Shedding properly, 2004 Passat Estate 1.9 TDI
Discussion
Jackandwrench said:
Your confidence is inspiring! Some real quality work here, it's one thing to repair a vehicle, it's another thing to improve it and surpass the manufacturers efforts along the way. I will continue to watch your work sir
Thank you. Most of the work has simply been refreshing worn out bits with the odd bit of early restoration thrown in. Apart from the heater matrix it has all been quite enjoyable.Diesel Meister said:
What I like best is the thoroughness / thoughfulness of maintenance / improvements, as well as the fact you've rolled up your sleeves. Not for me (I lack the skills, patience, time, tool, space...) but enjoyable to read. These Passats make for enticingly inexpensive, commodious and low-key transportation. Despite the board name, I'm not much of diesel fan at all but these are undeniably great tools for all-purpose hauling of people / stuff.
They are the best kept shed secret of all. These B5.5 Passat are the last great VW before they forgot what they knew about making good solid reliable cars.
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.
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.
Something I hadn't mentioned is that I've got yet another water leak. I've narrowed it down to the new water pump 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.
This is the leak patch on the garage floor, quite a lot.
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...
The new condenser is still looking good, just a few dead flies on it
I can't remember if I went into detail last time on this, but you simply unfix it and swing it to the side
My newest favourite tool, remote pipe clip remover. Wish I'd bought one of these years ago
And in action, no more slipping pliers
And the front is off
Ready for working on the belts
Just under an hour for that
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...
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.
This is the leak patch on the garage floor, quite a lot.
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...
The new condenser is still looking good, just a few dead flies on it
I can't remember if I went into detail last time on this, but you simply unfix it and swing it to the side
My newest favourite tool, remote pipe clip remover. Wish I'd bought one of these years ago
And in action, no more slipping pliers
And the front is off
Ready for working on the belts
Just under an hour for that
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...
Edited by colin_p on Friday 7th October 19:27
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
The cam belt is bone dry and as new.
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 !
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
The cam belt is bone dry and as new.
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 !
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
Thermostat housing, thermostat and 'o' ring, another £i gulp!
Genuine thermostat which was insanely expensive !
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.
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.
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
Thermostat housing, thermostat and 'o' ring, another £i gulp!
Genuine thermostat which was insanely expensive !
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.
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.
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.
Nut welded onto idler stud, in fact I was so quick in taking the piccy it is still glowing RED hot.
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.
You can see the coolant staining on the lower belt cover where it was dripping from. This vindicates my water pump diagnosis.
The six month old Gates idler oozing grease, a good catch finding this now.
Six month old Gates pump bottom, SKF pump top, a nice blue hue
All done, just need to put the front end back on now.
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.
Rubber mount on, that was tight!
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.
Nut welded onto idler stud, in fact I was so quick in taking the piccy it is still glowing RED hot.
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.
You can see the coolant staining on the lower belt cover where it was dripping from. This vindicates my water pump diagnosis.
The six month old Gates idler oozing grease, a good catch finding this now.
Six month old Gates pump bottom, SKF pump top, a nice blue hue
All done, just need to put the front end back on now.
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.
Rubber mount on, that was tight!
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.
I know the thread title says shedding properly but I'm doing it wrong as I spend far too much time and money on the car!
If I could edit the title I'd change it to anti-shed shedding or something.
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.
I know the thread title says shedding properly but I'm doing it wrong as I spend far too much time and money on the car!
If I could edit the title I'd change it to anti-shed shedding or something.
msremmert said:
Fair play to your dedication, I've actually learned a bit from this thread and your standard of work is incredibly high.
I've got a real soft-spot for my B5.5 and it's great to see some appreciation for the old tubs.
This was in May. Car did over 2600 miles that week and saw Prague and Austria. Didn't miss a beat.
Only on 156k - but still on the original clutch!
Good car.
/quote]
Shoooooosh !
The best kept secret will be out and people on here will stop recommending Saabs and Volvos
I've got a real soft-spot for my B5.5 and it's great to see some appreciation for the old tubs.
This was in May. Car did over 2600 miles that week and saw Prague and Austria. Didn't miss a beat.
Only on 156k - but still on the original clutch!
Good car./quote]
Shoooooosh !
The best kept secret will be out and people on here will stop recommending Saabs and Volvos
problemchild1976 said:
OMG now i've just had to go and buy a hose clip remover!! haha
JJ
Women buy shoes like that. JJ
Monkey magic, there simply is not enough.
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
Stranger things happen at sea and I like to make sure the new battery is the same as the old one.
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
And roll the sausage fowards
13mm socket on a 10" extension bar (bolt head shown with socket next to it)
Socket on bolt
Battery clamp bracket and bolt, off
Battery part way out, obviously undo the terminals !
Old and new
The carrier will take three different sized batteries if you so wish to upgrade, three holes for the clamp
Bit of rust on the carrier so a quick squirt of the Supertroll !!!
A quick squirt squirted !
And in
And loom rolled back into position
And done
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
Stranger things happen at sea and I like to make sure the new battery is the same as the old one.
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
And roll the sausage fowards
13mm socket on a 10" extension bar (bolt head shown with socket next to it)
Socket on bolt
Battery clamp bracket and bolt, off
Battery part way out, obviously undo the terminals !
Old and new
The carrier will take three different sized batteries if you so wish to upgrade, three holes for the clamp
Bit of rust on the carrier so a quick squirt of the Supertroll !!!
A quick squirt squirted !
And in
And loom rolled back into position
And done
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.
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.
New toy came today, a compressed air driven oil extractor.
This one, although only last week I paid £109 for it, £115 now!
http://www.ebay.co.uk/itm/360375849221?_trksid=p20...
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
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.
Air line spiggots, mine on the left, the one suplied on the right, glad I had a spare.
Ready to go
I have no idea what this hooped metal insert is for
Came with a brake bleeder adaptor as well, which is nice.
Down into the MK4 Golfs sump via the dipstick 'ole.
It and me working hard, in fact the compressor is doing all the work
Old, filthy but still perfectly useable Pela 600 in the back ground
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.
Swapped the 'o' rings over on the filter housing and popped a new filter on.
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.
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.
Need to do a change on the Passat in the next few days also.
This one, although only last week I paid £109 for it, £115 now!
http://www.ebay.co.uk/itm/360375849221?_trksid=p20...
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
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.
Air line spiggots, mine on the left, the one suplied on the right, glad I had a spare.
Ready to go
I have no idea what this hooped metal insert is for
Came with a brake bleeder adaptor as well, which is nice.
Down into the MK4 Golfs sump via the dipstick 'ole.
It and me working hard, in fact the compressor is doing all the work
Old, filthy but still perfectly useable Pela 600 in the back ground
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.
Swapped the 'o' rings over on the filter housing and popped a new filter on.
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.
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.
Need to do a change on the Passat in the next few days also.
layercake said:
You sir are a legand. .ive spend the last two days catching up reading your thread. You would put edd china to shame !
Lovely barge an and top fiddling I want one too ..
Thanks for that.Lovely barge an and top fiddling I want one too ..
Glowplugs are next on the list, means taking the stupid fuel filter bracket off to access Nr.4
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff