Missing oil galley plugs in the rocker arms

Discussion in 'Mk5 VW Jetta, Sportwagen, and Audi A3 TDI forum' started by gtturbo, Apr 16, 2015.

  1. gtturbo

    gtturbo New Member

    Joined:
    Oct 12, 2012
    Messages:
    4
    Car:
    Jetta TDI 2006
    Replacing cam on a 2006 TDI Jetta and the plug pictured below is MISSING. Any idea where I could get a replacement?

    NOTE: While removing the old cam inspect the oil galley plugs in the rocker arms. They sometimes have a tendency to fall out randomly over time and pressure. This one was laying inside the head when rockers and cam where removed.
    [​IMG]
     
  2. fxk

    fxk Member

    Joined:
    Mar 18, 2015
    Messages:
    48
    Car:
    2014 VW JSW TDI
    Location:
    Vast wilderness between DC and B'more
    Falls out randomly over time and pressure? Really? :panic
    I'd think about tapping the hole and putting in a setscrew.
    frank
     
  3. gtturbo

    gtturbo New Member

    Joined:
    Oct 12, 2012
    Messages:
    4
    Car:
    Jetta TDI 2006
    Thanks, sounds like a reasonable way to deal with it.
     
  4. xeno555

    xeno555 Well-Known Member

    Joined:
    Dec 12, 2011
    Messages:
    1,684
    Car:
    2012 TDI Tech Package 6mt
    Location:
    Mile High
    Mods:
    Malone Stage II. Rawtek 3" from Turbo to Tail. Slammed on Koni. TSW Nurmburg Rims. Whiteline Sway & Ends. Panzer Plate.
    Or deform edge of hole.
     
  5. Nick Broersma

    Nick Broersma New Member

    Joined:
    May 10, 2015
    Messages:
    2
    Car:
    VW Caddy 1.9 TDI
    Location:
    Netherlands Amsterdam
    Hello gtturbo,
    I have the same problem with my VW Caddy 1.9 TDI from 2006.
    I wondered what solution did you choose and did it work?
     
  6. gtturbo

    gtturbo New Member

    Joined:
    Oct 12, 2012
    Messages:
    4
    Car:
    Jetta TDI 2006
    Nick, I took the rocker to a machine shop and they turned down a new plug on a lath. We used red lock-tight and than drove in the new plug. Defiantly a tight fit . Than we used a punch and put four or five divots around the hole to slightly decrease the oppening . There was a discussion on tapping the rocker but the risk of breaking a tap in the hardened rocker was not very appealing.

    Hope this helps
     
  7. Ol'Rattler

    Ol'Rattler Well-Known Member

    Joined:
    Apr 24, 2011
    Messages:
    833
    Car:
    06 TDI Jetta
    Location:
    Marysvile, WA.
    Pretty common on the BRM's I would suspect. On mine, the most forward and aft plugs were sitting in head bolts when I changed the cam. My fix was to glue them in place with JB Weld.
     
  8. MyTdi2

    MyTdi2 New Member

    Joined:
    Jul 15, 2015
    Messages:
    2
    Car:
    VW Jetta TDI, 2004
    Location:
    Pearisburg VA
    I found one of those plugs a while back when I had the valve cover off. I had no idea what it was, until I found this. I guess those oil gallery plugs are very important, right? Does the camshaft not get enough oil if a plug is missing?
     
  9. Nick Broersma

    Nick Broersma New Member

    Joined:
    May 10, 2015
    Messages:
    2
    Car:
    VW Caddy 1.9 TDI
    Location:
    Netherlands Amsterdam
    [​IMG]
    It is easy to fix. A friend weld it. Price was round 30 euro. But it is important that the holes are closed.
     
  10. MyTdi2

    MyTdi2 New Member

    Joined:
    Jul 15, 2015
    Messages:
    2
    Car:
    VW Jetta TDI, 2004
    Location:
    Pearisburg VA
    Thanks Nick, Welding it would definitely be the best way to fix it. I put it back in with some thread locker.
     
  11. g.a.meek

    g.a.meek New Member

    Joined:
    Feb 18, 2015
    Messages:
    1
    Car:
    2009 Jetta TDI
    Location:
    Edmonton, Alberta, Canada
    Nick:
    I was changing my camshaft on my BRM Jetta TDI, and after reading your post about loose plugs, found the plug
    from the oil gallery of the injection rockers had fallen out. Poor workmanship on VW's part. Anyway, I cleaned the
    hole in the end of the injection rockers and degreased it and the plug. Then I put threadlocker on everything, and
    pushed it back in. Then I took a 2 mm diameter punch and drove the plug a little to expand the plug in place. I hope
    it never comes out, as it would be disastrous to have the injection rockers starved for oil. Thanks for your post, as
    otherwise I would not have checked the oil gallery plugs, as I assumed that they were always installed well enough
    for life, and would never have come out...! g.a.meek
     
  12. Ol'Rattler

    Ol'Rattler Well-Known Member

    Joined:
    Apr 24, 2011
    Messages:
    833
    Car:
    06 TDI Jetta
    Location:
    Marysvile, WA.
    Very bad idea. Welding will change the heat treat of the metal.
     

Share This Page