View Full Version : My B5.5 TDI diary.
Edit - April 2016, thought I'd update this.....
I've cross posted stuff from another forum, quite why I forget about this fine place I don't know.
Updates start from page 2.....
Hello,
I've been on here quite a while but have had an 18 month break after my A6 got written off. I bought a old Ford Focus as a temporary stop gap. The Focus was so good that the stop gap turned into 18 months!
I also very much enjoyed motoring on a shoestring budget which is why I've plumped for an old (2004) B5.5 Passat Estate.
I picked it up on Weds 27th July 2011 and intend to post up details of my ownership experience with it. My ownership experience will be totally hands on and I will endeavor to carry out all work myself.
This is the second Passat TDI Estate I've had and along with the Audi A6, all three have shared the same AWX 130hp TDI engine and 5 speed box. So I know my way around them.
From the ownership of my first, I posted up a few 'how to's' on here which seem to have been quite popular, the most popular being this one;
VW Audi Forum - The #1 VW Group Community (http://www.vwaudiforum.co.uk/forum/showthread.php?7845-quot-How-To-quot-Passat-B5.5-TDI-Servicing)
Anyway, the purpose of this thread will be to document how I get on with the car. Please feel free and please do post into here with any of your thoughts and comments.
Here is the car, quite unremarkable, but it is mine.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/general%2030jul11/Photo0495.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/general%2030jul11/Photo0496.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/general%2030jul11/Photo0494.jpg
Very pleased with it so far.
A niggle I had was it had a 'smell' in it which I diagnosed when viewing it. The passenger side taillight was not water tight thus letting a fetted pool of stinking smelly water form in the 3/4 panel behind the jack cupboard. So removed the jack cradle, cleaned out and no more smell!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/general%2030jul11/Photo0497.jpg
Another scary one I found was this...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/general%2030jul11/Photo0493.jpg
The oil filter cap is off a mercedes !! God knows why but it put my plans to do an oil change on hold until I can get the correct VW part. Luckily there was one on e-bay, so it was promptly bought and should arrive in the week.
Other than that I've given the car a good clean and polish and a full interior clean.
adamss24
31-07-2011, 02:52 PM
Looks good mate, hope this last you a damn lot longer than the a6 you wrote off ! Pity as it was such a good car...
Guest 2
31-07-2011, 02:57 PM
Looks very well, the Passat suits silver and the best looking.
Looks good mate, hope this last you a damn lot longer than the a6 you wrote off ! Pity as it was such a good car...
Hello Chris, long time no speak.
Yes still a bit gutted about how the A6 ended up but never mind.
Looks very well, the Passat suits silver and the best looking.
Absolutely.
My last B5.5 was also in Reflex Silver.
It is taking a bit of getting used to as my last two car have been black.
First and most important job was to make sure the plenum drains were clear. If these are blocked all sorts of problems can occur; water ingress through the pollen filter housing causing the central convenience module and wiring to fail, rotting out the brake servo which can possibly lead to a very expensive repair bill.
Anyway, this is how I did it. Please note I thought about taking the pics part way through the job so some may appear to be out of sequence.
Tools,
10mm spanner for battery terminals.
13mm socket with 10" bar for battery clamp.
13mm spanner for battery cradle.
Pressue washer (if you have one).
So;
1, Pull the rubber seal off at the front edge of the plenum cover.
2, Ease the plastic plenum cover out.
Some say that the wiper arms and the scuttle cover that butts up to the screen needs to come off to remove the battery. This isn't the case, you can move the rubber incased loom forwards to provide access to remove the battery but you need to be careful not to damage the very brittle windscreen scutte panel.
3, Picture below shows the 3 clips securing the loom in place, you need to roll the loom over the bulkhead to release the clips and also release the grommit where the loom pases through the bulkhead. Also shown is the scuttle panel part removed. (Ignore the fact all of the engine covers are also off as I was going on to clean the engine bay as well as doing this, you don't need to remove them to clean the plenum drains).
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/plenum%20clean/Photo0492.jpg
4, Undo the battery terminals, 10mm spanner, and set aside.
5, Undo and remove the battery clamp, 13mm socket on 10" bar. See picture below for location.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/plenum%20clean/Photo0490.jpg
6, Remove battery cradle, x2 13mm nuts and one 13mm bolt, see picture below. Note that the alarm sounder is secured by one of the nuts. Note this was taken on re-assembly so it appears clean!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/plenum%20clean/Photo0489.jpg
7, This is what I was faced with, a dirty but dry plenum! The location of the battery side drain is shown arrowed and the approx location of the drain under the servo is also arrowed. I chose to poke the grommits out. There are two schools of thought on this, one being that they should remian in place as they stop fumes rising into the plenum as thus into the car interior via the pollen filter which is in the plenum. The other is to remove and not worry about fumes unless your exhaust is blowing. Im not worried and so poked them out! You can make your own decision on this.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/plenum%20clean/Photo0484.jpg
8, Cleaned with TFR (traffic film remover) and my pressure washer. I also ran an open hose in there as well to ensure all crud was removed.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/plenum%20clean/Photo0487.jpg
9, With battery back in.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/plenum%20clean/Photo0491.jpg
10, Connect everthing back up, replace plenum cover and rubber seal, job done! Took me about 45 minutes in total.
Tailored car mats
Collinite 476s paste wax
Cigar lighter
All arrived today from various peeps off e-bay.
Ordered a towbar from PF Jones, some gliptone leather cleaner as well.
Want to order a cruise kit now but may halt the spending spree for a while.
Might have a go at the mission that is replacing the ciggy lighter bulb this evening, centre console out anyone
caldirun
01-08-2011, 09:04 PM
Great posts, I was worried after all the F words in the first post, welcome back Col.
Great posts, I was worried after all the F words in the first post, welcome back Col.
Nowt wrong with the blue oval.
The Pasty seems to be remarkably quick after 18 months in 90hp 200nm Focus.
I named my A6 Avant "The old hector".
I have just named the Passat, no more than a few seconds ago "The Vicars leather elbow patch".
Wadya reckon, I think it is well in keeping.
Start of April 2016 update,
Some of the posts below are old but the sum of them will bring things up to date.
Picking up the storey with the Audi A6 that got written of in 2009, then burning around in a Focus for a year then getting this Passat in 2011....
Nothing like waking up an almost 5 year old thread is there. :hyst
I've been on here since early 2007 and started with my 1st 5.5 which I px'd for an Audi A6 in early 2009. I loved the A6 but sadly it got smashed up. Audi 1, Merc 0 No glass or lights broke on the Audi quite strangely but it was banana shaped and the car was about 4" shorter than it should have been. Got a good pay out and burned about in this nice Jag for a while until I got the beast of a car, a 1999 Focus TDDI which the Wife now drives.
A6 as was. (notice the wheels...)
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P2150001_zpszwiypgav.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P2150002_zps1lvc3ehw.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P2150012_zpsfvzrsynt.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P2150013_zps3nzllmbn.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P2270070_zpsu86ckprf.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P4050151_zpsrrf9uvbp.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P4050153_zpstajnbzvz.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/P4050154_zpsmbxkb10d.jpg
A6 write off.
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/PB250080_zpsf5z1occ3.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/PB250081_zps9nspsxut.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/PB250082_zpsni4mv3r9.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/Image076_zpsmx2jcxo2.jpg
And the Merc that did it...
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/Image077_zpsnsasuedq.jpg
The nice Jag...
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/PC050098_zpsfhadzqpe.jpg
The beast Focus...
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/DSCF3314_zpseqkdnmot.jpg
http://img.photobucket.com/albums/v602/colin__/Audi%20A6/DSCF3312_zpsgb983ut0.jpg
My current car is a 2004 (53 plate) Highline Estate with an AWX TDI engine which I bought in late July 2011.
I've never intended to do a build thread as I never intended to do that much to the car. I have however done loads of stuff to it including cambelt, waterpump, full suspension re-build. The only things that could be classed as modifications are the installation of a comprehensive set of red ambient lighting inside and the three gauges.
Anyway, had a good post winter clean and polish of the current car today and fitted the wheels I've just refurbed.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3053_zpssxejzxz0.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3072_zps1tpfxcme.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3071_zpsmzmhvuni.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3070_zpsx7iupzfj.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3069_zpsbge31r4i.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3068_zpsrclnhjur.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3067_zpsn4d0urvg.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3062_zpsb4duarrp.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3061_zpsceqejeer.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3060_zps0b8kfafj.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3058_zpsihjeimaf.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Feb%2013/DSCF3052_zps3crobf2h.jpg
Front suspension build
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2684_zpsbcy6vs4g.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2686_zpsnkpttg8r.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2694_zpsgerunmqb.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2699_zpsnjflqagq.jpg
Knackered CV joint
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2700_zpsz3f6enub.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2703_zpspxv9rx0q.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20suspension%20Febi/DSCF2705_zpspkiuyskj.jpg
Winter steelies in all their 195 wide glory.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Winter%20steels/DSCF2846.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Winter%20steels/DSCF2849.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Winter%20steels/DSCF2847.jpg
Heated seat re-build (burn through replacement.)
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Heated%20seat/DSCF2653.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Heated%20seat/DSCF2650.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Heated%20seat/DSCF2648.jpg
Some really bad blurred ambient lighting pics. Ambient lighting is a bugger to photograph as if flash on you cannot see it, flash off and it looks too bright.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF2470.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF2469.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF2468.jpg
Well, the car has sat out in the rain since Friday evening when I got out of it and parked up having got home from work. I say sat out as I've been working in the ManCave / Garage doing other things. Have not even washed the car this weekend :0
My trailer had a bit of tlc.
I built it in 2010 and now was the time to fettle with it in preparation for the camping season which is coming up fast. Wheel bearing check and re-grease etc.
I can take everything camping ! Passat Estate + Massive trailer = still not enough room :hyst
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Apr%2013%20and%20trailer/DSCF3110%20-%20Copy_zpshtim6xbw.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Apr%2013%20and%20trailer/DSCF3107_zpsityk1lw5.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Apr%2013%20and%20trailer/DSCF3108_zps3m3xpxmn.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Apr%2013%20and%20trailer/DSCF3112_zpsdw8kaxjg.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Apr%2013%20and%20trailer/DSCF3113_zps1bvuzdqp.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%20Apr%2013%20and%20trailer/DSCF3119%20-%20Copy_zpselpwcsu5.jpg
It has been a long time since the last update.
The Febi suspension arm kit shat itself, two of the upper arm balljoints so I bit the bullet and went through it all over again but this time fittted a Meyle HD kit. This was for the MOT back in March 15.
Meyle HD kit
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4514_zpsarfnzrvd.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4515_zpsc7yudcxr.jpg
Pinchbolts came out easily as expected
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4517_zps4wd7ycie.jpg
Crappy old but not that old Febi arms
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4519_zpsi25ziow2.jpg
Setting the design height
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4525_zpsdyuddmdo.jpg
Problem again getting the lowers out. Nightmare. The taper inserts came out still attached to the balljoint
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4526_zpsr67y1o9t.jpg
Stub cut down so my splitter would fit, then it was off.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4527_zpsaehq4djd.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4528_zpsusznvnkl.jpg
'S' / 'toe' curve height measured
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4529_zps7kcum0i9.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4531_zpsr6akxhlb.jpg
Current shots taken in Feb16 with the winters on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4964_zpsmgrhbbx8.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4967_zpsdkc4qd56.jpg
Got some new carriers
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4968_zpst4ghn92a.jpg
Painting the carriers, the bolts are so I can pick them up whilst painting
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4969_zpskwgq8u4n.jpg
And now the biggy......
I noticed last year when doing the arms, the front springs were starting to corrode. I thought I'd do something as at 140k miles things were probably a bit tired anyway...
Bilstein B4's
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4971_zpspthaexwe.jpg
Eichbachs, didn't really want to but it was cheaper to buy the B4's and Eibachsthan it was to get replacement OE kit. Looks like I'm modding the car just a little bit after owning it for five years afterall !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4972_zpszr4lh3fm.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4973_zpsrjbgldkw.jpg
Had some shenanigans with the cambelt on my Wifes Golf, also a 1.9 TDI but with an ASZ engine, similar to the AVF in the Passat.
The Golf is a 2001 with the earlier type dampered cambelt tensioner so I thought it would be a good idea to see if it was possible to convert it to the later friction type tensioner as fitted to my Passat.
It is a big nope. The engine block is not tapped in the correct location. Pictures say more than words;
Dampered and Friction type setups side by side. The red dot shows where the stud for the later idler / deflection should be.
http://img.photobucket.com/albums/v602/colin__/TDI%20Cam%20belt/DSCF4957_zpsjyidbica.jpg
Another pic showing the backplate differences
http://img.photobucket.com/albums/v602/colin__/TDI%20Cam%20belt/DSCF4958_zpsyflcr5vi.jpg
http://img.photobucket.com/albums/v602/colin__/TDI%20Cam%20belt/DSCF4959_zpsy44tjlbe.jpg
Not a lot of room to work in on the Golf, this is with the engine mounting out the way, which isn't when you are building things up, you have to work round the engine mounting
http://img.photobucket.com/albums/v602/colin__/TDI%20Cam%20belt/DSCF4961_zpsdiahvmng.jpg
Green dot shows where the later type idler / deflection pulley stud is located. This earlier block was not tapped for it. On the earlier type the idler bolts to the damper.
http://img.photobucket.com/albums/v602/colin__/TDI%20Cam%20belt/DSCF4962_zpsgb88en1g.jpg
For reference, these are the tools you need to remove the camshaft inner pullet / hub (which you need to do if you want to remove the backplate.
http://img.photobucket.com/albums/v602/colin__/TDI%20Cam%20belt/DSCF4960_zpsdl5u692i.jpg
The new rear calipers arrived today. Nice and bright and shiny but they wouldn't stay that way for long, so I painted them. Got a new set of banjo bolts and washers also as you never know...
New
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4992_zpsrxbfk62a.jpg
1st coat. The paint is still wet so they look shiny black. It is a satin paint so when they dry they'll calm down a bit.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF4993_zpsykl6vez3.jpg
Back to the Passat.
By the standards of some on here I've done very little to mine despite having had this one since July 2011. But I'm starting.
Finally got all the bits together for the suspension.
Rears comprising of the shock, topmount, bumpstop and cover.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF4995_zpsoruglzqc.jpg
It may be obvious to many of you who have done this many times but there will always be those who have never done it and are wondering how to build up a front McPherson strut. Note that I use DIY grade spring compressors.
Building up a strut is much easier if you can hold it in a vice.
Strut in vice with lower mount cup and lower mount rubber in position. The Bilstein's use a different diameter cup to the stock one but the rubber is the same. As I'm doing a straight swap and the purpose of this exercise is to freshen up the car, there would be no point using the old rubbers, but you could...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF4996_zps79ellstf.jpg
Spring on and compressed. Be careful doing this, I'd hate to imagine how much energy is stored in the springs and if the compressors slipped off what injury you would sustain. For me personally it is one of those jobs I hate doing when working on a car. Make sure the compressors are straight and tighten them down bit by bit swapping sides as you go.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF4997_zpsp4lqudwx.jpg
Top plate on, again with a new rubber. All that needs to go on now is the top-top mount and then the washer and finally the nut. 19mm ring spanner on the nut with the shock piston counter held with a 5mm (or could have been a 6mm) allen key
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF4998_zpsrnthfoxy.jpg
Some measurage....
Front
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF4999_zpsg96hkqyd.jpg
680mm with the car sitting on its 195 x 15 steelies
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF5009_zpstkgfkcxp.jpg
Rear
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF5002_zpsqb8kvmqc.jpg
About 685mm
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF5004_zpsx1dhj3wm.jpg
I'm also going to fit a pair of new CV joints. Whilst it all apart and for the price it'd be silly not to. The boots are not 'gone' but are showing signs of going soon so whilst it is all apart it'd be silly not to. A joint with all the clips, a new bolt, a boot and grease from J&R is very reasonable cost wise.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF5005_zpshaqhw4mb.jpg
And the rear calipers got another coat and have dried nicely...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Struts%20and%20brakes%20Feb%202016/DSCF5007_zpseft5nzgv.jpg
A busy day....
This morning off to my Dads, he is 82, to remove the old and fit a new shower. Late this afternoon I decided to drop the rear beam...
The rear beam removal process is would be the same for front wheel drive B5 /B5.5 Passats and Audi A4 & A6's.
To remove the beam, unlike many cars, the rear hydraulic brake lines do not have to be opened requiring the braking system to be bled, which is nice. Doing this is a fairly full-on and assumes you can already do basics like brake disc and changes etc.
1, Loosen wheel bolts
2, Jack the car up, both sides at the back and support with axle stands.
3, Remove wheels
4, Undo rear brake calipers and pads
5, Remove brake disc
Now the fun starts...
6, Remove the 5nr hub housing bolts, these are allen key bolts and mine didn't look like they were going to play the game, thankfully they did.
7, The hub flange has holes that you can pass through a 3/8 allen key socket
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5012_zpsltofxqpv.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5011_zpslq3itwwe.jpg
They were quite crusty rusty and I thought I would have problems..
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5013_zpsytx8ykjr.jpg
Why VW are so obsessed with allen key fixings I don't know. They are ok when things are new but when they get old and rusty fun and games can be had
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5014_zps39x9bmmz.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5015_zpsxkuzpkn1.jpg
8, Brake cailper carrier bracket off, same size allen key
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5016_zpsg0bejeuq.jpg
9, Wiggle and tap the hub off the axle
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5017_zpsixtkvuiu.jpg
10, You can see the hub dangling on the ABS sensor cable. Not ideal but the cable is quite chunky
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5017_zpsixtkvuiu.jpg
11, This is the bit that took me far longer than anything else and that was removing the ABS sensors. This can be a nightmare but I very slowly and carefully prized them out of the hubs. They have little plastic clips that first need to be removed. You can see the damaged I caused to the outer lip which is the leverage point. Start with a small screwdriver and work up to bigger ones. Again, slowly gently catchy monkey.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5019_zps8owx84sr.jpg
12, The hub off, discshield and the abs sensor clip in the foreground.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5020_zpsnvksdmz3.jpg
13, The naked beam end
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5021_zpsijnq7nnn.jpg
14, On each side you will note that there are 3nr brackets held onto the beam with 10mm nuts onto studs, ondo them and them pull the brake line and abs sensor cable out of the green clips. Once done, tie the caliper up out the way.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5022_zpsuq3kuqxh.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5023_zpsdtnz0jev.jpg
15, Same process on the other side, another pic of me undoing a hub bolt
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5025_zpsnrawt1p9.jpg
16, Undo the "massive" pivot bolts for the beam. These are 21mm so you know as not many tool kits have this size and you will need a good ring spanner to counter hold the nuts as a socket will not fit the outer end. Not pictured but there is a plastic cover that is secured with x4 10mm nuts and one screw, remove it.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5026_zps3e8bj2wn.jpg
17, Support the beam in the center with your jack and remove the bush consoles, x3 18mm bolts. Mark or be aware of their position ready for re-fitting, you don't want to loose the alignment.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5026_zps3e8bj2wn.jpg
Supported on jack, one side done..
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5027_zpsclxbb78v.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5028_zpsrtrooqar.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5029_zpsefyfnw6g.jpg
18, And lower it down. Job done. Note the brake calipers and the like tied up out the way with the beam removed.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5029_zpsefyfnw6g.jpg
I'm going to re-use the 'big' bolts and inconsequential fixings but i'll be buying x10 new hub allen bolts and x4 new caliper carrier allen bolts.
Some people go out on a Saturday night...
Beam looks good, certainly better than the one I last did on a Golf. Inteerstingly the fixing studs for the passenger side sheared. I'll have to weld some news ones on.
Drivers side, the studs are there
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5033_zpsexaglrow.jpg
Passenger side they are not
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5034_zps6wzfuhj5.jpg
Not that grotty
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5036_zpsu5ezlfx7.jpg
The Lemforder bush / cassettes are as good as new, just a bit grubby
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5037_zpsutz3dtvf.jpg
A proper wire brush
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5038_zpsswkorpbg.jpg
Cleaned
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5039_zpsfaov2nwm.jpg
Grotty hub / wheel bearing.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5040_zpsuf8yrpv7.jpg
Cleaner
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5041_zpsjdtvavgj.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5042_zpsih7utaql.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5043_zpsmbrchtiq.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5044_zpste1p91ga.jpg
These are the big pivot bolts, I dread to think how much they cost...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5045_zps1vib9hr9.jpg
Painting tomorrow.
Another busy day. I seemed to be out there all day without much happening but I was fat out.
I jet washed the beam and them de-rusted it as best I could which took ages and ages. There are loads of nooks and crannies which you cannot get to on it. The important thing is that it wasn't too bad.
I also took the rear arch liners off along with the sill covers. I've not seen anyone else do this on here despite being on here since 2007. I just wanted to clean things up under the covers and inspect things for rust. The good news is there is none as expected. There is only some minor crush damage where the car has been jacked up without care but nothing to worry about.
Dirty beam
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5046_zps1k3vm0ww.jpg
Grotty beam end
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5047_zpsu8a6rxrv.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5048_zpsqfdgycuq.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5049_zpss0a7jiwo.jpg
Funny plastic strap on the anti roll / torsion bar. Like a cable tie but on steriods!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5050_zpsm9oinxwo.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5051_zpsdiqyh2x7.jpg
Part cleaned off of rust
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5052_zpsija4nhfe.jpg
Those two studs that had sheared off, I had some bolts, a tad longer but they'll do the job
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5053_zps7btw5dp9.jpg
In position
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5054_zps8jaudwkt.jpg
Welded on using my ancient Clark MIG. I worked out that I've had this welder 25 years !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5055_zpsuqzv1zpa.jpg
I also welded the existing studs on a bit better so they don't in the future shear off. Come to think about it, I did have a mysterious rattle squeak noise, it must have been the handbrake cable knocking on the beam.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5056_zpsnc9p1znp.jpg
Hanging up waiting for paint. I wanted to use the daylight to work out the car.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5057_zpspx5izdbk.jpg
Got the shocks off and the rear arch liners. The shocks are really quite worn comparing them to the resistance of the new ones, they move very easily with much less resistance.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5058_zpspjmchuat.jpg
Mud built up
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5059_zps490vegtm.jpg
Not too bad, a lot of this is factory applied wax
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5061_zpsih2gvgfb.jpg
Another shot of the bracket(s) that bolt to the beam via the studs, two of which I've welded new ones on..
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5062_zpsweevtjbd.jpg
The goodies in the boot waiting to get fitted, not the stereo though and I don;t know why that isn't indoors.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5064_zpsdxhmzfky.jpg
Sill covers off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5065_zpskglgjlkg.jpg
Moody interior shot, I liked the angle!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5066_zpsdbfhx6bl.jpg
Next shots are of the sills, before and after cleaning...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5066_zpsdbfhx6bl.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5068_zpszrgscuv6.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5069_zpskd0jvjrh.jpg
A lot of mud
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5070_zpsosjqwxag.jpg
Minor crush damage
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5071_zpsoh70ttv2.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5072_zpsgenxioxr.jpg
Cleaned and totally rust free
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5074_zpsu3txas2r.jpg
More crush damage at the back, again not too bad
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5075_zpskehwi8jl.jpg
Clean
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5076_zpscnvh58ca.jpg
Clean, but there is a funny water trap. This is where the mud was!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5077_zpspy4gaufw.jpg
Paint time now.
Came in after the filty cleaning session earlier, had a good shower a Sunday roast.
Then back out there to get the 1st coat of paint done.
Beam
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5080_zpsy2piegwk.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5081_zpsunkprg9a.jpg
Disc shields and bush / cassettes which I laquered.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5082_zps8ojazgw7.jpg
Rear caliper carriers hanging up to dry
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5083_zpshwtbzub7.jpg
Under crackers all scrubbed clean and dry
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5085_zpstjuougqn.jpg
Wheels bearing / hub units. These were a rusty mess.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5084_zpsh1kcwfrn.jpg
A little bit more done.
Blacked up the lowers, it actually easier to do this on the car. I never thought I'd say that!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5088_zpsa2ot7flp.jpg
And the arch liners
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5090_zpsv1pmf0iv.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5091_zpshpk8ked3.jpg
Things have dried nicely, a nice OE looking satin black. Except car makers due to the cost don't paint things or paint them properly like this and therefore in a few years they turn red rusty and get crusty.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5092_zpsknxsqovh.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5093_zpsfz9myhh5.jpg
These were saved so cleaned them. For reference they unscrew from the studs on the beam.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5094_zpsifclzzlr.jpg
I've ordered about £60 of new bolts from VW today as well. I was going to re-use some of them but thought why not. Also ordered a load of the T25 trim screws as well off e-bay as most of mine are a bit scabby.
Working from home!
During my "lunch" I tackled the slightly bubbling rear brake lines.
Note that this is a temporary measure and I'll tackle the brakes once the suspension is back in place. I also noticed the rear flexi hoses had a few surface cracks in them. Good enough for the forthcoming MOT but not for me. To undo the flexies it means splitting the joint between them and the main front to rear hard lines. From bitter experience I know that these won't split or undo without ruining the main front to rear brake pipes / hard lines. So the that whole job is on the list sometime soon but not immediately.
It is still good enough (hopefully) to pass its forthcoming MOT but I'd not be happy with them as they are.
So a temporary fix was to remove the plastic bubbled coating, scrape and sand the corrosion away and then paint the exposed lines. Sounds like a lot but this only on the short hard lines that clip to the beam. The corrosion ironically was where the green clips are. These particular pipes are £18 each new but as stated above I don't want to disturb the hydraulic circuits just yet.
When doing work like this, things do escalate and unplanned works do creep in. I'll now leave the new rear calipers and drain down the and bleed the system once.
Anyway, I did of course take some photos, saying that, the camera really struggled to focus on the thin pipes so some are a bit blurred.
Bubbly
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5099_zpsnhdjwrhk.jpg
Part cleaned, notice the white corrosion, these lines are aluminium it seems unless there is some ali in the plastic coating
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5100_zpshkgpj3ku.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5101_zpsihjn64v7.jpg
Prepped
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5102_zpsaqrpb8dy.jpg
And painted, I'll give these at least three coats as the brake hydraulics side project may not follow immediately.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5103_zpskqvg1dqb.jpg
During my "lunch" or was it the teabreak? I also popped down to VW and picked up £64 worth of bolts !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5105_zps7wmtkknh.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5106_zps8d5im2yd.jpg
It was the big beam pivot bolts that cost most, almost a Kings ransom on their own! And good job I counted them as there were only nine of the hub bolts, one short.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5104_zpscq3ukgys.jpg
You know I said there was no rust...
Well, I had a very very good look and found some. Very minor superficial surface rust but I found some. So, I whizzed it off and touched it up.
Can you see it? Clue I've removed the wheelarch liner clips
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5107_zpsz5ufglio.jpg
Same again but whizzed off ready for paint
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5111_zpsspqv2cdr.jpg
Some here, whizzed off ready for paint
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5108_zpspkkazryr.jpg
Just a tad on a spot weld, in fact there were a few like this.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5109_zpst68lrdyi.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5110_zpshndqqoek.jpg
At the moment I'm waiting for a few bits and bobs to arrive before re-fitting the beam and building things up. I also had a think and decided to go for it on the brakes, I've ordered new flexis, hoses and a roll of kunifer to make up new front to main lines if things go wrong.
I also spent five minutes fitting the bushes / cassettes and green clips back on the beam.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5112_zpstkksakcx.jpg
Some will be bored to death of this and some will understand.
Another busy evening.
I got the beam back onto the car with the assistance of my 15 year old son. It would have taken me much longer to do on my own. The bits and bobs I was waiting for turned so it meant I could get things done. I've ended up getting one side 3.4's built up on the beam and then decided I'd had enough. I didn't take any photos of the build up but will when I do the other side.
A load of nice new shiny and rust free trim screws turned up. These are the T25 torx ones that fix many many things to the car, I got 50 delivered for not much. Funnily enough they arrived just as I was putting the arch liner back in so some of the pics below are with the me using the old screws as a temporary measure.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5120_zps1ge381s4.jpg
Scabby old vs shiny new. It is the small things.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5122_zpsbsy6kyc9.jpg
Oh no... There is run in the paint! This is an example of where I splodged it on on the bits where there was rust!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5114_zpsseum6ckd.jpg
This tin of waxoyl must be 20 years old. I looked all over the tin and couldn't see a www dot anywhere on it. The irony is the tin is a bit rusty, maybe I should waxoyl it?
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5113_zpsvaxrpdya.jpg
Dabs of waxoyl on the arch where the liner tightly fits against it. It'll also help the mounting screw holder holes to not go rusty like the two I had to deal with in a previous post.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5115_zps56ngmnql.jpg
Arch liner on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5117_zpst5n51wgm.jpg
A bit more dabbaging of waxoyl on the shock top mount.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5116_zpsyijnzcva.jpg
Shock on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5119_zpshcevnofl.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5118_zpsguma5lgr.jpg
The spring cups turned up each in there own nice red box.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5123_zpskce4iijm.jpg
The old uppers were possibly re-usable but the lowers were quite knarled up. As I'm going this far, I though whats another £27 or so....
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5124_zpsjs9wb6p1.jpg
A pointless shot of old and new
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5125_zpsgutainp8.jpg
Shiny screws
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5127_zps8khodxbs.jpg
Cleaned up the carrier sliders. They were actually perfectly good from five years ago when I last changed the discs and pads. All I had to do was clean and re-grease
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5128_zps9knubzwz.jpg
Greasing anything on the brakes should be done with ceramic grease. NEVER use copper grease.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5129_zpszxj9mubw.jpg
Trial fit of pad in carrier, I wanted to know if the paint had caused clearance issues. It hadn't
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5130_zps76grfb59.jpg
So, beam on !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5132_zpsz10rbqif.jpg
One side 3/4's done before I gave up.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5134_zpssayyye63.jpg
More completely mind numbing updates tomorrow.
A jolly good session has been had. The rear end is now complete. I've still yet to do the brake hydraulics but as I've mentioned that will be a separate project from the suspension.
As I mentioned in the previous update post, I 75% finished one side last night after getting the beam back on the car with the help of my 15 year old son. This afternoon I finished the 25% of work on the side I'd started last night and then proceeded to build up and finsh the other (drivers side). Whilst doing the driver side I took some pictures...
Passenger side done (except for the brake hydraulics)
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5137_zpss9ccgsi3.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5136_zpsxrchhe9a.jpg
Which me the drivers side to do. This is as it was after fitting the beam last night. All I've done is tie the brake caliper back up out the way.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5139_zpsqce1m4fm.jpg
You will note the marks on the paint. This is where I'd 'levelled it off' in truth removing a run with a wood chisel. The hub needs to fit a flat surface.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5140_zpsz1wsxyym.jpg
A bit of dabbage of waxoyl on the mating faces
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5141_zpsu34ad3uf.jpg
Hub on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5142_zpsrxs4rhae.jpg
Brake caliper carrier bracket going on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5143_zpswly50d8c.jpg
All tightened and torqued up
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5144_zpsvzyopgaw.jpg
New nuts and washers on the handbrake cable brackets
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5145_zpstahryik3.jpg
Caliper piston wound back in although the picture below gives no clue
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5146_zpsrcf4rtnw.jpg
Those cheese haeded bolts that were crusty rusty, I didn't want these nice new one going the same way, so I painted them!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5147_zps439neonj.jpg
And I painted the new nuts on the handbrake cable
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5148_zpsnjg9ayul.jpg
Disc on, a nice feature on the rears is that you do not have to remove the carrier bracket to remove and fit the disc
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5149_zpsvyan5g4s.jpg
Diego. He is the research and development bloke at Brembo and such is his importance there is a pictore of him on the brake pad box. I wonder what he drives? I bet he has got an old Alpha and goes for long boozy lunches at various pavement cafes and that is where he gets his ideas from.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5150_zpsmdfhrmsj.jpg
When fitting pads, a blob of ceratech grease needs to go on the pads end ears. I'm hoping the built in squeal shims will do their job and hence have not applied any to the backs of the pads.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5151_zpszznoyogf.jpg
Pads mounted
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5152_zpsffuatjyx.jpg
Old caliper back on for now
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5153_zpsdmxwjwxz.jpg
Job done. All that hard work will never be seen except by me and the MOT man. But whenever I drive the car, I will know and be safe in the knowledge that the car is "sorted".
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Rear%20beam/DSCF5154_zpsoic4d6hf.jpg
A slow day, lots of time spent but seemingly with nothing happening.
Saying that, I did spend a fair bit of time tidying up as things were a right mess with tools everywhere. I hate that and when in that state you can spend, I do anyway, more time looking for tools than actually using the damned things. You put one down and then five seconds later you cannot find it. So I tidied up.
Then I commenced the front end. Jacked it up, axle stands and wheels off. Then wheels back on and down off the axle stands as I'd forgotten to undo the CV joint nuts. And back up it went.
I started to tackle the passenger side first. I've previously had issues with the lower arm balljoints releasing from knuckle so have left them as were / is. I released the uppers though with the infamous pinchbolt coming out easily as expected, it has only been a year since I last replaced it. What was surprising though was the complete absence of any copper grease which I liberally coated it with.
Upper arms released, lower shock mount bolt undone, the three top mount / upper arm carrier plate bolts undone and them I wriggled the strut assembly complete out from the car. Nice.
I swapped the strut over for the new one and refitted it back on the car, no drama. When I do the drovers side I'll take some pics.
I then whipped the complete drveshaft off the car for the CV joint swap on the bench, a much nicer place to do it. With the shaft on the bench, I cut the boot off and gave the joint a tap with the lump hammer and off the joint popped.
Cleaned and inspected the splines, all good.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5155_zpst500btjp.jpg
Old joint. I shall carry out a clean up and inspection of it when I've finished doing the car, more out of curiosity than anything.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5156_zpsfcdowpny.jpg
New boot on and then a trial fit of the new joint, just to make sure...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5157_zpsq7rjpoif.jpg
Greased it up, the full sachet supplied with the joint and fitted it. Then fitted the clip. A pair of pliers like this are essential for this job.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5158_zpsuomlcpc8.jpg
Cleaned up and carefully inspected the inner joint boot. It is like new with no signs of wear at all. Not bad for something that old.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5159_zps5zsirno1.jpg
A random shot of the dirty disc shield.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5160_zpstioeibqg.jpg
Back onto the car. This era of VW and Audi's are prone to the front wings going rusty. Starting from here and also where a lump of foam in close proximity remains wet. Mine was / is spotless.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5161_zps4et7dgqi.jpg
Same here, no rust at all
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5162_zpsmyfbffah.jpg
Edge of the bit of foam on the left, again spotless and rust free.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5164_zpsql8zaric.jpg
Subframe alignment holes for reference. I'm not dropping the subframe this time as I don't have an engine crane any more. You need to support the engine to remove the subframe. What I will though is touch up the subframe on the exposed bits facing the wheelarch.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5166_zpsgyituscq.jpg
A tiny bit of surface rot on the subframe. Not the best pic but this type of rot leads to bad things and maybe in another 20 years it could cause an MOT failure!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5167_zpsbecyet6o.jpg
On a Ford of this era, a seam / joint like this would be rusty, this is as clean as a whistle, no sign of rust at all.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5168_zpsia8dfxwt.jpg
Same here, no sign of rust and testament to the VW build quality. Very pleased to see nothing in these areas. I do know that there is a bit on the drivers side but that may be due to a bad accident repair earlier in the cars life.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5169_zpskduuvckh.jpg
And that is it for today, I really couldn't be ***** to do anymore.
Another non day.
I got the bumper and part of the front end off as well as the front wings and gave it all a good jet wash and scrub clean So I could inspect things. My suspicion always was that the car had early in its life been involved in a dink to the front drivers side, those suspicions were confirmed when the wing came off, it was / is a replacement.
Having carefully inspected everything for rust, all is good except for some very minor bits here and there which will be easy to deal with. One bonus is there was a bit where I was sure it was a bit rotty but for the time being it seems now that the dirt is out the way it just some runs in the paint.
Font end off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5170_zpsbwahl6kc.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5171_zpsmczctdda.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5172_zpsqgtajbgy.jpg
Dirty but rust free
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5174_zpszic2jbb3.jpg
Mud trapped by the poofa block type thing
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5177_zpsmfrb4fwd.jpg
Removing the big foam rubber poofa block type thing.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5175_zpsrkqccnkm.jpg
A poofa block !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5176_zps5eyhvwqb.jpg
The poofa block stops crud collecting here at the wing base but not all. No rust though in what is a mud trap
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5182_zps8jfdgn3n.jpg
You can see the depth of wax applied from the factory, good work VW
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5180_zpsvbo6dwgb.jpg
Suspicion / exibit Nr1; overspray on the cable gaitor
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5185_zpsripi7omx.jpg
exibit Nr2; paint off the wing bolt
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5173_zpsfemfgdoz.jpg
Wing off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5178_zps1xvywa3v.jpg
And the other wing off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5179_zps5dxyn2h4.jpg
Initial inspection, just dirty
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5181_zpswggcstn9.jpg
Hinge and bracket! I can clean these now which is very difficult otherwise
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5183_zpswlfu2hsq.jpg
Wings. the factory fitted one is silver, the replacement on is black.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5186_zpsm0pukfbu.jpg
Very clean and totally rust free although I've to carefully inspect these
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5187_zpsrpju1shq.jpg
Another poofa block of foam. This one is bad as it is the primary cause of wings rusting on this vintage of VW / Audi cars. I'm not sure if it is going to remain or if I'll remove it. It is the bit that touches the lip / edge of the arched bit. It obviously chaffs and and stays wet and lets rust get a hold. I've no idea why this car seems to be un-effected by the issue. I was at least expecting to see the start of some rot, but as said I've yet to take a close look.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5188_zpsioxxaf9h.jpg
The other side of the mud trap
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5189_zpseblzv1nb.jpg
Wings on the garden seat cushions. The Wife will be pleased just as she will be when she finds outs about me using all of her cotton buds I used earlier to clean the brake slider brackets!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5190_zps40vubpxy.jpg
A quick look after jet washing.
Spot welds again as were a few on the back showing some light surface rust. I wonder why they are susceptible?
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5192_zpsmnoxa9hz.jpg
A tiny bit of rust but above the paint runs which I thought were rust. The black stuff is factory applied rustproofing wax and nothing to worry about.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5193_zpspddo3pdf.jpg
And just another tiny bit of surface rust. Likely to be as a result of low standards in the repair done years before when the wing was replaced.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5197_zpspyc0njjj.jpg
Sunday evening.
What would you do? Watch whatever cack is on the telly, too early for "Netflix and chill" not that the Wife has any idea what that means so I guess it is a no-no, go to the pub or if you have a lit garage mess about with lumps of your car?
I thought it'd be nice to mess about with the car or lumps of it.
The front wings as taken off the car earlier on. I gave them a good clean and had a good look at them. Good news, almost completely rust free and what bits there were were only light and superficial. Wanting to keep them that way I set to work. The replacement wing by the way is a genuine VW one not a pattern part so i guess it must have been fitted very early on the cars life.
I spot sanded the few bits of surface rust off them, mainly on the return edge where it folds back under the wheelarch and then got the rattle cans out. Ordinarily I wouldn't attempt any spray painting when it is this cold and damp as it can lead to the paint 'blooming' but the areas were small it meant I could use the electric paint stripper as a drier for the paint.
After sanding the rust spots out, I lightly sanded the rest of the lip to act as key, then primed, base coated and two coats of laquer. It was a very quick process as I was drying it almost immediately with the heat gun and secondly the finish is not important.
I then masked off and applied a nice thick coat of my favourite black paint on the section where the wheelarch liner bear onto and could possibly rub and chaff the paint off. I plan another two thick coats of this. Much like Gandalf telling the Balrog that he shall not pass, I said to myself "these wings shall not rust" or that is the plan.
Quite how the car had avoided the rust issue on the wings in the first place is unexplained but I'm very pleased that it hadn't as I was expecting to have to do a lot more to the wings. A bonus. The foam rubber poofa block on the wing is not going back on I've decided. Don't confuse them with the other poofa blocks that will be going back on by the door shuts.
A post wouldn't be complete without pictures...
As clean as a whistle
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5199_zpsadrwgig5.jpg
As was this one.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5200_zpsqsr7h7nk.jpg
Clean wing with now redundant poofa
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5198_zps8zz1yjdl.jpg
An action shot of me somehow drying paint with the heat gun and taking a photo.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5202_zpsf2ugdaz2.jpg
The wings cunningly hanging up from the garage roof on bungy chords
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5205_zpsrq02eqx2.jpg
Nice gloopy thick coat of paint.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5204_zpsp8dz6lky.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5203_zpsmx8jqske.jpg
Photobucket for some reason changes the order of the photos so some of this may appear out of sequence.
I've almost got the front suspension built up and finished but came in for my 'tea'.
When using a wire brush in an angle grinder, sometimes this happens. Not too bad in the finger, having one in your lip stings a little bit.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5206_zpsl73okdo4.jpg
Cleaned off the surface rust
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5207_zpsfqzec5yo.jpg
And painted it
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5208_zpsatf6q8r8.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5209_zpsft65eibs.jpg
Also had a go at the crush damage on the sills. They will never be perfect but I can add back so form of protection.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5210_zpshg7jaszu.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5211_zpsv6gefwh3.jpg
Bashed back as good as I could get it and cleaned off the surface rust
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5215_zps6gkegoic.jpg
The rear sills were easier, got them nice and straight
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5216_zpsodebyomq.jpg
And then, you guessed it... paint
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5218_zpsraqj94lx.jpg
Sometimes something happens that makes you think, 'oh dear' but in real life the words are stronger.
Remember the new front brake carriers, well I came to fit the first one. Sxxt the bolts don't got in. Sxxt, no wonder they were cheap. I got the drill out, the carrier in the vice took the photo below and started to drill and then off popped a washer, one of the ones I'd put on to prevent paint going on the mating face. Turns out that I'd painted them so well it wasn't obviously visible.
Emergency over!
Comparing the existing one with the new one which the holes are too small on....
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5221_zpsqoba9ivt.jpg
The offending washers prized off!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5222_zpsa7nkkkbn.jpg
What a plonker.
So here we go, the drivers front wheel
As it was at the start. With the wing off you get a view not normally seen.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5223_zpsvsdcwye3.jpg
Starting off the the upper arm pinchbolt. These rust solid in place and can cause a whole world of pain trying to remove. I've never had any bother with them. When I initially removed these from the I plusgassed them every day for a few weeks before hand, they were tight but came out. I've replaced them twice over as well since and always slather them in copper grease when they go back on. Strangely allmost all traces of it are gone each time they come back off.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5225_zpsn7dmz9ru.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5234_zpsb94qb2rc.jpg
Pop the upper arm balljoints out of the knuckle top
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5235_zpslwvjcs4b.jpg
Trackrod end. Not the feeler gauges in there, this dimension needs to be preserved. That dimension and what it signifies and does could take up a thread on its own.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5227_zpsqpqzipxr.jpg
Caliper spring off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5228_zpsqmqnsyxr.jpg
Then the caliper, two allen headed slider bolts on the back then you have to lever the caliper off the disc. Pic is the caliper unside down on an axle stand showing the slider bolt ends
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5229_zpscyfbibx2.jpg
Then the caliper carrier bracket and then the disc which just lifts off, well did on mine, others may be stuck with rust and need a whack. You can see the wear on the carrier here and where the pad end was sticking.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5230_zpsw0o7l7as.jpg
Into the engine bay to undo the carrier plate for the strut and tops arms, x3 bolts. One here
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5230_zpsw0o7l7as.jpg
One here
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5237_zpswvtlqb8z.jpg
And one here
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5238_zpsacilfslp.jpg
Remove strut / shck lower bolt
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5232_zpsa3ysnkl6.jpg
Press down and take the shock, upper arms and carrier assembly complete. More later on that.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5239_zps2gqsftw0.jpg
Pull the abs sensor out of its housing, I'd already cleaned it in this pic. Reason for removing is not to damage it when pulling the cv joint out of the hub and also so it is out the way when you tackle the driveshaft inner joint bolts.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5240_zpsfvgdbz5a.jpg
ABS sensor safely tucked out the way.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5241_zpsk2xeuknm.jpg
My method of removing the driveshaft inner bolts. These are 10mm triple square "cheese heads". In the pic two bolts in the drive flange where the wheel bolts go with a breaker bar to prevent things turning. And then a 10" wobble extension bar, another 10" extension bar and a 5" extension bar, a total of 25" with the triple square bit on the end with another breaker bar on the other to do the undoing...
Looks bonkers but beats struggling under the car itself
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5242_zpsqkom14cb.jpg
How long...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5243_zpsbok4e4vo.jpg
There she blows. I had the break the joint between the 'flange' and the joint with a screwdriver lightly tapped by Mr Ballpien Hammer.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5244_zps2zvipl5q.jpg
You can then pull the knuckle forward and withdraw the driveshaft from the car. Much easier than splitting the lower arms providing you pinch bolts are good.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5245_zps97wz8dig.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5246_zpshnwuiqpy.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5248_zpsphwf3sxa.jpg
On the bench to have a look. Regardless of condition I was swapping the CV joint. The hadn't failed but it wouldn't be long until it did.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5250_zpsnve0exxc.jpg
Split the clips
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5251_zps3ml3lbg1.jpg
Cut the old boot off, new stanley blade for this job!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5253_zpsx57kxxxs.jpg
Mess, clean as much of this off as possible using the kitchen roll you stole from the kitchen before you start hittng it with the lump hammer.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5254_zpsnja5x2jd.jpg
Joint popped off the shaft after some whacking with Mr Lump Hammer (pictured). I had to give this one a good clout and would have really struggled if I didn't have a bench vice. For this reason alone it is worth taking the shaft off the car. I would never have been able to have hit it hard enough with the shaft still on the car and would have risked damage to the inner joint and or gearbox bearings.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5255_zpsdsqm5oud.jpg
Clean the shaft end, really clean it! Then trial fit the new joint with no circlip just to make sure everything is good before you apply grease into the new joint.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5256_zpssplahgnu.jpg
New CV joint kit
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5257_zpsq5zrx5dn.jpg
Concave thrust washer on, note direction, plastic sleeve
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5258_zpssicr6ve9.jpg
Deliberate mistake in previous shot. PUT THE BOOT ON FIRST, you plum!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5259_zpsgz0tjsu4.jpg
That is better, this time with the boot and the new circlip.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5260_zpsylnvsy7x.jpg
New grease in the joint. Some say put half in the joint and half in the boot. I say put it all in the joint and let what will be work its way into the boot when in use. Also less messy to fit doing it my way.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5261_zpsfoexvqhn.jpg
I've said before and say it again, if you are doing this get some of there clip pliers. Also; TOP TIP, if you have never done this buy a few spare clips as you WILL ruin a few until you get the hang of it unless of course you are a super hero type.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5262_zpsdakbasix.jpg
As was on the passenger side shaft the inner joint boot was as new.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5263_zpslweq4eqc.jpg
A moody sidelit shot of the gearbox drive flange.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5264_zpsx2h747ro.jpg
Action shot - SHAFT SCREWED to FLANGE ... only finger tight.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5265_zpsdmvloirh.jpg
Back the to upper arms and strut
Old strut
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5266_zpskqe77mjn.jpg
The spring was getting crusty, another year or two like this, this would have snapped.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5267_zps81pra9yl.jpg
Two 13mm nuts secure the strut to the carrier. Everything looks messy but this is mainly waxoyl from last time I had this off, no need to clean it.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5268_zpscvnizvhh.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5269_zpsriyqf6ik.jpg
Man maths time. This dimension should be 47mm for standard ride height. I guessed it would need to be 40mm for the revised ride height. I was going to go for 42mm but thought sod it and went for 40mm.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5270_zps6cugmqb2.jpg
Back on the car, new strut on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5271_zpsxmeead3i.jpg
An random shot of the completed passenger side. As I've said with the wing off, you get a full view not often seen of the full mutlilink suspension.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5272_zpsk3vmy4ek.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5273_zps95b8dxkq.jpg
Back to the drivers side. Strut in, driveshaft in
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5274_zps92jwxypx.jpg
I've got it all back together and have fitted the bumper back on for now as I wanted to check the panel fit when the wings went back on. I'm really pleased with the condition of the car underneath. The fact that the wings didn't any sign of the usual rot was a massive bonus. Assembling everything back to together waxoyl was used and should see the car in fine fettle for a long time yet.
Waxy goodness
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5279_zpsvtm1bene.jpg
Very pleased with the front wing condition and now with added protection, the strip of thick black paint slopped on.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5276_zpshjv2csjv.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5277_zpsy9q6cxuf.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5278_zpspiwyhlri.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5280_zpszrjc1npi.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5281_zps7xblcxad.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5282_zpsniqososs.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5283_zpsbul6zha8.jpg
The sill covers also got a splodging
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5284_zps5mmcrp0p.jpg
As did the edges of the wings
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5286_zps1rs6ku1z.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5287_zpsylby6bog.jpg
All done. Arch liners back on, sill covers on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5289_zpslgzomu3a.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5290_zpsbzucbk8o.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5291_zpsqbcokfjq.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5292_zpsjqm149fj.jpg
All that is left suspension wise is yo get the car over the pit and loosen then re-tighten the lower arm bush bolt to suit the revised spring height. I also need to refit the lower engine covers and the rear beam cover.
Just to show it is like any normal car, the indercovers are a bit battered and very dirty.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5292_zpsjqm149fj.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5294_zps3jnj88nr.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5295_zpscbbxfrdx.jpg
Sorted.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Front%20end%20refresh%20Mar16/DSCF5296_zpspygeza7i.jpg
Next phase is the cambelt and all of its associated gubbings.
I last did this back early 2012 and did just the basic belt, tensioner, deflection pulley and water pump change. The car has covered about 40,000 miles in that time and so it is time to replace. I also relaced the aux belt and aux belt tensioner last time but re-used the A/C belt and tensioner.
This is especially so as the car has recently developed a bit of a squeak when it is cold. I've just been out and started it up cold after over a week of it being sat while I did the suspension work.
I have assembled the necessary bits and bobs. I'm doing everything!
Cambelt kit. I went again for a Gates kit. I really like them as they normally as in this case come with a genuine Litens tensioner.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5300_zpsis0xaglb.jpg
With this kit came a water pump as well. Yes, it is a plastic impeller and yes I prefer them as any failure on the waterpump is less likely to lock the belt and cause engine failure.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5303_zpsmdmz99l8.jpg
Auxiliary belts and both tensioners.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5305_zpsmlifxmty.jpg
Genuine INA alternator pulley, a new tool to extract it, and the viscose fan bearing.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5302_zpsfcjsawst.jpg
An tool just as essential as spanners and sockets, a laptop with a VCDS / Vagcom cable.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5306_zpswphndqfm.jpg
I also checked the syncro angle for the camshaft timing before the belt change. I set this to 0.0 four years ago when I last did this. 40k and four years later it is at 1.1
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5309_zpsum58kuyh.jpg
I'm currently in two minds as to get out there and get stuck in. Both of the kids are flaked out with some flu like lerg which no doubt I willl also get. The question is and as i'll be doing this over a few days is whether to start it at all. If I get the lerg I won't much fancy doing anything to the car. I had set aside and planned some 'off the road' time for it but this will extend that. I also have a few meetings to travel to next week.
I decided to crack on....
For those that think I'm mad, I am but I find it quite theraputic taking photos and then talking about them. It is a bit like going through old family photos but instead looking at oily bits of metal.
So...
To undertake such a task you need a fairly comprehensive tool kit including a set of torx bits, a socket set or two in 1/2 and 3/8 and even 1/4 drive with various extension bars, breaker bars and even wobble bars. A good set of spanners including 15mm, 16mm and 18mm which a lot of basic spanner set miss out. Also a set of allen keys.
An essential part of doing this job, like any cambelt change job is to have the correct locking tools so as to enable you to time up and lock the engine in the correct position. Years ago a blob of tipex sufficed but not these days despite what some bloke down the pub says. You must use proper locking tools. For VAG these are generally quite cheap, which is nice.
Also before you begin, plan the job and make sure you have everything to hand as far as possible. If you are doing this on your daily driver plan for having to use alternative transport in case things go wrong, they often do.
As for time, I can do this in a day without breaking a sweat but I'm going to take much longer this time as I will be properly cleaning everything and refurbishing some parts.
The first job is to take off the engine undershields which I won't go into. If you cannot take care of that you should be attempting a cambelt change!
Take the front grille off, one torx bolt each end
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5310_zpsqhb29aav.jpg
Pull this tab and lift the grill upwards
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5311_zps4zxv9jaq.jpg
You can take the grille off now or later. I hate the silly little clip for the bonnet release so leave it until I have to remove it. I work round it for the most part. Four torx bolts along the bottom of the grille for the top bumper fixings.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5312_zpsdemuuygl.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5313_zpsznxuiw5v.jpg
There are also four torx screws under each wheelarch which hold the back of the bumper to the wheelarch liner. Once the screws are out wiggle the bumper off at the wings and pull forward. Don't drop it a scratch it!
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5314_zpssyiasuo2.jpg
Next is the plastic bracket behind the grill, five torx bolts, two at each end and one in the middle.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5316_zpslyeshacy.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5317_zpsd5bg40wg.jpg
Bracket off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5319_zpslom1dmtr.jpg
Headlight off now, not essential but I do. Four torx bolts for each one. Two on top, easy, two difficult ones, one of which is under the rubber cover on the slam panel
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5320_zpsue2er8je.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5321_zpsrzp8njyp.jpg
Keep your bits and bobs in an orderly fashion. There is so much to take off you will forget where things go otherwise.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5322_zpsaohol2ms.jpg
Pull the rubber off around the engine
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5323_zpsj65caog0.jpg
And remove the plenum cover
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5324_zpsu29z3fkb.jpg
Next separate the bonnet pull cable, lever open this thing
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5325_zpsavmhus7h.jpg
And pull the cable apart, like so...
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5326_zps9tvypkf2.jpg
Lock panel fixings now. The lock panel is the whole front end panel that the headlights fix to, the radiators are mounted to and of course where the bonnet lock is located
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5327_zpseu72t5sl.jpg
Remove the various shrouds, philips screws hold these on
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5328_zps96njqopr.jpg
Unplug the horns! One each side
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5329_zpst3s8c2og.jpg
Remove the wing bracket to lock panel screws and on the passenger side the washer bottle screw
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5331_zpsegc5a1uy.jpg
The actaul bumper crash bar now. This is held on by big torx bolts and also two tiny 10mm nuts. Undo them the nuts
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5332_zpsetouz5o1.jpg
Then the big torx screws. These can be very tight and can round off causing a proper nightmare. I had this last time where I ended up having to drill one out. Make sure the torx bit is firmly in position, even tap it in lightly with a hammer. Use a breaker bar if needs be to crack them loose. At this point the front end will come away.
You have two choices;
1, Take one torx bolt out each side, then install some studding (threaded rod) so as to support the lock panel when it is pulled forward to create room to do the belt change. Most garages will do the belt change with the lock carrier pulled forward like this.
or
2, Carry on and take the whole front end off. This is about an extra half hours work but for a DIY'er pays dividends in so far as you can actually properly see the belt area and get up close and personal with it. You can also inspect the radiator which will be likely be rotten and leaking coolant anyway.
So....
Undo the big torx bolts
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5333_zps0m50n75u.jpg
Unplug the A/C pressure switch, not really necessary but safer to do so in case it gets snagged
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5334_zpsvvgh05tn.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5335_zpsf0x69kfr.jpg
Take the crash bar off. At this point the front end will be "flopping" about
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5337_zpsahwhli1x.jpg
Another shroud
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5338_zpsvdupwqc9.jpg
Shroud coming off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5339_zpsncuf8azg.jpg
And low and behold a rusty radiator header tank. I really wasn't expecting to see this as that rad was new four years when I last did the belt
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5340_zpsnudn6zrw.jpg
Undo these 10mm bolts, two each end, remove the brackets and lift the A/C radiator up out of the mounting brackets on the water radiator..
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5342_zpsv9zjtwb2.jpg
And swing the A/C out to the side. Gently does it, it is delicate. It makes a lovely trip hazard.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5343_zpswvfrrrss.jpg
Drain your coolant, then undo the coolant hose clips, you need to pry then undone.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5344_zps7cpqjbno.jpg
Should have done this earlier, but undo the two 10mm bolts holding the power steering fluid cooler, unclip the outside coolant temp sensor and swing them out the way much you did with the A/C rad.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5345_zpsovpebrst.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5346_zps7cocycwb.jpg
Pull the lock carrier forward a bit then undo the wiring connectors by the power steering fluid tank for the fan etc and then lift the lock carrier off the car
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5347_zpsut3cwvup.jpg
And there we are, a naked front end ready to do the belt change on. It took me about 90 minutes to get this far without any issues and with me knowing how to do it. If it is your first time, double that to three hours.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5348_zpsruxqw0cz.jpg
So, knowing the radiator was as rotten as a pear despite only being four years old, it has to be removed from the lock carrier. Two clips and it is out. Push the clip in and pull it up and out, the rad then swings forward and out of the lock carrier.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5349_zpskzivksnq.jpg
Not pleased
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5350_zpssxtrhfys.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5351_zpsz8mfqcew.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5352_zps46k6s1ip.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5353_zps5s7mcnqs.jpg
I took the front thingy ma bob thing off which acts as a locator for the front engine mount / stabilser and cunningly as a pipe for the boosted intake air from the turbo to the intercooler.
I did this as it was scabby rusty and likely in a few years to perforate which would mean the engine would loose boost.
The lock carrier and the thingy thing with the intercooler on the "Workmate"
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5355_zpspawosxce.jpg
Gungy gungsville. Do you like the nive little red hat I've put on the turbo inlet?
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5356_zpsufwguxgj.jpg
Had a bit of a mission getting the hoses off the thingy thing
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5357_zpsxvuonwd9.jpg
The snub nose front engine mount. It was in very good condition but I'm ungrading it to the more beffy version off the V6 TDI
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5358_zpsvpbmux03.jpg
Some people call these Sponge Bob's ring piece.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5359_zpsmmkfrzzx.jpg
And then I cleaned up the thingy thing, this took as long as it did to get the front end off the car. It took an age first getting the gunge off then cleaning the rust off as best I could.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5360_zpswgppydwo.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5362_zpsowlddaov.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5363_zps28nbudjh.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5364_zpsiwpefdgw.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5365_zps2bxlfqwb.jpg
And then, you guessed it. I painted it ! Three coats for this thingy thing !
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5366_zpslkz3mkrf.jpg
Cracking on with the cambelt change itself.
Whatever cambelt you are doing you must have the correct timing tools.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5373_zpsci25abr6.jpg
Engine as is after taking the front end off.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5375_zps0vq3rren.jpg
Engine top cover off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5378_zpsr9vsmffh.jpg
I like to loosen a few key components to start with. If you get stuck on these then you are, well stuck, so it best to get them over and done with.
Prise out rubber cover over crank pulley bolts
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5379_zpslsqybnvi.jpg
8mm allen key socket for the viscose fan, if you are lucky this will undo whilst the aux belt counter holds the fan pulley, I was. If not in the past I've used some soft jawed pliers to counter hold the puuley
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5380_zps1sabpquf.jpg
Fan coming off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5381_zpsosedbpgj.jpg
Fan off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5382_zpssgbk8axf.jpg
Crank pulley bolts. These are made from cheese and easily round off. These were re-sued from last time I did the belt which would have been the second belt change on the car. They did not and would cope with a third belt change. Despite having good and close fitting tools they rounded off. Luckily for me as I've got stuck at this point before I had a set of Irwin bolt grip sockets as pictured. Lightly tapped on to each cheese head it had them off. If you are doing this, make sure you have a similar means to get past this hurdle if these cheese heads round off!
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5384_zpsdw52nqsm.jpg
Counter holding crank via 19mm center bolt and then using another breaker bar and the bolt grip socket
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5386_zpsxlty3y3k.jpg
Also make sure you have the means to get the old cheese heads out of the bolt grip socket. They are very good at gripping bolts and need some whackage to get them out.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5387_zpsbmsb8clc.jpg
Damned things, all out.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5388_zps0zajpoar.jpg
Aircon belt, loosen pivot bolt
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5389_zpskktbdlmq.jpg
Then the clamp bolt
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5390_zpstcu3ea8b.jpg
Take the belt off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5391_zps24qhawju.jpg
Taking the tension off the aux belt, 19mm spanner counter clockwise, take the belt off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5383_zpsmzpvm7zt.jpg
Aux belt tensioner lower bolt
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5393_zpsn9p9azgc.jpg
Viscose fan hub already off, remember the first bolt undone from the back..
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5394_zpsby4axguw.jpg
Aux belt tensioner upper bolt
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5395_zpskvmr2oas.jpg
The growing collection of lumps of car
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5396_zpsjpv961ck.jpg
Both aux belts off including tensioners, fan and fan hub off
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5397_zpsjkoyni5t.jpg
Top cambelt cover off, two spring clips. You can see the five 10mm bolts that hold the two lover covers on, take them out and remove!
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5398_zpsss5w6cgd.jpg
Evidence of the old water pump leaking, crystalised coolant This is another reason why you should always change the waterump
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5400_zpsrexu9tbk.jpg
Out curiosity, I wanted to see what the belt tension was. It was out a bit but as expected after 40k on the car.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5401_zpspsozujtv.jpg
New belt on.
If you have done one of these on an 8v PD engine they are incredibly tight to fit un-tensioned which is why I favour leaving the deflector pulley off until the belt is mounted. It also helps if the tensioner is right out on the end of its mounting stud with the belt looped over its lip and then draw the tensioner in whilst pushing the belt over the cam pulley.
From the last post, naked bare timing end of the engine. I spend quite a bit of time making sure everything is as clean as I can get it. I used almost a whole can of aerosol brake cleaner doing this washing every sign of grease and grit away focusing on the pulleys.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5424_zpswzqzbbll.jpg
First job is to swap the mounting studs out for the tensioner and idler / deflection pulley. Ye olde lock nut trick is the one to use for this.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5426_zps0oz5qfsh.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5427_zps5lspbiaw.jpg
I like the Gates kits as they use Litens tensioners
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5428_zpsp74x1ooo.jpg
Make sure the angled elbow bit fits into the corresponding slot in the backplate seen in the background
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5429_zpsb0c3cvmc.jpg
Like so
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5430_zpsha0zfld7.jpg
New waterpump on, new tensioner and mounting studs on.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5431_zpsnkwgssg5.jpg
Belt on. Make sure the cam pulley is centered in the middle of the elongated slots and is free to rotate. Obviosuly both locking tools are in at this time. As above these are a tight fit and can take some time and effort to fit. The PD TDI belts are very heavy duty things being twice the width of a normal belt. Massively engineered I suppose as the cam drives the unit injectors.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5432_zpscmwfmkp5.jpg
Tensioning the belt. This is a bit of trial and error as when you tighten the tensioner lock nut the tension increases.
To prove the point, this is the basic tension before tightening the nut. The pointer is in the middle where it should be
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5435_zps8bwtjzko.jpg
But when tightened it is clockwise out of the 'window'.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5436_zpsw0zmecol.jpg
So to get the tension spot on, start low or slightly anti-clock from the center of the window so that when you tighten the nut it pulls it to where it should be. Start here.....
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5437_zpsb46svcs5.jpg
One attempt, nearly there.... I gave up taking photos at this point but it took another two goes to get it '****-on'. Now tighten the three 13mm bolts so the outer cam pulley is locked back to the inner pulley.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5438_zpsl60u36re.jpg
So now, you have enverything tightened up, the engine timed up with the locking tools in and the tension set. You now need to 'prove' your work. Pull the timing tools out and then turn the engine over two or four times via a socket on the crank pulley and then put the locking tools back in position. All being well the tools will glide back in. If they don't you need to undo the three bolts on the cam pulley and tweak thing a bit (much like you did when you set the initial timing).
The best way I've found to do both this for the initial timing at the start of the job and the final adjustments is as follows;
Get the crank locking tool in.
If the cam locking pin won't go in then remove the crank tool.
Finely rotate the engine until the cam pin goes in, you cannot see the 'ole for it so it has too be by feel or this way. Rememeber mine was about 1/4 of a tooth out.
Undo the three cam bolts
Offer up the crank locking tool so you can see which way you need to turn the engine, it should be close.
Both tools should slide freely in and out.
Tighten the three cam sprocket bolts back up.
Check the belt tension again, the pointer.
Remove the tools and rotate the engine again 2 or 4 times.
Repeat until you are happy.
****-on
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5439_zpsj3w6z6ey.jpg
For me, the way I left was that the timing tools went in with just a knats-**** of a tweak required to get them both in, they did were just a bit tight. I'm not too worried about it as it will be close enough and i'll check the timing (syncro angle / torsion value) with the diagnostic software once everything is screwed back together.
It is quite easy to adjust if needs be when the car is fully back together, all that is needed is the engine cover taken off and the upper cambelt cover unclipped so as to allow access to the three cam sprocket bolts.
Covers back on and job done, well the cambelt change is anyway.
Quite exciting and into uncharted territory.
I swapped out the viscose fan bearing after some head scratching and cobbling together some big sockets and some thread bar. The bearing itself is a snug interference fit into the huge aluminium carrier bracket that holds the alternator and power steering pump also. A **** up would be expensive but I forged ahead regardless and did it.
I also swapped over the alternator over run pulley clutch type thing, very easy to do once you work out it is a left hand thread, d'oh !
Blurred shot of the fan bearing being drawn out
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5441_zpsqvtk6qku.jpg
Pulled out to the edge of the casting, a bit of a re-think and a bigger socket that the bearing can be drawn into
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5442_zpswvqjrx8o.jpg
And the bearing out
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5444_zpsddze0n4c.jpg
A 30mm socket was a perfect fit for drawing the new bearing in
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5445_zps4inooltk.jpg
New bearing with socket pushing on the outer race, starting off...
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5446_zpsfu5h5yvv.jpg
Side view of my Heath Robinson setup for drawing the bearing in. Very pleased with how it went.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5447_zps4yw1cod8.jpg
2/3's of the way in
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5448_zpspyloxlzb.jpg
In
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5450_zpsdkydldau.jpg
The H.R. tool. The small socket is 30mm the big one is huge.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5449_zpsndyg55lb.jpg
Cap off alternator pulley
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5451_zpsmazuwvlb.jpg
The extractor tool. The old pulley unscrewed and the new one went on very easily
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5452_zpsf41uj6x1.jpg
All of the aux components on, new tensioners and new belts.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5453_zps18ofyyxx.jpg
Just about finished. All there is to do is reset the front lower arm suspension bushes for the revised spring height, put the undershields back on and have a jolly good tidy up. It would also be rude not to give the car a clean as well.
I spent some time replacing the vacuum hoses that are ordinarily hidden when the front end is on.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5454_zps3thydbcb.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5455_zpsyarzpjvk.jpg
And then carefully cable tied the vacuum lines togehter so they cannot rub and chaff
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5456_zps4afitdwe.jpg
And then spent what was an eternity cleaning the the intercooler and pipes
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5457_zpsscbbl43l.jpg
New 'green' seals for the boost pipe junctions, new chesse heads for the crank pulley and some 'o' rings for the radiator. The 'green' seals are about £6 each and are revised from the older 'black' ones. Legend has it that a key ingredient of the green seals is a special rubber compound from the amazon rainforest that has to be collected by licking the leaves of the special trees and then spitting the juice into a jar. I've just made that up but for the price I'd like to think something exotic has to happen to make them!
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5458_zpsdznriays.jpg
And then I spent ages assembling and all the boost pipes off the car as they are difficult when on the car. I wanted to make sure everything was just with them before fitting them
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5459_zps9s1zfp2o.jpg
One green one black, I swapped there for two new greens and used the exiting green higher up on a joint which is more accessible.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5460_zpsrppmlopq.jpg
Getting there
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5462_zpsu4aetpgi.jpg
The new rad, Eurocar parts are a funny company. This time I went for a "Magnelli Marelli" rad instead of one of there EIS cheapies. The bonus was when I went to collect it was that it was a OE Valeo item with galvanised header tanks. Nice.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5463_zpssatunnoj.jpg
The new radiator, fun was had. I had to cut this lug off to make the A/C rad on top.
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5464_zpsbd2fo6eu.jpg
Quite pleased with how the cars sits now
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5472_zps8z334bfr.jpg
For a bit of madness, I like to layout all the bits I've changed and take photos of it!
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5465_zpspyficghb.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5466_zpsscpknzgk.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5467_zpsstszlwnm.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5468_zpsmhpulbsc.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5469_zps8yz03g8z.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5470_zpsre6dl9oe.jpg
http://img.photobucket.com/albums/v602/colin__/2016%20TDI%20cambet/DSCF5471_zpsyy7nalvq.jpg
It is a good job I'm hands on with the car.
Just seen this...
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5474_zpse0kzk4pc.jpg
That is a very sweet and acrid tasting drip of coolant on the passenger side floor mat. Sticking my finger above into the heater ducts, they are wet.
Gutted.
As far as I'm aware, the only way to change the heater matrix on these cars is via the full removal of the dashboard and heater box.
Not a job I really want to do. Despite the love for the car, at times like these, the £250 per month PCP and or a company car seem like reasonable prospects.
Has anyone done a heater matrix change?
Another pic taken today.
I need to get the matrix done as soon as before it fails catastrophically.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5489_zpsnpk7l7td.jpg
Despite the heater matrix issue, the show must go on...
Gave the old hector a good clean and a polish today along with blacking up all of the lowers, that takes ages.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5486_zpsf2l5lkxo.jpg
Clean and shiny engine bay, as clean as the rest of the car.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5488_zpswuheadst.jpg
Lovely new belts and pullies and gubbings
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5490_zps9teuyame.jpg
The plan is to buy a new matrix this week and start stripping down on this coming Friday evening which isn't a problem for me as I'll do it under the very well lit car port rather than the garage as I'll need room to work on both sides which I can't do in the garage.
I'm really not looking forward to doing the matrix as I think it is going to be a massive and fiddly job.
F***king Hell, what a nightmare.
At the start I looked at the Haynes manual, rolled my head back and laughed like a pirate, then closed the book. Turns out that was a good call as it would have been useless, skipping out ALL of the man traps.
Five hours work and the heater box is out of the car. I would say at least half of that time was spent scratching my head working out what was stopping whatever bit coming out I was trying to take out.
The biggest man traps are, in no particular order...
1, The cross member, so, so many cables clipped to it with those stupid stupid clips, many of which you cannot see.
2, The cross member, so, so many bolts holding things and it in, many of which you cannot see.
3, The cross member, for some bizarre reason there are two legs that extend forward towards the engine bay which act as a support cradle for the ECU connector plate.
4, Did I mention the cross member?
5, The right hand side plate which forms the stereo housing, two hidden impossi-bolts near the bulkhead.
6, The sunlight sensor loom was a casualty right at the start, snapped the really thin cables, thankfully an easy fix.
7, The heater ducts, some are clipped, some have fixings and you never know which is which.
I knew it was going to be tricky and it lived up to my expectations. I'm currently in the position thinking how the hell am I going to get it all back together and I'm normally supremely confident on all things car.
Anyway, some photos. There is so much to do I didn't even begin to take them of all the stages but the order of work is basically;
a, Stereo out and all associated gubbings
b, Glovebox out
c, Panel above pedals out
d, Front section of cener console out
e, Dash top off
f, Clocks out
g, Drop steering column onto axle stand
h, Cross memeber
i, Heater box out.
First of all, the human cost. Not too much claret was spilt but there are plenty of sharp edges!
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5525_zpslkjlypcp.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5524_zpsafjlhild.jpg
Will it ever look like this again?
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5491_zps058bixic.jpg
Stereo gubbings out
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5496_zps86npzaft.jpg
Everything out ready for the dashtop to come out
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5497_zpsv0zmgozz.jpg
Yey
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5498_zpsozll5dir.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5499_zpsxgh6gojk.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5500_zpsuelmblww.jpg
Coolant everywhere
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5502_zpspifcmej1.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5503_zpsbrlaaujt.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5504_zpsetsu4ngl.jpg
There are two screws that need to be undone via the ECU housing not mentioned anywhere
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5506_zpsvrdjbi6f.jpg
Crossmember finally out, there is also a single bolt engine up under the scuttle so the wipers have to come off.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5507_zpsrmqfx7uy.jpg
Crossmember out
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5508_zpsmtwq9lnj.jpg
Disconnecting the A/C manifold
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5510_zps50sk7tl7.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5511_zpsuml3rypc.jpg
Heater box partly out, at this stage I was undoing and unclipping cables
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5512_zpsp0bvwl0u.jpg
I put the right hand bracket back once it was finally off, this is the one with the impossi-bolts on it. Note to self when things go back in...
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5515_zpsqsfunmw8.jpg
Impossi-bolts are at the end of the arms
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5516_zpsmpogi1sy.jpg
And finally the heater box came out of the car. All I did was take the matrix out to have a look. It is pretty bad.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5517_zpsplosuca0.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5518_zpsbugije1x.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5519_zpsejqiit5g.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5520_zpsadk9phwn.jpg
A bit wet in there
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5521_zpsnqi1ze8d.jpg
The infamous V71 motor, not where internet folklore mainly says it is. It is actually on the far left hand end of the heater box and knowing this I reckon it is do-able with the heater box in the car like it is on a MK4 Golf which I've done.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5522_zpsjg1ycbrq.jpg
Took out the auxiliary electric heater which was soaking wet.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5523_zpsk75hszn5.jpg
I've got to get it all cleaned up, new matrix fitted and back together now. That is going to be fun.
Not much to say really.
I took the heater apart to clean the leaked coolant of it and to have a look more than anything. Also a good to check if there was anything silly that had happened causing the matrix to fail. There wasn't.
I took a load of pictures more for my benefit in case I had trouble working how it all goes back together but I might as well post them up.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5528_zpshkjvpfcn.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5529_zpsl2uwz7wa.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5531_zpsyymfwmeh.jpg
The heater assembly splits into three main parts, the heater section, the A/C section and the air intake section
Heater section below
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5532_zpsf9wzppys.jpg
A/C evaporator
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5533_zpsqcacdsqi.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5535_zpsiupaxya4.jpg
A/C evaporator left, heater matrix right
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5536_zpsgmbtvoks.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5537_zpsmxxwrril.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5538_zpswx9hcsmn.jpg
Manky and well worth the effort of splitting it open and cleaning it all up
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5539_zps8vidifna.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5540_zps3treutc2.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5542_zpso0t5ampe.jpg
All cleaned, dry and back together
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5543_zps7kls9b4s.jpg
New matrix in
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5545_zpsopv2wiby.jpg
The V71 is not going to happen as this clip is broken and would be impossible to obtain.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5546_zpsdwjj6jlv.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5547_zpsthgqwe7u.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5548_zpsmolq9adf.jpg
And the front comes off yet again...
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5550_zpsrbmhzxlb.jpg
I may have mentioned that a boost hose popped off and popped off again. That'll teach me to mess about with things that are not broken. Corrosion was probably holding it in. I did also mention I had designed an elegant solution using nothing more than my imagination. Well I put it into practice and it sure as hell beats spending £50 on a new hose from the dealers!
I give you an exhaust clamp.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5551_zpsj1ascsvq.jpg
And another. And some head scratching working out the "technical" details of my design...
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5552_zpscdd5qqhg.jpg
Itchy head being scratched some more
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5553_zpsozhznajh.jpg
I think you can see where this is going now
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5555_zpsjnsydnnl.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5554_zpss5lbtc5x.jpg
Offered up
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5556_zps0euqvefg.jpg
Done
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5557_zpsyd1qmvkv.jpg
That clamp works a treat, I have thoroughly tested it and there has been no boost pipe pop-off-age. Well chuffed, the cost was less than a fiver. Obviously not do-able unless you can weld some nuts onto the clamps.
And then I had to finish off by swapping over the aircon bits. Well, I didn't have to but just wanted it done.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5558_zpsn6dp8ilp.jpg
Shiny shiny new thing
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5559_zpshgqt3nha.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5560_zpszf421a8d.jpg
PAG46 oil, bought only for me to wet the new 'o' rings. This is my new favorite smelling oil, it is gorgeous!
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5561_zpse3bkrdmy.jpg
Those seals that 'dry' out if you believe the folklore
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5562_zps0hkgyind.jpg
Shiny on, grubby off
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5563_zpsx4tq91gd.jpg
Nice, bolting shiny new things onto your car is the male equivalent of women shopping for shoes and having warbrobe full of them. I probably didn't need to do the shiny shiny thing, but why not!
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5564_zpsjmoowdn7.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5565_zpspbnt7kpf.jpg
Swap the pressure switch over
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5566_zps38uaf6wx.jpg
Old o ring
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5567_zps2ketp6nq.jpg
New o ring, I bought a full set of new ones from VW for very little.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5568_zpsoseuwpk9.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5569_zpseh70jxsb.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5570_zpsyvrcbcqq.jpg
Receiver / drier now, so I believe these should be replaced periodically anyway so it was long overdue on this 12 year old car
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5571_zpszptdqyvp.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5572_zps8lozgmvl.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5573_zpsykqz9bpm.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5574_zpsdpumdk3q.jpg
Things nver quite fit when using pattern parts. Very close to the horn bracket so I sleeved the pipe and cable tied it on
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5576_zpszftjiukd.jpg
Job almost done.
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5577_zpsbksag2w6.jpg
http://img.photobucket.com/albums/v602/colin__/Heater%20matrix%20Passat%20Mar16/DSCF5578_zpsdcajdt75.jpg
I made another boost hose clamp today and fitted it and did a how-to, posted elsewhere but also posted here, because why not!
You know them, you love them but probably hate them and they are the poorly designed clips for the intercooler / boost hoses, I'm going to call them boost hoses from here on in. I've recently been faced with a bill of £50 for a very short hose with one faulty and worn connector on what is otherwise a perfectly good hose.
So rather than spend £50, I spent less than £5 doing two connections.
What happens is there is a steel "ring piece", yes a "ring piece" on the end of each hose connection with two lugs punched into it. These lugs have a spring clip bear onto it which from the factory secures the hose in position. As the fitting tolerances are quite loose for these things, in use and an in time, due to movement, the punched lugs can wear away giving nothing or a decreased bearing for the spring clip to act upon. Not to mention that this design is not oil and therefor air tight which costs you power and efficiency.
So, one day you will be driving along, hear a very loud pop / bang and loose power. In a diesel there will be a smoke screen and there may or may not be an engine light that comes on.
I'd recently been doing some work on my car where I'd swapped the older 'black' seals for the revised 'green seals'.
After some head scratching and thinking I came up with this fix. It is not strictly a normal DIY job as it does require some welding. But most people know a bloke who knows a bloke who would and could make them some.
What you need;
Two exhaust clamps, one for the hard part of what you are fixing to, measure this. And another clamp for the hose part, this second clamp needs to be 5mm smaller. In my case the 'hard' clamp was 70mm, the hose clamp 65mm.
Two 50mm long M6 bolts, two M6 steel nuts and washers to suit.
Two M8 steel nuts.
These are the bits
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5579_zpsr048dihq.jpg
Position the clamps in a vice or clamp them so as to get them to align as best you can, set them so there is a 2.5mm gap around the edge from the small to large hoop.
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5580_zpsodmorkda.jpg
Line up the 50mm bolt (actually a fully threaded set) with an M6 nut on and an M8 nut loose as below. Ignore the other M6 nut it was only on to support and get better alignment.
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5581_zpshywguhea.jpg
Weld the nuts to the hoops like so...
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5582_zpsuhxe7okf.jpg
I went round and added additional welds. Not pretty I know but this is what you will end up with. On the small hoop two M8 nuts welded to it, the large hoop having two M6 nuts welded to it.
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5583_zpspnjkl70k.jpg
Assemble like this...
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5584_zpsx6pq4aj9.jpg
Fully built up only to show what they look like
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5585_zps8slafrdr.jpg
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5586_zpswcjivo7m.jpg
To the car, this is what I was fitting it to
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5587_zpslzrrbxgq.jpg
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5589_zpsqkniaokm.jpg
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5590_zpsvahmqvze.jpg
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5591_zpsreac3ypw.jpg
http://img.photobucket.com/albums/v602/colin__/Boost%20hose%20clamps/DSCF5592_zps3ldufzro.jpg
The pictures should be self explanatory but some notes on fitting; don't do everything up really tight otherwise you risk cracking any plastic bits. The 13mm clamps nuts are done up first on the larger hoop on the 'hard' part, then the 10mm bolts are tightened pulling the small hoop onto the edge of the fitting and lastly the 13mm nuts on the smaller hoop are tightened. When I say tightened I mean just a smidge!
The last job was to coat them in wax to stop it all going rusty!
How OCD and or totally mad is this...
Pics below are about three years or so old. At the time I thought it would be a good idea to take the badges off the tailgate as they only served to trap dirt and were difficult to clean.
Took the badges off and there were two dents staring at me, previously hidden by the badges. I regretted taking the badges off straight away.
Ho-hum, I thought I'd just live with it. The thing is though, although small, the dents may as well have been massive as they were all I'd see when I looked at the back of the car.
Well, having done all the work I've recently done I gave in and spent £50, yes £50 getting the dents pulled out by one of those wizard like dent puller wizards. I swear it is witchcraft!
There is no point posting up any pictures of the dents removed as it just looks like a tailgate without dents in it. But these are the offending items, am I mad ?
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF3064_zpsm4xcbact.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF3065_zpshmy7ia6u.jpg
A rather mundane update.
I've been simply driving it but yesterday I got two new tyres fitted to the summer wheels, fitted the summer wheels and gave it a good clean.
Ready to go on.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5613_zpsurjfhhd5.jpg
I did black em up
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5614_zpsroqvkumr.jpg
The two existing tyres, about 1/4 worn.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5615_zpsvodmg25x.jpg
Mid range Falken ZIEX's, cost me £110 for a pair this time, fitted at home, no endless waiting in a grubby waiting room thumbing through six year out of date evo mags or tyre fitters weekly.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5616_zpsi5imaesl.jpg
Winters
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5612_zpsfmjfc4z2.jpg
Summers
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5617_zpsjlmh5jgh.jpg
Car mats scrubbed and hanging on the trellis to dry
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5611_zpskrx7bsjx.jpg
Quite happy with the old hector
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5618_zpsswp59hdb.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5619_zps3e29qtpd.jpg
I did say it was mundane, but sometimes mundane is good.
Had a bit of a diagnostics session on the car today. All much as expected.
Engine, no fault codes found.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/engine_zps8a7ai7pu.jpg
Quick check of the syncro angle for cam to crank timing. The new belt has been on for a month or two now, spot on at 0.0
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/synchro%20angle_zpsav8rqysp.jpg
Central convenience system, as expected and known the driver door lock is knackered. I changed that later on...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/locks_zps47jjqp8e.jpg
Something I've known about for a long time but didn't realise it was measureable. Zoze crazy Germans decided to make the wing mirror heaters come on when the switch was in the middle position. Every other car I've had has had the heated mirrors come with the heated rear window.
Heated mirrors, Off when the mirror switch is on, in this instance to the left hand mirror
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/mirror%20off_zpslqoj3cwf.jpg
Mirror heating on when the switch is off. Bonkers
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/mirror%20on_zpspevhn0az.jpg
More knackered lock action!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/drivers%20door_zpsmoxniut3.jpg
Climate control. I know all about the V71, it is knackered and I can live with it. I might have to attend to the V68 at some point though.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/V68_zpsjbntynaj.jpg
No idea what this one means. This on the instrument cluster. I've cleared the code and it has gone away!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/instruments_zpsmimgcxem.jpg
Rear parking sensors, even had a look at them, quite a lot of data from them considering it is ealry 00's technology.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/parking%20meas_zpsfpfi5cfi.jpg
Parking sensors again.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/park%20settings_zpshg8aggqt.jpg
Now how boring was that !
That dodgy door lock.
I changed it out for a £20 e-bay special today and it works perfectly. How on earth they can make them for that let alone ship them here is a mystery.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5620_zpsgvufct6i.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5621_zps0xe6tkep.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5650_zpshrrjifoc.jpg
The inner door panels unlike other cars which use a flimsy sheet of polythene are sheet steel on these which adds to the panzer tank ambiance. May other car makers do the same these days, I don't know.
The panel seals do get bit leaky with age but only very minor signs of it here. Good news
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5651_zpsrzwvmofm.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5652_zpsqyz24ip0.jpg
It seems a lot of people tape the glass up whilst doing the work, I found it easier to simply take it out
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5653_zpse2grjixe.jpg
Very minor signs of water leakage, and photobucket again randomising the order of pictures!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5654_zpsgwxxjnsr.jpg
Inner door panel off, the sealant had gone brittle and crusty
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5655_zpscjcf5nes.jpg
Stupid stupid clips that hold the door lock to the inner panel
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5656_zpsw98j4mcr.jpg
Grommit, I couldn't find Wallace
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5657_zps1ao6hbi6.jpg
Where's Wally ?
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5658_zpsvq2vqvhv.jpg
New vs old lock and white splash shield. I had to transfer the locking rods and cables from the old to the new
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5660_zpsuiimp0ue.jpg
And drill out a pot rivet. It is one tool I don't own and that is a pot rivet gun. Alas I used a cable tie on reassembly much to my peril, more about that in a mo...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5663_zpsqh2efdic.jpg
Oh dear, it was a good idea at the time
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5664_zpslhf664f5.jpg
Attention then switched to the inner door panel, cleaned it up.... a bit.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5665_zpspqsx5jsj.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5666_zps7aytnpni.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5667_zpsmms5kjus.jpg
Cleaned up the actual door, half done
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5670_zpshma7ckwg.jpg
Done
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5671_zpssowrldwn.jpg
Bead of butyl sealant all ready
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5672_zpsmvi8cwac.jpg
Cleaned the glass
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Drivers%20door%20lock/DSCF5677_zpsbesakx3f.jpg
And then it all went horribly horribly wrong. Remember that cable tie I used instead of a pot rivet... It caused all sorts of alignment issues and I had a total and utter nightmare getting everything back together. I won't go into all the gory details but there was lots of swearing, a few f**k it moments, coming indoors after saying b****cks to it and even some "what have I done to my car" thoughts. Suffice to say, after a few cups of tea indoors watchinng telly for a while I went back out to survey the grim scene. That lovely neat bead of sealant went blimmin everywhere, even got some up my nose and in my ear.
And I overcame the issue, got it all back together and the new lock works a treat. Getting there was not my finest work but I'm happy with the end result which is a car that once again locks with the remote.
That will teach me not to do sod all for the whole bank holiday weekend and then suddenly at about 5pm on the bank holiday Monday to actually get off my **** and do something productive.
I had all weekend of the long weekend and did nothing then tried to cram it in at the last minute, what a pleb.
So....
This pesky coolant leak.
If taking the whole dshboard apart ranks as 10/10 for difficulty then this is a 9/10, blimmin nightmare.
Access is tight to say the least and it is one of those jobs where there is no particular plan, you just have to keep going until you can get on it and then remove it. For me that meant a lot of dismantling, far more than I was expecting. The main issue that hindered progress were those sprung hose clamps many of which were blind to my dumb tools, i.e. pliers and slip joint pliers. If anyone is thinking about doing this then one of those fancy remote tools for doing this would be a big timesaver. I ended up having to carefully hacksaw through one of them.
Here is a bief summary of the work.
1, Upper engine cover off
2, Air filter assembly off
3, intercooler ducts off
4, Fuel filter off
5, Fuel filter bracket off
6, EGR off
Then...
7, Outer coolant flange off, x2 10mm nut-bolt type things, cable bracket also via an outer nut.
8, Remove outer hose off oil cooler
9, Carefully cut the siamese joint on the oil cooler to coolant flange so as you can get that hose off. Alternatively if you have one those tools you could back off the srping for this hose on the flange, I couldn't get near the clip so elected to take the flange off with that hose attached.
10, I has massive grief taking off the large 90 deg elbow so took the whole metal top hose pipe off which allowed me to wiggle it off the coolant flange.
11, Coolant flange itself, x1 nut-bolt thing, this also carries the turbo oil feed pipe bracket via a dummy outer nut and then x1 10mm bolt.
Some pictures...
Hacksawing through blind clip, I simply didn't have a tool to get this off and I have a lot of tools... except the one for this job!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5696_zps3vsrelzb.jpg
A right pain to do
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5697_zps5atvcetq.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5698_zpsot3rbdde.jpg
Main metal top hose pipe with the 90deg elbow still attached, that elbow would NOT come off of this pipe, if I'd gone any further I'd risk destroying it in the process.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5699_zpsbwxz8yh7.jpg
A slightly better view. You can see the flange main spiggot now the hose is off and you can also see the outer flange, outer nut with a cable bracket on it and the inner nut-bolt
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5700_zpspjttd0im.jpg
Flange off laying on its back, I then went on to cut the siamese section and taking the hose end off the oil cooler
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5702_zpsiyqn84ps.jpg
Flange on the bench, ooo-err Mrs.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5703_zps9xzti4ci.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5704_zpsrtmqj1zl.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5705_zpsgjp8b76w.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5706_zpstpsutjbd.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5707_zpsebm1n4cf.jpg
New 'o' ring in, but I'm not convinced.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5708_zpsn5di3nto.jpg
This is how much the new 'o' ring has protruding
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5709_zpsw0c8yije.jpg
But having taken this pic and seeing this I'm quite happy to fit it all up tomorrow once I've had a clean up. It looked like the 'o' was different but upon reflection I think it is just heavilt deformed.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5713_zpstc9uivnn.jpg
Not a nice job to do.
Just a bit of final closure on the coolant flange seal job. This is more for any poor souls who have to do this job at some point in the future.
This is where I mentioned that the coolant pipes were siamesed together, there is a rubber lump that joins the two hoses together. The options are to cut and separate the two hoses or struggle on undong another three very inaccessable hose clamps.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5714_zpskjhcphm8.jpg
Not neccessary but I gave the steel main coolant top pipe a few coats of sating black paint, in a few areas the paint had rubbed off.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5715_zpsjyruk5fi.jpg
This is the outer flange that I bought, about £8. I didn't bother fitting it at risk of undoing the quick connector to the heater hose but pinched the new 'o' ring and used that on re-assembly. I didn't want to risk the quick connector failing as this would have been costly, the heater matrix pipe with the quick connector on it costs about £40
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5716_zpsvc9l2ofa.jpg
Main coolant flange bolts, the normal looking one is on the drivers side of the flange, the nut-bolt one pass side. You fix these and on the pass side one the turbo oil feed bracket goes onto it and is then fixed by another nut.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5718_zpsyjgotgln.jpg
Wriggling the main flange back into position, note, you really cannot see much at all but the camera can go places where your head doesn't fit.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5719_zpsoku8sqht.jpg
Drivers side main flange bolt, 3/8's 2.5" bar & 10mm socket shown here.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5720_zpsksddegr9.jpg
Pass side nut-bolt thing with same 2.5" bar & 10mm socket. This one is done by touch and feel only, you cannot see anything.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5721_zps1muql3fu.jpg
I changed to a 10mm deep 3/8's socket here because I couldn't get the ratchet on with the 2.5" bar. You can just about make it out.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5723_zpsbm80l48v.jpg
Outer flange, access is better for this but you need a 10mm ring with a very small head so it doesn't hit the flange body
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5725_zps70byiz2j.jpg
Same as the main flange pass side bolt which hold the turbo oil feed pipe, the outer flange pass side nut-bolt holds the injector loom.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5726_zpsa2ivnvgu.jpg
Injector loom on the nut-bolt
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5727_zpsplubqkz0.jpg
The chaffed fuel hose fom the filter to the tandem pump. I took a punt and bought some 8mm hose which actually turned out to be 3/16's when you opened it. A 1m length is just about enough, I din't measure it but the hose is approx 900mm long, it takes a long and winding route between the filter and the pump!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5728_zpsctxmli9x.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5729_zpsene8h7rv.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5730_zpsjvcajo2o.jpg
I had some spare coolant hose, so I cut a short length off and split it down the middle
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5731_zpsqxegwsbz.jpg
And one the new fuel hose was I over sleeved it with that bit of coolant hose.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Coolant%20leak%20Apr16/DSCF5732_zpsqplbx6ir.jpg
I strongly urge everyone who has a B5.5 PD TDI to check this hose in this location for chaffing. If it failed it would have been very messy!
caldirun
07-05-2016, 05:36 PM
Another great post, you must have great patience to do the job and take photos at the same time, just a little error, the hose is marked 5/16" not 3/16" so for an 8mm equivalent its only 0.06mm under, well within the variation on a hose bore.
I have sold both my B5.5s and now have an Exeo CR Tech 2.0 tdi, a very similar car but with lots of bells and whistles, I would recommend any B5.5 fan to seriously consider looking into this a 2012 can be bought for £6000 to £7000 and almost everything is familiar.
Another great post, you must have great patience to do the job and take photos at the same time, just a little error, the hose is marked 5/16" not 3/16" so for an 8mm equivalent its only 0.06mm under, well within the variation on a hose bore.
I have sold both my B5.5s and now have an Exeo CR Tech 2.0 tdi, a very similar car but with lots of bells and whistles, I would recommend any B5.5 fan to seriously consider looking into this a 2012 can be bought for £6000 to £7000 and almost everything is familiar.
Thanks for the reply. It does take quite a bit of effort to post everything up and mistakes do happen.
As for the car, I've been driving these B5.5's for almost ten years now and am obviously commited to this one with the amount of work I've done to it.
I really do not like the modern stuff at all with that 2.0 TDI in it, early ones with their oil pump drive issues and the later ones with the injector issues. I do remember well when the PD engines came out and they were a huge risk as the injectors cost a fortune. It turns out that the 1.9 PD in the B5.5 Passat / C5 A6 / B6 A4 / MK4 Golf era cars has been remarkably reliable.
I still cannot think of anything I'd want to replace it with.
caldirun
07-05-2016, 06:35 PM
Fair comment, I had 2 B5.5s and put 200K on them, only put 30K on the 2.0 tdi, better for economy by 10% and some very nice improvements for maintenance, time will tell!
Gazwould
07-05-2016, 07:25 PM
B6 ? How ever is a B6 ever better than the legendary B5.5 ?
I thought about changing earlier this year as I fancied a change but then thought nope may as well stay with the devil you know.
Most of the stuff I've done was planned, suspension and belts but the heater matrix, flange seal I most certainly could have done without. The door lock also was a pain.
caldirun
07-05-2016, 09:16 PM
Done about 5 door locks, not bad, the worst job by far was the V71 swap (photos in my previous post)
KieranM
09-05-2016, 11:09 AM
I like the look of the Exeo's, but my concern is the boot, I can take 3 mountain bikes, 3 people and kit in my B5.5 estate, not sure I could with an Exeo. Pretty much decided to stick with my b5.5 for now and continue using it, maintaining it until it stops.
caldirun
09-05-2016, 11:24 AM
I like the look of the Exeo's, but my concern is the boot, I can take 3 mountain bikes, 3 people and kit in my B5.5 estate, not sure I could with an Exeo. Pretty much decided to stick with my b5.5 for now and continue using it, maintaining it until it stops.
There is an estate version, the ST
http://www.zercustoms.com/news/images/Seat/JE-DESIGN-Seat-Exeo-ST-3.jpg
KieranM
09-05-2016, 11:37 AM
That is very lovely, but looking at the sloping back end (presumably for fuel efficiency), I'm not sure I could get as much stuff in, however it is certainly on the list for replacement when my b5.5 decides to stop.
Gazwould
09-05-2016, 03:41 PM
Exeo estate are based on Audi A4 B7 Avant chassis so will not have the extra rear leg and boot room a Passat B5.5 wagon has .
KieranM
09-05-2016, 04:01 PM
Exeo estate are based on Audi A4 B7 Avant chassis so will not have the extra rear leg and boot room a Passat B5.5 wagon has .
Indeed they appear to be a bit of a reverse tardis, appear to be a large car, but actually quite small inside. Nice cars still.
I had an A6 C5 Avant (see page 2) and the load area was smaller than the B5.5.
KieranM
09-05-2016, 04:45 PM
Did it go around corners better than the Passat? Mine is totally standard, it does hold the road really well, but doesn't half roll around a lot!
Gazwould
09-05-2016, 05:03 PM
You'd think you had a sports car if you did Eibach Pro kit springs with Bilstein B4 oe Sports dampers .
Finish off with a Sport's solid 29mm front arb an Audi S4 underbrace and Audi A6 C5 Allroad upper strut brace brackets and alloy strut bar or Passat W8 steel strut bar .
KieranM
09-05-2016, 05:14 PM
Sure, that would make a big difference, I'd like a balance between improved cornering, but not so low it's a nightmare on overly keen speed bumps (many in North Wales), and bumpy mountain biking car parks, I do a lot of sitting in my car commuting (lack of work in North Wales), so wouldn't want to ruin the ride (should such a magical combination exist!)
Gazwould
09-05-2016, 05:59 PM
That's the thing that combination doesn't ruin and what the thread OP Col has .
The A6 was ok, it was lowered from the factory.
My Passat now handles very well for what it is although I never thought it was that bad to start with. As a car I prefer the Passat much more than the A6.
KieranM
10-05-2016, 10:53 AM
Well it's certainly a possibility, need to do both rear locks, the instrument LCD is pretty much blank after 3 seconds of driving unless it's hot, and there a number of scratches and a couple of dents as a result of others (mostly), on a car that's done 155k, I'm not sure I want to spend that much, but it is a possibility, sadly I don't have use of a drive let alone a garage, or the associated tools, or the associated skills to do a lot of the stuff myself. Couple of months ago there was a highline on 50k on ebay for 3k, sold within not very long, would have definitely been worth a look.
The cat (a'hm) is fitted.
Sat indoors it was fast approachin 9pm, I couldn't bear it so got the spanners out.
Although this is a very common thing to do, there seems to be very little in the way of information as to exactly how to go about it, so....
1, Engine upper and lower covers off, all of them. If you need me to explain that, STOP, and get the car in the garage.
2, Jack up the front as high as possible and secure it properly, axle stands etc.
3, Remove airbox, to do this there is one screw securing a bracket that hold all the vac lines, undo it and undo the 10mm bolt on the wing. Take the top off first after undoing the clips then the bottom section whilst holding the vac lines to one side.
4, Start under the car. If the clamp will not undo or yield you will waste time putting the turbo flange nuts back on. Undo the cross brace and remove, 2x 17mm bolts. Undo the clamp nuts, both of them. Pry open the clamps. If this goes well, stay under and...
5, Undo the 12mm turbo flange nut that is nearest the engine block, you cannot reach this from above and even from below movement on the spanner is limited.
6, Topside, undo the other two turbo flange nuts, again I had to do these with a 12mm ring spanner. I've got loads and loads of tools and despte that, a 12mm ring was all that would work.
7, Pull the cat flange off and away from the turbo and give the whole thing a twist, you are trying to break the stiction on the clamp below and you'll get much more leverage from above.
8, Below, I used a trolley jack handle and a lump hammer... bash the clamp backwards, stop, wiggle and twist, bash, stop, wiggle, twist until the clamp has backed off enough to release the exhaust section. You may need to use moderate violence.
9, Back above, corkscrew the old section out. Oh it won't, back below wiggle it, oh it won't come out, tiwst, wiggle twist, top side, under the car, back up top, down below. It will come out though and from the top out through the engine bay. IT REALLY WILL.
10, Back below, get your lump hammer and from behind bash the clamp off the exhaust. Reason being; so you can lube the threads and open it up a little so as to make re-assembly easier. You could of course do it bandit style and leave it on.
11, Assemble the cat and downpipe off the car, don't worry as it goes back in much much easier than the old one did coming out. I did offer up just the cat section with the thought of doing the intermediate flange nuts and bolts up insitu. I quickly forgot about that as access would be terrible.
12, Fit the new cat and downpipe section, center the clamp and tighten it all up.
13, Fit all the other gubbins back.
Pictures are always useful....
I made sure it all fitted
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5737_zpsn1fppep0.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5738_zps8ttowttk.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5739_zps6rpg2qsv.jpg
Airbox on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5743_zps1twhctem.jpg
Airbox off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5744_zpssxjl5sel.jpg
Remove that cross brace
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5745_zpsbq0ezgmt.jpg
Plusgas on the clamp, the nuts were 'kin tight.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5746_zpsym2779zv.jpg
Not the best shot but a view from underneath looking at my arm and the 12mm ring spanner on the inner turbo flange bolt. I could find another way to get on that nut.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5748_zps36aktskf.jpg
Same again looking up this time with my arm not in the way
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5749_zpss1srycp8.jpg
With arm !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5750_zpslvr44otv.jpg
Partly wiggled out
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5751_zps4pwuiw3j.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5752_zpsj1uzaqms.jpg
Old and new
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5753_zpsdvznm9us.jpg
The clmap off the car. I spent a bit of time cleaning the threads up and copper greasing them and I also opened up the clamp a little bit to make the re-fit easier. Time well spend I think, it would have been a right old struggle under the car without having done this.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5754_zps5a9ewlqd.jpg
I marked the new section to show the half depth position
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5756_zpspvz3rq1z.jpg
Old (left) and new turbo flange gasket
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5757_zpszyrizrcy.jpg
Clamp slid up the pipe to ease fitting
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5758_zpsn2if4wct.jpg
Old and new
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5759_zpsacxgbsyn.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5760_zpsrjeansur.jpg
All done, only the covers to fit
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5763_zpshc5dwb41.jpg
All done just the gubbins to re-fit
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5764_zpsmjkv1zd3.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/dec%20cat/DSCF5765_zpsoigveuxe.jpg
mrnice
23-05-2016, 02:42 PM
Hi Col, thanks for the invite from over in A6 land, just read through half the thread and bookmarked rest for later, awesome stuff!, I do like your detailing touches (painting axle beam, cleaning plenum & everything etc), it makes such a difference to work on a clean car (though mine usually isn't!).
Looking forward to digesting the rest soon,
Cheers!
mrnice
23-05-2016, 02:50 PM
Ps I just clocked you had a coolant leak in the same place I did at the back of the head. Ooh, that was a b@stard of a job!
Yes, that coolant flange is a right piglett to get on and off.
mrnice
24-05-2016, 12:34 AM
Ok, got to the end, excellent thread in all. Best bits were the the heater matrix (dashboard out is my biggest fear), oh and the cat, I forgot that as my turbo had puked oil into it I thought it a good idea to replace it, so that's another hideous job we've both done. Much fun trying to manoeuvre the whole silly pipe up through the engine bay...
Look forward to updates!
Taking a car allowance and running a car on beans means you can do things on a whim.
I give you my £80 new DAB head unit.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/DSCF5768_zpsneugikmo.jpg
Planet Rock in the car is now a reality again !
Still regret selling the Blaupunkt Woodstock all those years ago and new it was £400 in 2004! Just shows how much things have moved along.
mrnice
24-05-2016, 11:45 PM
Ooh I like that!, does it use the std aerial? Fancied dab in the car for a while now but the car has kept me too busy with it's more vital functions..
No, you need a DAB aerial. I splashed out on a combined DAB/FM jobby but it sits on the roof and looks exactly the same as the OE VW one.
mrnice
25-05-2016, 04:48 PM
No, you need a DAB aerial. I splashed out on a combined DAB/FM jobby but it sits on the roof and looks exactly the same as the OE VW one.
Thanks Col will look into this!
KieranM
21-06-2016, 05:59 PM
No, you need a DAB aerial. I splashed out on a combined DAB/FM jobby but it sits on the roof and looks exactly the same as the OE VW one.
Did you have to replace the cable at all? Or was the replacement aerial plus the head unit all you needed?
Yes, I ran three new cables, a DAB, an FM and a power cable from the head unit to the aerial. Sounds tricky but isn't.
KieranM
22-06-2016, 01:48 PM
You're right, it does sound tricky!
It's not, you are running them at the same time from the same place to the same place.
The love affair continues...
Gave the old girl a good seeing to yesterday and finished off her off this aftermoon.
Wash / dry
Quick polish of the paint
Windows inside and out
Pulled the rubber mats out and gave them a scrub
Blacked up the black bits
Quick polish of the wheels
Blacked up the tyres but not shiny shiny, I hate that.
Not bad for a 13 year old car approaching 150,000 miles.
Sadly for you lot, or anyone who takes the trouble to read this, part of my reward for that effort is to post up some pictures. Rather pointless as it just looks like any other car.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6271_zpsxlmqkd2i.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6272_zpsnjdoca92.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6273_zpsxnlw51ng.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6274_zpsgchpcugj.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6275_zpsooslvkv8.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6276_zpsjdduju74.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6277_zps7sitldqg.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Clean%202nd%20Oct%2016/DSCF6278_zpsfhfn0wrp.jpg
zollaf
02-10-2016, 01:47 PM
keep up the good work col, and no, it doesnt look like any other car, it looks like a well loved old passat that will last for a very long time.,.
KieranM
02-10-2016, 02:21 PM
I concur, about the only thing that looks vaguely the same on my car is my headlights after a well needed sand and polish. Lots of scratches and dents otherwise either there prior to my ownership or as a result of other's carelessness. Good work!
mrnice
02-10-2016, 08:38 PM
Great stuff Col, still looks fresh👍
Something I hadn't mentioned is that I've got yet another water leak. I've narrowed it down to the new water I fitted only six months ago.
Obviously to deal with it, it means doing what is another cambelt change.
Tonight is the night...
Started at 5pm....
A nice leisurely session getting the front end off...
Stereo on. That technics amp I bought in 1986 still going strong in the garage.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6281_zpsmc8fcsss.jpg
This is the leak patch on the garage floor, quite a lot.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6282_zpsgo7fn7y3.jpg
Ready to go. I'd already taken the engine covers off the other week when I was investigating the leak so didn't have to do a full job...
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6283_zpsnzennip1.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6284_zpszsmqyo1p.jpg
The new condenser is still looking good, just a few dead flies on it
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6285_zpsox2eoxc2.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6286_zpsvgfbshgx.jpg
I can't remember if I went into detail last time on this, but you simply unfix it and swing it to the side
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6287_zpspxn6mkfx.jpg
My newest favourite tool, remote pipe clip remover. Wish I'd bought one of these years ago
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6288_zpskisdtbhz.jpg
And in action, no more slipping pliers
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6289_zpskihlmbr2.jpg
And the front is off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6290_zpsu9x5h8pu.jpg
Ready for working on the belts
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6291_zpsi5xmfhgx.jpg
Just under an hour for that
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6292_zpshkdqshnz.jpg
Then the Wife got home from work so I'm indoors for a little while, a cup of tea blah blah...
I'll go back out at 7...
zollaf
07-10-2016, 06:56 PM
hahaha, glad the leak is from the new water you fitted 6 months ago, and not some old water :)
hahaha, glad the leak is from the new water you fitted 6 months ago, and not some old water :)
LOL ..... water pump
It is the thought that counts....
Hmmm...
Velly velly interlesting.
The waterpump is ALL good. On closer inspection and only possible when stripped down a bit and with the alternator removed I found the source and it is the thermostat housing!
For anyone that has monkied about changing the thermostat on one of these, there is a blind side close up against the main carrier bracket that cannot normally be seen.
I can SEE it now though and am not happyas I could have saved a massive load of work.
Pump all good
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6294_zps2mr6ynye.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6295_zpsyj4ruav9.jpg
The cam belt is bone dry and as new.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6296_zpsm3f2ki8r.jpg
All is not lost as if you look at the middle pic, there is some evidence of gease escaping from the idler pulley. It is probably nothing but as I've got a new cam belt kit i'll change it.
So much for getting this done this evening, i'll be off to dealers to get a new stat housing, and stat in the morning, doubt they'll be able to get one before Tuesday !
MiniMental
07-10-2016, 08:44 PM
Nice thread, just had a look through and I have to admire that car. Just out of curiosity. How on earth did you get every nook and cranny under the bonnet so clean! Did you take engine out and steam clean everything or something? Or am I kissing something.... I toyed with the idea of power washing mine but figured fuel, electrics , oil and other bit n pieces generally don't go well with 175bar of water at 200L a min.... even the chassis where the front bolts on looks like it's just left the factory.... Would love to get mine that clean....
zollaf
07-10-2016, 09:12 PM
it is rather clean, anally clean. wish mine was that clean. my car, not the other :)
anyway, nothing wrong with a jetwash in an engine bay. a good rinse, then gunk or other de greaser, a good scrub with a brush, toothbrush for the nooks and crannies, even ear buds for the proper tight spots. a bottle brush, washing up brush, anything with bristles. then rinse. dont get the jet too close to anything that look important. it all gets wet when you go through a deep puddle so it wont harm. when finished run the engine to dry it all out, go for a drive, airline etc, then apply shiny stuff to make it shine. wd40 is good, or just polish n wax on the metal bits. makes working on it so much nicer.
There are two main ways I keep the engine and engine bay clean;
1, Aerosol brake cleaner for the really gunky bits.
2, TFR (traffic film remover) and a jet washer. I do blow any connectors etc out with an airline afterwards though.
Actually in my last few posts, the engine and bay are quite filthy by my standards.
Another thing is, and if you read back, I've taken considerable time and effort to clean, paint where neccessary and have fitted many new parts.
But I do take good care of the old bus. When I wash the car, which isn't that often, the weekend was the first wash it has had in a few months, I do give all the door shuts and exposed bits in the engine bay a wipe down, that keeps it clean. I do do 5,000 miles oil change intervals and do jet wash the engine after each oil change.
mrnice
07-10-2016, 10:11 PM
Good work Col, I've been here before, difference is I stripped it down to find it was indeed the water pump leaking (a febi part, fitting 12 months prev). The thermostat housing is a bit of a fiddle and made of quite brittle plastic if I remember...
MiniMental
07-10-2016, 10:55 PM
I might follow up on that advice from both you and zolla regarding the engine bay then, mines not bad but in places its terrible. Rocker cover is seeping oil above inlet manifold, looks an absolute state. Intercooler is also seeping steadily from the bottom hose. Undertray is saturated with it :/ it's not manky otherwise though. A lot of the mess is sponge that's fallen apart off the TDi cover. I recently saw a silver Audi TDi engine cover, looked nice.... im quite an@l about certain things.
Last year I bought a battery cover, new bolt covers for the engine and air box covers because they were missing... I couldn't cope when I opened the bonnet and saw they weren't there.... got them all from
VW main dealer for a couple of quid... though, I got my arm stuck down the side of the turbo the other week, and it was hot... so in the "yank" I snapped the outer lug off said airbox cover and it's now held down with a bungee which is driving me crazy... somewhere in my gearbox swap yesterday I lost one of the above bolt covers which has ****** me off no end. I'm in the middle of relocating from Cumbria to Wiltshire, I have spare bolt caps etc, but they're 300 mile away at home! Trip to VW Salisbury coming up I think....
I have paintwork that need repairing/sorting also; but struggling to find a good, affordable body shop to sort it out :( worrying me as part of it is above windscreen, leading edge is going rusty in places from stone chips....
Those little plastic covers that clip onto the engine cover to hide the fixings...
I'm convinced every main dealer mechanic simply throws them in the bin at the first service. I've never seen a car with them yet unless someone has rebought them.
Gazwould
07-10-2016, 11:59 PM
The dealers play tiddlywinks with them , then they get run over .
Good news!
Off to the dealers this morning to collect a new set of four crank pulley 'cheese' headed bolts along with some trinket type parts I've been meaning to replace for a while. Enquired about the thermostat housing, they didn't have one but did say that the TPS they use did. So they phoned ahead. Got there and they were all ready, all I had to do was pay, very pleased.
A big thanks to Windrush VW Maidenhead.
That said still and expensive day. But I would fancy buying the similar parts for any other make, I'd reckon they'd cost a lot more.
First the vanity trinket items; new windscreen scuttle paneland battery cover
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6297_zpsdmhf0u5s.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6298_zpsnvpntgtw.jpg
Thermostat housing, thermostat and 'o' ring, another £i gulp!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6299_zps0xnn03ck.jpg
Genuine thermostat which was insanely expensive !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6300_zpskv2hbtpc.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6301_zpsjwa8nilr.jpg
And for those who don't know, the thermostat twists into the housing via some very delicate clips in the housing which are so so easy to break. Break the clips and you are in a world of pain fitting the stat.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6303_zpsyukr8wvc.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6304_zpsty5seusk.jpg
All the time constraints of getting the job done are now out the window, it is now 3pm on a Saturday afternoon and I still haven't started, I might have another cup of tea and only then consider getting out there.
Rob69
08-10-2016, 03:57 PM
Thought a scuttle panel would cost more than that - i need one for mine.
mrnice
08-10-2016, 06:06 PM
Was it the housing that was £8ish?
Scuttle panel was £18
Thermostat housing was £8
mrnice
08-10-2016, 07:13 PM
Thanks Col, thats fairly reasonable, my housing had one of the lugs missing
Problems problems.
You know I was harping on about how delicate the little thermostat holding clips are in the housing... well I managed to break one, idiot. The one that was left did the job though. I broke it even with the alternator off the engine, idiot.
The SKF cam belt kits comes with both the nuts and the studs for the idler and tensioner, for the Gates kit fitted six months ago it only came with the nuts, I had to buy the studs separately.
Anyway, after the debacle with the snapping of the thermostat housing clip I was looking foward to some nice plain sailing to complete the tasks at hand. Not so.
Pair of locknuts on, the tensioner stud came out without issue, onto the idler stud. Despite only being in for six months the idler stud would not come out. I wound the locknuts tighter and tighter, nope. Eventually the thread on the stud gave up and I would have been in big trouble. Thankfully I have couple of welders and used my MIG to weld the nut to the stud and wind it out.
New studs and nuts that came with the SKF kit, only a five minute job to wind the old ones out and fit the new ones, or so I thought. Nope.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6308_zpsr1opw7dm.jpg
Nut welded onto idler stud, in fact I was so quick in taking the piccy it is still glowing RED hot.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6309_zpsblovtro4.jpg
Having burnt myself many many times in the past doing welding, I did remember to pick the stud up NOT with my hands. That saved muchos muchos pain, which was nice. Top tip for any aspiring welders; NEVER weld wearing rigger boots with your trownies tucked into them, they catch the weld spatter like nothing else, been there, done that. These days don't weld much but when I do I favour wearing carpet slippers to do so, you can get them off and get any red hot bits of spatter out of your socks quick sharp. Today I forgot about that I was wearing my steel toe capped boots as I don't own any rigger boots. I was lucky and didn't burn my feet.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6310_zpsbvo8bxsk.jpg
You can see the coolant staining on the lower belt cover where it was dripping from. This vindicates my water pump diagnosis.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6311_zps2evzeuhq.jpg
The six month old Gates idler oozing grease, a good catch finding this now.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6306_zpsyiz19oyf.jpg
Six month old Gates pump bottom, SKF pump top, a nice blue hue
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6307_zps13wmcdu8.jpg
All done, just need to put the front end back on now.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6312_zpsencikruo.jpg
One thing I had previously neglected to do was change the front engine mount from the sponge 1.9 version to the rubber V6 verson. The old sponge one was in very good condition.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6313_zpsblqmkdd8.jpg
Rubber mount on, that was tight!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/DSCF6314_zpsupqepb6b.jpg
All done.... for now.
I just want to drive and not worry about the damned thing.
A quick check with VCDS and I've got a 0.0 syncro angle, no funny noises and everything back together. I just need to drive it about a bit and keep an eye on the coolant level, you need the thermostat to open for that and idling on drive drive isn't going to see that happen.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Passat%20cambelt%202%20Oct%2016/syncro%20angle_zpsowvyujsz.jpg
Monkey magic, there simply is not enough.
http://img.photobucket.com/albums/v602/colin__/monkey-aka-monkey-magic_zpslevciiws.jpg
The battery finally expired so I had replace it. An easy enough job to do....
Pull the rubber off the plenum cover edge and wriggle out the plenum cover
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6338_zpshs9bsvfd.jpg
Stranger things happen at sea and I like to make sure the new battery is the same as the old one.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6339_zps5erieu1t.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6340_zpsre3cdxp4.jpg
A really habdy little shortcut on doing this is to roll the loom on the bulkhead forward instead of taking the wiper panel off and all the hassel that entails. Start at the right hand side
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6341_zpsvtc4iz40.jpg
And roll the sausage fowards
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6342_zpsgt7tufmb.jpg
13mm socket on a 10" extension bar (bolt head shown with socket next to it)
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6345_zpspvglfks7.jpg
Socket on bolt
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6346_zpsuffdrh9c.jpg
Battery clamp bracket and bolt, off
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6347_zpsiptig46v.jpg
Battery part way out, obviously undo the terminals !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6348_zpsjcthqiey.jpg
Old and new
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6349_zpsbro06li6.jpg
The carrier will take three different sized batteries if you so wish to upgrade, three holes for the clamp
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6350_zpsekhgqj0z.jpg
Bit of rust on the carrier so a quick squirt of the Supertroll !!!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6351_zps9cz2sa7b.jpg
A quick squirt squirted !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6352_zpsbk12xjfe.jpg
And in
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6353_zps8plodsli.jpg
And loom rolled back into position
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6354_zpskagqwxp9.jpg
And done
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Battery/DSCF6338_zpshs9bsvfd.jpg
Rob69
20-11-2016, 08:15 AM
Must be one of the best looked after b5's in the country, looks great.
MiniMental
20-11-2016, 09:11 AM
^^^^ Showcar ^^^^
How much you charge to get one in that good a cosmetic condition mate [emoji23][emoji106] Awesome.
2005 Passat Variant PD130..
No school like the old school...
No way is it a show car. It is clean in all the right and wrong places but a show car it isn't. The paint is no where near good enough.
MiniMental
20-11-2016, 04:51 PM
Either way mate, look immaculate from here [emoji106] nice job [emoji5]
2005 Passat Variant PD130..
No school like the old school...
A bit late this year but with the help of my teenage sons (it would have been quicker on my own) finally got the winter tyred steels on the car.
Eagle eyed viewers may notice the ice on the ground around the car, that is what prompted the change along with the fact that the side roads (where the Sun has not been on them) here in Maidenhead have remained icy all day. You know it is bad when the normally sub-tropical Thames Valley ices up.
Further good news today, the Mrs Golf passed its MOT with no advisories. Completely expected a full clean pass but I always get a bit edgy at MOT time. In fact, I had all four wheels off the Golf, jetwashed and cleaned it yesterday, the water from which caused the ice!
Anyway, slightly cleaner steels on a very dirty Passat.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Winter%20steels/DSCF6370_zpsthdqzjcx.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Winter%20steels/DSCF6371_zpsnqjuisra.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Winter%20steels/DSCF6372_zpsoroejzbd.jpg
New toy came today, a compressed air driven oil extractor.
This one, although only last week I paid £109 for it, £115 now!
Sealey Tools TP6904 Vacuum Manual Air Fluid Extractor 9 Litre 9L Water Oil New | eBay (http://www.ebay.co.uk/itm/360375849221?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT)
I've had a Pela 6000 manual oil extractor since 2004 which has served me well. One thing that annoyed me somewhat was the constant pump pump pumping you'd have to do but despite that it is, was and still is by a considerable margin much quicker and easier than doing a gravity oil change.
Not satisfued with already how easy it was I wanted even easier so I treated myself to a new one.
The Wife got home, I went out and did the business...
Out of the box
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6373_zpskmnmiqhi.jpg
As it is a manual and compressed air driven machine, this bit is for connecting the manual pump to it. I have no itnention of ever connecting it.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6374_zpshpade1gx.jpg
Air line spiggots, mine on the left, the one suplied on the right, glad I had a spare.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6375_zpsw5dltjiq.jpg
Ready to go
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6376_zps9xbji9jg.jpg
I have no idea what this hooped metal insert is for
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6377_zpsbjgzqdbr.jpg
Came with a brake bleeder adaptor as well, which is nice.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6378_zps4vtpi076.jpg
Down into the MK4 Golfs sump via the dipstick 'ole.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6379_zpsycmmpog1.jpg
It and me working hard, in fact the compressor is doing all the work
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6380_zpsvxtvlmto.jpg
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6381_zpsdsduxbal.jpg
Old, filthy but still perfectly useable Pela 600 in the back ground
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6382_zpsq6r4ij2g.jpg
How do you know when you have hit the bottom? By putting a bit of tape on the tube just a bit deeper than the dipstick is long! I am a rocket scientist.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6383_zpskgvoqqau.jpg
Swapped the 'o' rings over on the filter housing and popped a new filter on.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6384_zpsrtv7wnmk.jpg
Cleaned out filter housing, another 130cc or of oil comes out of the oil cooler at the bottom which wouldn't if you were doing a gravity drain. On these 1.9 PD TDI engines you will always get more oil out with an extractor than not.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6385_zpsldijgzqb.jpg
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6386_zpsmwvhoueu.jpg
4.4 litres of oil taken out in less than five minutes. I've got a quite beefy (for a DIY'er) 3hp compressor and it coped fine.
http://img.photobucket.com/albums/v602/colin__/Sealy%20oil%20extractor/DSCF6387_zpsm8ijwneb.jpg
Need to do a change on the Passat in the next few days also.
Alhough the car started well, I thought it was about time to change the glowplugs. The car easily started but ran just a little bit lumpy for five to ten seconds and chucked out a bit of white smoke from a cold start.
So, after extensive research as to what plugs I needed I order some and they turned up today, some Beru GN046's...
Nothing to do at all about glowplugs but I thought I'd take this picture
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6392_zps541ryluc.jpg
This is what arrived today. Rather than oom and arh for the rest of the week I thought that there is no time like the present, I have a lit garage and decided to crack on.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6394_zps2ud2c2kn.jpg
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6395_zps6aoisqry.jpg
You obviously have to go through the well worn process of whipping the engine cover off. Below are my bits of pipe lagging I now use since the OE foam bit that surrounds the rocker cover turned to dust about three years ago. They work very well.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6396_zpsz9hv4fzt.jpg
The next few shots are a bit out of sequence as I started at Number One plug which I wanted to do without the distraction of taking pictures.
Old and new plugs side by side, spot the difference, more on that later.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6397_zpspkbbnhx9.jpg
I used some needle nosed pliers to pull the plug leads off. I used a 2.5" long deep 10mm socket and a "wobble" extenion bar, all 3/8's drive. Numbers 1, 2 & 3 easy peasy. Very light pressure to undo and they all came out and went back in without any issues at all. Below, me removing Nr.2 plug.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6399_zpsrczjdtgu.jpg
Number 4 is slightly more fun. As some will know, the conventional wisdom is that the fuel filter bracket is supposed to have to come off to access it. Not so, I simply moved the fuel filter out the way and was able to easily get on the plug with the "wobble" head extension bar.
On Nr.4
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6400_zpstpfuofn3.jpg
Slightly closer shot on Nr.4
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6401_zpsadarblvf.jpg
Closer still of Nr.4
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6402_zps12ztg601.jpg
All done.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/Glowplugs/DSCF6404_zpscpy4dhtm.jpg
The old plugs with the soot wiped off the tips, they look quite good but looks can be deceptive. I did a quick check with my old meter (no lead correction) and got the following;
1, open circuit = knackered
2, 2.27 k
3, open circuit = knackered
4, 7.63 k
So well worth doing the change.
http://img.photobucket.com/albums/v602/colin__/monkey-aka-monkey-magic_zpslevciiws.jpg
More the plugs themselves.
After extensive research the conclusion was that the car needed Beru GN046's or Bosch ending with 2023.
Imagine my surprise when pulling the old ones out so see Bosch items but OE as they had the VW logo on them. The information on the old plugs is as follows;
Bosch
0 250 202046 11v
FRANCE 391 (955)
(VW logo) N10579201 (RB3)
Having done a bit of cross checking these are the same as the Bosch 0250202023's and Beru GN046's with the N10579201 being the VW EO part number. Phew !
Thing is though, the taper looks a bit different, I hope things are not going to bugger up !
MiniMental
24-01-2017, 12:24 AM
So, did they solve your rough start issue mate? I have same issue by sounds of it.... hmmm.....
2005 Passat Variant PD175 ;)..
No school like the old school...
I don't know yet as I did them this evening. Tomorrow morning I'll know.
Glowplugs and the virtues and having good ones that actually work and do their job;
Before;
Glowplug light on, went out after a few seconds, nothing untoward.
One or two seconds of cranking then it'd catch and start.
A reasonable plume of white smoke out the back for about 10 seconds, this was unburnt diesel.
For those ten seconds it ran lumpy, obviously as it was missing on two cylinders.
After those ten seconds the car seemed to clear its throat but there would still be a bit of smoke out the back.
This morning;
Glowplug light behaviour exactly the same.
Started almost instantly.
Only the faintest little puff of white smoke.
No lumpyness at all in the running.
Much quieter engine.
I'm very pleased with the results and should have done this a while back.
I've been reading up on the glowplug function as well for these old 1.9 8v PD TDI's and what the glowplugs do is;
Preheat (as you would expect).
Afterglow for about four minutes or until the engine revs exceed 2,500. This happens each and every time the engine is started regardless. This is what makes the engine quieter and smoother at a cold start.
The glowplug system is 'dumb' i.e. the ecu will tell them to do what needs doing but there is no monitoring back to the ECU if something is wrong.
My advice is that if there is any doubt, you get anything more than a puff of white smoke, the engine is lumpy, then change the glowplugs.
The MOT is looming up, winter is all but over so it is time to get things spick and span.
I like to give the car a really good clean prior to the MOT and also wash off any salt and crud I can from underneath.
But first a little job on some new center caps for the summer wheels, which are due to go back on very soon.
Ols set of caps, new ones on the right. The old ones are only a year old and are suffering from the tin worm already.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6417_zps4onmcoz3.jpg
Not good how the tin worm has set in regardless of these not being gnuine items, I did wax them throughout the year.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6418_zps2imsdfpk.jpg
Nice new GENUINE VW items
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6419_zpssc1adzkp.jpg
A quick panel wipe to clean off any grease
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6420_zpse0selzi3.jpg
I then rumaged around and found this can of clear laquer, just enough in there for two coats to the caps.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6421_zpsfalixqrc.jpg
A pointless photo of the 1st coat drying, you cannot tell from the pic !
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6422_zpsdjqqd4qi.jpg
While the 1st coat was drying I got my "car coat"
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6423_zps4bwempel.jpg
Not the best pic but this was the state of the underbelly and one years worth of crud.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6424_zpsnwcpsmoj.jpg
And then cleaned. Washed all the salty crud off with some TFR and a brush. It always comes up like new.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6425_zpso3arliun.jpg
I do love the cheapy winter tyres. The steelies are going to need a bit of paint this year though and I will need a new set of winters for the front, they are worn out to the point where they would be no use in the snow, not that it ever snows here!
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6426_zpszbx5cqsh.jpg
Wheelarch salty crud, to be cleaned off in a forthcoming episode
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6427_zpsk6bxrodu.jpg
Another pointless photo of the nes caps in their 2nd coat of laquer, not that you can tell from the photo.
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6428_zpsiiqbih0x.jpg
More MOT prep and this is mainly for the OCD of it !
Only for the OCD among you.
Summer wheels layed out ready to fit
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6435_zpsslyeulvv.jpg
Center caps in
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6436_zpsrzdsegry.jpg
Cleaned the wheel nut covers
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6437_zpsgrc6xqkk.jpg
Goodbye to the winters until next winter
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6438_zpsv9fbkmar.jpg
I only cleaned under here the other day
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6439_zps3m4h1tqu.jpg
So I had to clean it again
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6440_zps5p2xxaap.jpg
Brakes were looking a bit scabby
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6441_zpsmp9ojlhb.jpg
So a quick lick of paint, a very quick blat only on the outwardly visible bits
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6442_zpsxox52dth.jpg
Back one with the paint still wet, that'll dry down to a nice satin finish
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6443_zpsr3uvenva.jpg
Summers all on
http://img.photobucket.com/albums/v602/colin__/AA%20Passat%20Highline/MOT%20prep%20Mar%2017/DSCF6444_zpsz5ewbpp7.jpg
It has been a long time.
And now I've got the ability to post pictures again, it'd be silly not to. (I'll have a go at filling in some blanks up thread when I have time).
A few of the car in general first, it is still clean and still good.
The old hector itself
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20180519_103508_zpsbvnhtvin.jpg
Immaculate rear wheel
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20180519_103522_zpse2k4bskf.jpg
Immaculate front wheel
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20180519_103544_zpspxh9qacu.jpg
Onto the current project which is rear brakes. Here we have a pair of new calipers, pre painted satin black by me, discs, pads, brake pipes and hoses and a roll of Cupro / Kunnifer / Copper Nickle brake pipe just in case things get nasty.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_165446_zpszyahqgfd.jpg
Since I last updated this thread, I acquired a stealth sub set up second hand, which was nice.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_165453_zpshpfsc0w0.jpg
And of course the amplifier
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_165212_zpsmzwfznom.jpg
More to follow when I get stuck into the work. Fingers crossed that things that need to come undone, come undone without drama and I don't need to make any brake pipes.
caldirun
04-07-2019, 06:35 PM
Looks really good, best of luck with the callipers
Not rushing, in fact copious squirts of plusgas and waiting for "the pans to soak".
Got the old caliper, main hose/axle brakepipe and flexi hose off.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_201741_zpsd13ehzas.jpg
And there is the problem, I'm not sure how but the seal was ripped and water obviously got in and seized it.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_201751_zpsx0urgjxq.jpg
New stuff mocked up
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_202137_zpstvz5vr1x.jpg
Schoolboy error in **** poor planning. I need four of these clips. I could go full bandit and refit the old rusty ones but that would be a bodge. Hope to get some tomorrow.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190704_202200_zpsiytagwzv.jpg
Good new. The passenger side brake union also undid without issue so there is no need to make any new brake pipes. I'd rather have an unused roll of cupro pipe than the hassle of running new pipes, especially the drivers side one which runs above a heatshield.
Popped into my local VW dealer earlier as well and ordered some of the spring clips for the princely sum of 60p each! I'll collect them tomorrow morning.
Old calipers, axle brake semi flexi / semi rigid pipes, and main flexi's all off. All will be replaced.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_185851_zpsfloeocor.jpg
The rear brake pads. The set on the left are those from the binding caliper side, they are about twice as worn as the other side.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_185859_zpsxcsukuge.jpg
I've taken this opportunity to take the arch liners off and have a look. Things are holding up quite nicely from when I last did this back in 2016 although there are few bits to touch up. There is however a bit more work to do at the drivers side sill end.
Drivers side sill end, a mud and water trap and some tell tale rust staining.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_185927_zpsrxr93fij.jpg
No such issues on the passenger side except for a bit of surface rust from a sill cover fixing screw.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_185918_zpsaelgk03d.jpg
Touch ups from 2016 doing well
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_185937_zpswpffqouf.jpg
All the work I did cleaning off and painting the suspension components is holding up very well also.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_191109_zpsn4ewp4xq.jpg
After a quick jet wash that sill end rust looks a bit ominous.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_191048_zpss03zj19j.jpg
I'll wait for things to dry then get the grinder and cup brush out on the sill end a bit later and touch up with some POR15 paint (my new favourite). I will also give the arch liners a clean.
More to follow...
And there is the problem owning an old car that you care about a bit too much. That quick rust job is turning into a bigger one. I've just spent the best part of an hour and a half digging out a block of seam sealer which must have been 40x60x60mm to establish the extent of the rust.
Whilst doing so I've come to the conclusion that sometime in it's life the car been accident damage repaired at that exact point on both sides of the car with the drivers side (this rusty bit) taking the main brunt. I reckon the car had been reversed back too far over a drop and once the back wheels cleared it grounded at this point. When I bought the car there was no visible evidence on this (now rusty) side of any damage but some on the other side, some cracked plastic.
Pictures can say more than words, these are after I'd dug out the seam sealer.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_211422_zpseepfjb0b.jpg
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_211429_zpslsczjp6p.jpg
And there is the pile of it painstakingly removed
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_211439_zps7cruqunk.jpg
In this picture you can see where I believe to be the extent of an accident repair with the difference in paint colour. I looked at it from various angles to eliminate "the light" causing it but it is there and the camera picks it up well.
https://img.photobucket.com/albums/v602/colin__/Passat%20Highline/Brakes%20Jul%2019/20190705_211555_zpssiqov5iv.jpg
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