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pesky oil leak...solved?!?!!!!!(B5 V6) Rear Oil Caps in head

64K views 64 replies 30 participants last post by  PZ  
#1 ·
So Ive had a pesky oil leak that Ive been chasing for probably 6 months now. At stop lights shortly after startup I would get a burning oil smell and sometimes I would even get smoke coming out from the fenders or up by the windshield wipers. I would also get drips of oil (maybe the size of a quarter per day) on the ground. Well, in troubleshooting this dilemma I replaced my front and rear cam seals and my valve cover gaskets. This cured most of the leaking...replacing the front cam seals got rid of the drips. Well, I thought all was well but I would still get burning oil smell and smoke. Turns out it was the cam seal caps on the back of the motor. I could reach back on the rear of the valve cover and feel the little black plastic cap and could wipe up about a dime sized drip from below it every day. The oil was leaking out of this cap and dripping onto the exhaust. I took it back to my mechanic and over the next 2 months he replaced the caps 3 times and still to no avail. Well, after a little digging here on the site I came across a thread that mentioned replacing the caps on a cold car. It said that if the caps were installed on a warm car and not allowed to seat for 24hrs they would not seal properly and would continually leak. I would always drop my car off to my mechanic in the morning and get it after work...never allowing the caps to seal properly. I told my mechanic this and he said he too had just learned this. I asked him if he had a spare set of caps and he did so he gave them to me and over last weekend I swapped them out, cleaned out the area where they go back in, coated the new caps with a think smear of silicone grease (orange looking stuff...my friend had it) and reinserted them. Well its been 1 week and I have not had a single drip! I really think there is truth to installing the caps on a cold motor and then letting them seat for a good 24hrs before getting the car to operating temp. So if you are having trouble like this, try what I did. It should cure your problem.

FYI, to get the caps out - driver side - remove the coolant tank and move it out of the way, then take a large flat head screwdriver and tap the end with a hammer, denting the cap and then pry it out of the hole. wipe out the hole with a rag and maybe a little carb and choke cleaner on a rag to make sure there is no chunks or debris in there. It just takes a firm press to put the new one back in. pass side - remove the intake hose between the airbox and the throttle body and repeat the same prying procedure. Should only take about 15min for both sides. Good luck all.
 
#4 ·
Mine was leaking on the pass side the exact same way. I drove out the old one just like you described. When I installed mine, the car was cold. I just put a thin film of silicone sealant on the sealing ridges and popped it in by hand. Waiting about 24 hours before restarting. It's been completely drip free for ~3000 miles now.

-Nick
 
#7 ·
I have been chasing the same for about a year!:banghead: The leak was very small. Could smell the burning oil about 2 or 4 times a week. For those of you doing this yourself (like I will) the pn is 078-103-113E (it is for my '99 AHA anyway). BTW the cover/cap whatever you want to call it it is acutally a steel cup covered in rubber like stuff. Take care not to dent it when installing !:wrench:


Mark
 
#9 ·
Nice!

FWIW, two of these come with the VCG repair kit from Blauparts for $65.

World Impex carries these caps for $15 each. Looks like $6 from ECS. Obviously the former is the better value if you think you might need the rest of the kit, too.
 
#10 ·
Cheers! been having small oil drops in ground, and randomly burning oil smell since i bought the car. Previous owner had just changed the valvecover gasgets, so i was mentaly prepairing to rip off the toothed belt (and change it) and change the crankshafts front seal...

But, got my finger crossed that it would be this :)
 
#12 ·
Here are pics from the back of the engine with the trans removed. The caps are the black parts above the exhaust.

Back of Left head:

Image


Back of Right head:

Image
 
#14 ·
i've changed all seals and gaskets but i still get the smoke smell and see it when i come to complete stop....anyhow are these the caps in RED circle that has to replaced?
Image



if so what is this part called or do you guys have the part number for a 2002 GLX passat...

what sealent is best to use when replacing the caps.

thanks,
 
#15 ·
They are just called sealing caps. That is what they call them at the dealer. I just picked some up from them not even an hour ago. They ran just under $16 ea. They are metal and have a rubber coating on them. The part number on my receipt is 078-103-113-e. I have a 2000 v6.
 
#16 ·
I was having this same issue and had my mechanic install the cam tensioner gaskets. Would these normally be replaced as part of that job or would I have had to request this specifically, most likely? I guess I could just go take a look. Thanks for the pics!
 
#19 ·
Sealant should not be needed when these are replaced. It should not hurt if you use it, just don't overdue it as the sealant can plug the oil drain behind the cap.

These are usually not part of the CCT seal replacement, but as often as they leak, they should be.
 
#20 ·
Okay, so I fired up the car today after letting it sit for 24 hours after installing the new cap and some red rtv on it. All is good. I have no more leak. It did take me awhile to wash off all the oil residue on the exhaust to get rid of the smoking but once that was done I've seen no more leakage or smoke. Only time will tell how long it lasts, but so far so good.

Also, to the guys post just above this one. He is correct that no sealent should need to be used. However when I spoke to my dealers tech. he verified that they also use this trick about 80% of the time as many of the them continue to leak after replacing the cap if they don't use a sealent. I agree with the last post that it really doesn't take a lot. I Be sure and be careful to remove any from the back lip of the cap. Just put a small amount on the ribs on the side of the cap and that is all.
 
#25 ·
The 1.8T does not use the cam cap. You just have the cam chain tensioner gasket and half moon back there. There is a writeup for replacement in the Info Forum.
 
#29 ·
just want to thank djkynz for the thread and PZ for the Pictures of the caps!!! i think I may have solved my on going small leak and burnt oil smell I've been having for the past several years. and it only cost me a little over $4.00 and 20 minutes. I brought it in a long time ago to have the dealer find the leak and they kept telling me a leak is when it drips and hits the ground, which was covered under warranty and a seep isn't, so they called mine a seep. so i said screw it and just kept adding oil, since the dealer was going to charge me lots find it and fix it, and spending a few bucks on quart of oil every 5k wasn't that bad. But, thanks to thread I think I may have resolved my issue. Thanks again!
 
#31 ·
BRILLIANT! I've been dealing with this phantom leak as well.. had my valve cover gaskets replaced & then my mechanic also used some UV dye to try to trace it after de-greasing the entire engine.. said it was the oil coolant lines.. which I'm inclined to believe it is.. but this makes sense as well. Going to look into it this weekend or the next..
THANKS again for the awesome info.. I love this forum so much.
peace
 
#32 ·
So I had these replaced 2 weeks ago and that damn smell was still there, I checked this morning and sure thing they were leaking.

I spoke to the Indy that replaced these and he told me that they were under pressure and that the valve covers had to be taken off and a special fork like tool to pry these off.

Is he selling me a bill of goods or can they be popped off with a hammer and screwdriver?
 
#34 ·
Hammer and screwdriver is all you need.

I did mine a while back but i put silicone sealant around the cap and I let my car sit overnight in order for silicone to harden.

I've had no oil smell in my car since i changed my caps.

hope this helps.:wrench: