Complete B7 Swap Kit bought from Korwerks LLC
This included an 0A3 6speed transmission, transmission support bracket, starter, clutch, flywheel, bell housing spacer, prop shaft, fuel tank, complete rear subframe, front cv axles, and bell housing bolts.
Got the engine in the garage and mounted on the engine stand ready for tear down. This BHW that I picked up has around 180k miles. I did get to hear it run before it was pulled and it sounded good.
Super dirty engine. Valve cover has been leaking for awhile.
So sadly upon tear down I found exhaust port 3 & 4 wet. Looks to be oil or fuel.
Also found that the rocker arm oil rifle plug had popped out. This is a known issue for PD TDIs. Which will create low oil pressure in the cylinder head.
Oil doesn’t seem to have come from the injector. It’s a tad bit wet around the outer part of the cylinder but very wet inside the exhaust port. This engine had been sitting for a few years before it was pulled. So I will be replacing all the valve seals anyways.
I inspected the cylinder and found no issues at all with any of the cylinders. They all still have good crosshatching with no wear. Cylinder 4 is dry so I’ll finish deep cleaning and reassemble.
Balance Shaft will be getting deleted seeing as I see it as a failure point and like the simplicity of just running a regular oil pump like what’s on the ALH.
I’m using the KermaTDI Balance Shaft Delete kit with the BRM chain and oil pump sprocket for the increased oil pressure. So first things first is removing the oversized BHW Balance Shaft sprocket on the crank. Even with the correct tools and heat the sprocket just wanted to break.
Ended up using a carbide bit to cut a notch in the sprocket and hit it with a chisel cracking it. It fell off after that. Cleaned up the area and now I will set my new ALH crank sprocket on.
Using a Hot Plate I got it up to temp.
Perfect!
Test fitting
This is the oil supply rifle for the balance shaft that I am deleting. We will need to plug that port otherwise it will be a low oil pressure issue.
Went with a 1/8 pipe plug.
Put a little International Gray RTV on it and sent it home.
Trimmed the oil drain windage baffle tray so it will sit properly.
I’m using the smaller sprocket off a BRM for “increased oil pressure”. Not sure if it’ll help with the issue of PD TDI eating cams but we’ll see.
Bottom end is finished.
ARP Headbolts Finally came in!!
Deck is clean and good to go!
Head is set and looks beautiful!
Next is cam bearings. I’m gonna reuse my cam because it looks and feels fine. I’m hoping to get a Colt Cam within the next 20k miles so hopefully it’ll hold off till then!
Always love the look of these lifters!
All tuned up!
Resealed the injectors.
Seeing as there’s a little bit of a fuel shortage I figured it’s probably a good time to go ahead and start pulling all the gasoline parts off my B6 Chassis.
B6 A4 Quattro BHW TDI Swap
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