Broken TDI Timing Belt Carnage: Full disassembly of a BHW PD TDI

Picked up this 2L BHW PD TDI out of a Volkswagen Passat with a broken timing belt. Skip to 6:05 and 7:45 if you just want to see broken timing belt carnage.
This video is of me stripping the engine down to bare block for some future goodies and videos. This is the most powerful and robust PD TDI available in North America and has some nice upgrades for the smaller/older TDI's such as the 2L pistons/block, larger injectors, larger oiler cooler as well as heavier rods.
:00 Intro
2:22 Removing the camshaft
3:15 Removing PD injectors (Generic auto body slide hammer worked okay)
4:13 Removing the very stubborn/stuck #1 injector
5:17 Removing injector wiring harness
5:48 Removing timing belt inner cover
6:05 Me blabbing about cam/bearing wear and inspecting damage
7:17 Removing head bolts
7:45 Pulling the head and checking out bent valves
8:13 Oil pan removal
8:57 Removing the Balance Shaft Module
9:54 Removing pistons and rods
12:57 Removing oil filter housing and oil cooler
13:33 Removing crank sprocket and front cover
14:53 Dropping the engine on myself
15:22 Removing rear cover/rear main
15:42 Removing mains and crank
17:22 Checking out the parts lay-out
18:18 BHW piston and rod comparison to ALH piston and rod

[@amorag59]

Very nice, someone paid the big bucks for the gear drive upgrade on that balance shaft module!

[@JoshsJettas]

Yeah I wouldn’t imagine that’d be a cheap part at the dealer. The hex oil pump drive is a little scary though

[@darrenlub]

Good job on the video's. Im about to do cam on 06 brm, damn expensive for a german cam, too risky to use over sea's parts. Looking for a good used one on ebay. Dont wanna put too much money into a car thats not physically worth it. U have any good leads on a cost effective cam.

[@BigGroupHug]

Solid stuff buddy, where'd you get your training?

[@JoshsJettas]

I did an apprenticeship for Agriculture equipment technician, TDI's are similar just smaller. Get to do a lot more repairing/modifying/disassembly when its your own stuff.

[@wvjeepguy8178]

A guy has one of these for sale a few hours away. It has some damage..wondering if it'd worth getting to rebuild or if there could be too much damage to make it worthwhile.

[@JoshsJettas]

Some damage as in the belt broke? Normally the piston just makes some contact with the valves as in this case, a quick buff and it’d be good to go. But sometimes the valve breaks and that makes a mess

[@laaribi_abdo]

Good job but i don't understand why you dissambly the bloc engine, when the timing belt was broken only the valves damage

[@JoshsJettas]

It’s getting freshened up to get ready for bigger turbo and nozzles. But yes could get away with just replacing the head and valves for timing belt damage.

[@Superduty_59]

I have now 8 TDI's. I just picked up a cheap local 06 BRM with what is a broken timing belt. Still have to pull cover to be sure. Car is in great shape with brand new tires and brakes for $400. Was going to pull a good engine from my other 06 to swap in but I think I will just see how much damage on this one first and maybe fix this engine.

[@JoshsJettas]

If the valves just kissed the pistons you’d be fine with a head replacement, but if pistons are marked bad or a valve floated around in there your better with a complete swap. No harm in spending the half hour to get the head off and see what your dealing with.

[@darrenlub]

Good job on the video's. Im about to do cam on 06 brm, damn expensive for a german cam, too risky to use over sea's parts. Looking for a good used one on ebay. Dont wanna put too much money into a car thats not physically worth it. U have any good leads on a cost effective cam.

[@JoshsJettas]

Not sure if you had watched one of my earlier videos, it was specifically inspection and replacement on a 06 BRM with some cost effective options. Your cam, followers, cam bearings and cam cap/injector rocker bolts will all be junk. -Idparts sells a billet kit for $600 USD. -A more cost effective option is a new/used BEW cam (less aggressive=less wear), new INA nitride followers, new/used cam bearings (only bottoms wear so get tops out of the engine with the used cam?) and grade 12.9 cam cap bolts and injector rocker bolts. That video covers size and torque specs. That video was on a $300 car, I bought a used BEW engine for the cam and bearings specifically, bought new Ina nitride lifters and fastenal 12.9 non stretch bolts. That car has 50k on it since and running great.