Passat B6 BKP Cylinder Head

[DieselMonster]

Hi all, thanks for stopping by to help! So I'm stripping a bkp cylinder head and I don't have a clue how the top bearing plate is removed. I've taken the bolts off but it's also has a sealant. I've checked all over internet and you tube but due to not many PD vags having this style there isn't any info. I want to remove the plate as it sandwiches the cams.

[Daniel71]

it's just the sealant and 2 guides, knock it gently with a soft-face hammer and must come out

[DieselMonster]

I've been hitting it with a hammer wrapped in cloth. I think I've seen the two guide pins, they are two metal pins. I've been hammering along the seam where the plate meets the head. Am I meant to be hitting just the plate with an effort to slide it off the cylinder? I can't see that happening as it has guide pins going through the plate. All I can think of is giving it direct hits from the injector loom and top half circle of the cam so it pops off. I've tried that, wrapped a large flat face screw driver and pounded it with a hammer but all that's happened is the screw driver ripped through the cloth and chipped the plate. Any suggestions on specifically where I should be hitting it with a hammer?

[DieselMonster]

I've done it! Smacked it a few more times palette side cam wall and it popped off, just need patience. Now I'm gonna remove glow plug and injectors. Now I'm just wondering how I remove rockers. It seems they all have a long metal bar running through them. So if I tap that and then pull the bar from the other side of the cylinder head the rockers should be free.

[Daniel71]

check this video from min. 2:52 Full set / Juego completo VOLKSWAGEN PASSAT 2.0 TDI 16V BKP . - YouTube

[DieselMonster]

Perfect, that's how I was thinking they were assembled, now I'm just thinking how I should disassemble them, I guess it's just a case of wacking them the opposite direction they slide in from. I have been hitting one of them, I used an injector screw head with a hammer. It has come out a few millimeters but that's about it, I think I should keep trying and it will eventually pop out. I've seen that video before its great, especially when you have the same cylinder! The purpose of me stripping the head is to have it skimmed and sold as a bare head. I also have another whole bkp engine that had knocking noise, I can't wait to strip it!

[DMitch16]

The bearing frame you tapped off is usually removed with a special VW tool as the frame is more fragile than it looks and any slight twisting or warping will cause abnormal wear on the camshafts. The frame may even suffer tiny cracks which will weaken it and possibly lead to a failure of some sort.

One rocker rail has an internal screw thread into which you are meant to screw in the end of another VW tool, a small slide hammer which you then use to tap the rail out catching the rocker fingers as it moves. Again any bending or distortion of these rails will affect the smooth motion of the rockers which are meant to glide on them with a minute film of oil. The other rail has a retaining bolt and should come out like the first.

[DieselMonster]

Thanks for that, a bit late now though �� I've taken the top plate off as mentioned, I did do some screw damage to the top oval which goes over the cam but should be okay as its not the inside of the housing where it needs to be secured tightly, also I won't be using or selling this plate.

I didn't understand your rocker explanation clearly. I understand that one of the rail holes has screw thread inside them but I don't quite understand how the vw tool works. Is there any possible way I can replicate this tool and remove the rail? Yes I've seen the other one with a retaining bolt, it'll need to be removed before it goes anywhere. I've been tapping the other rail that has no retaining screw. I'm thinking of lubing the rail up so the rockers slide nicely without too much friction. What else can I do to remove the rail without too much fight?

[DMitch16]

The rail comes out from the gearbox end of the head only - the VW tool (which is a slide hammer) screws into the rail as it is threaded at the end with the same thread pitch and diameter as the rail hole and then short tapping outward pulls the rail evenly out.

I have previously, before buying the tool, screwed a bolt into the rail, snapped mole grips onto the bolt and tapped the mole grips. The rails are not usually stuck tight but can be a little stiff to start with. The trick is to make sure the rail comes out straight and that the rockers are not under any tension which will hinder removal.

[DieselMonster]

Sounds good, what if I use a bolt and attach a hook onto the bolt and have it pulled using scissor jacks? I don't have mole grips. I guess there are a few options. I think pulling it out is better than pushing it out. The rail can't be bent if pulled out.