dowells (sp?) and slid it out. We then pushed the half-moon seal out and carefully place the new one in. We then replace the gasket, making sure it was in place with the dowells and bolted the tensioner back down. Putting everything was the reverse of taking it off. Overall, it took about two hours, of which more than one hour was just fiddling with the actual seals and gaskets (old and new). I know this write up is not as detailed as other, but I would like it to show that what many consider an expensive job does have a cheaper alternative. Email me if you want to try it yourself and have questions. __________________ 2004 VW Touareg 4.2 V8; white/grey 2000 Audi A6 2.7T 6-speed; silver/black 1999 Passat 2.8 V6 GLX; black/tan - SOLD

02-10-2005, 11:49 AM	#2
JimR Member Account #: 1018 Join Date: Mar 2000 Posts: 46,941	Sounds like the same problem. And we think we know the root cause of the seals blowing out. There's also a green vacuum check valve in the vicinity, that also should be replaced. Read here, then open a new window for the link in this post. You'll need both posts. __________________ JimR '07 A3 3.2q Lava Gray '99 A8 4.2q Pearl White '99 A6 Avant 2.8q Silver (My old car, son now drives) '06 Boxster S Guards Red (wife's wheels) Support the troops "Over the years, I have come to understand a critical difference between the world of fear and the world of freedom. In the former, the primary challenge is finding the inner strength to confront evil. In the latter, the primary challenge is finding the moral clarity to see evil."

02-10-2005, 11:53 AM	#3
SoFla 2.7 New Member Account #: 69890 Join Date: Feb 2004 Posts: 168	Thanks Jim. Do you know where those parts are on the 2.8 V6 The link references the Y-pipe on the 2.7T __________________ 2004 VW Touareg 4.2 V8; white/grey 2000 Audi A6 2.7T 6-speed; silver/black 1999 Passat 2.8 V6 GLX; black/tan - SOLD

02-10-2005, 12:34 PM	#4
Eric 2.7 Member Account #: 61325 Join Date: Aug 2003 Posts: 2,808	I also did mine w/o loosening cams. The only tough part is making sure to get the mating surfaces clean. I used quite a few Q tips (numbered and counted of course). __________________ Eric 2000 A6 2.7T DIY Mule: Full Timing Belt Replacement, Cam Seals & Cam Tensioner Gaskets, Engine Mounts (TWICE! Thanks Hamburg-Technic/ECS), O2 Sensors, 2ndary Coolant Pump, '03 OEM Sport Suspension, H-Sport Sway Bars, Control Arms, Tie Rod Ends, CV Joint Boots & All Kinds of Maintenance Stuff. Retired: 1996 A4 2.8 2wd 12v 1987 4000CS Quattro 1980 4000 2door (not even an "S")

02-10-2005, 01:11 PM	#5
OOOOya AudiWorld Senior Member Account #: 74843 Join Date: May 2004 Posts: 2,030	I spotted it on my 2.8 it's in the same place as the pictures illustrate in the thread that has the watch for scale. __________________ present: 2002 S6 Avant (his) 1999 A6 Avant (hers) past: green 1999 A6 Avant - total loss

02-10-2005, 01:22 PM	#6
JimR Member Account #: 1018 Join Date: Mar 2000 Posts: 46,941	Up high, between the engine and firewall. Take off the covers, and dig around back there, and you can see it. __________________ JimR '07 A3 3.2q Lava Gray '99 A8 4.2q Pearl White '99 A6 Avant 2.8q Silver (My old car, son now drives) '06 Boxster S Guards Red (wife's wheels) Support the troops "Over the years, I have come to understand a critical difference between the world of fear and the world of freedom. In the former, the primary challenge is finding the inner strength to confront evil. In the latter, the primary challenge is finding the moral clarity to see evil."

02-10-2005, 01:24 PM	#7
JimR Member Account #: 1018 Join Date: Mar 2000 Posts: 46,941	Here I really need to do a consolidation thread on this subject, I have a lot of good links. Ijust added yours to the collection. Click __________________ JimR '07 A3 3.2q Lava Gray '99 A8 4.2q Pearl White '99 A6 Avant 2.8q Silver (My old car, son now drives) '06 Boxster S Guards Red (wife's wheels) Support the troops "Over the years, I have come to understand a critical difference between the world of fear and the world of freedom. In the former, the primary challenge is finding the inner strength to confront evil. In the latter, the primary challenge is finding the moral clarity to see evil."

02-10-2005, 01:48 PM	#8
SoFla 2.7 New Member Account #: 69890 Join Date: Feb 2004 Posts: 168	Thanks Jim. __________________ 2004 VW Touareg 4.2 V8; white/grey 2000 Audi A6 2.7T 6-speed; silver/black 1999 Passat 2.8 V6 GLX; black/tan - SOLD

02-10-2005, 06:28 PM	#9
a_o_smith AudiWorld Super User Account #: 73987 Join Date: Apr 2004 Posts: 11,154	numbered and counted...theres a screwdriver living under my engine right now ;-) __________________ Present: 2001 TT 225hp TQM, Valentine One, K40 laser diffuser, and an L7 in the trunk 2008 CBR600RR, Graffiti, integrated tail, F/E, PCIII & exhaust on the way Past: 2001 ming 2.8 >>[?] means i have no idea what im talking about >>My tech articles: tip recode for everyone, dissable running lights, O2 sensor replacement, Lemmiwinks explanation, TT sub install >Questions on theses? email me: aosmith@gmail >>pic poster >>>Manual Tranny Tips, TT Front Plate Removal >>>>Linkedin

02-11-2005, 04:07 AM	#10
Eric 2.7 Member Account #: 61325 Join Date: Aug 2003 Posts: 2,808	I love dropping stuff in engines. Once spent 45 minutes trying to get a screw that I dropped : ))) __________________ Eric 2000 A6 2.7T DIY Mule: Full Timing Belt Replacement, Cam Seals & Cam Tensioner Gaskets, Engine Mounts (TWICE! Thanks Hamburg-Technic/ECS), O2 Sensors, 2ndary Coolant Pump, '03 OEM Sport Suspension, H-Sport Sway Bars, Control Arms, Tie Rod Ends, CV Joint Boots & All Kinds of Maintenance Stuff. Retired: 1996 A4 2.8 2wd 12v 1987 4000CS Quattro 1980 4000 2door (not even an "S")

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