VW Passat B5 PD115

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GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
I purchased this car as I took on a job that I was going to be covering a fair amount of miles a day and are pretty much renonwed for reliability. Long story short I ended up back at my previous job a few later and decided to carry on with the car. I also have a late 2013 Ford Mondeo estate also that I have given to my Mum in the mean time, she loves it compared to her MK4 astra.

Anyway a lot of this at first will be copied and pasted from my thread on UK Passats so I'm sorry if I miss anything out ha.

I purchased the car for £750, 89K miles, 1 owner & FSH & a bunch of receipts. Very Grandad spec. Headed up to Manchester a few days later to collect.

Will now start sticking up some photos on posts.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Pictures from day of pick up..





Car also hit 90,000 miles on the way home



[u]Few things I need to work on.[/u]
- Car came with a Blaupunkt tape player and cd changer, gonna change this to something a tad more modern, its very dated
- Inside is clean but it needs a freshen up
- New front wipers.
- Headlights need restoring and a change of bulbs.
- O/S/R window is stuck, it moves a few mm and jams. O/S/F sounds like it may start playing up soon too
- Possibly needs a clutch, not sure if it just feels heavy after a long day of driving compared to my 2013 mondeo or not.
- Red screen on speedo goes on and off when it feels. Anyhelp for this will be great.
- Temp guage dropped below 90° a few times, believe thats a coolant sensor or thermostat?
- In urgent need of an armrest. Also a few new interior plastics etc. (Think I'm going to to get a few trims from B5.5)

Few pics from today.






















GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Had a few issues with my aux belts. Couldn't of come at a worse time as I was planning on having my cambelt etc done. But needs must this was fixed on short notice at a friends garage after a tow home.









At this point I removed my engine cover and some worn foam from the bay ready for a clean up at some point.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Few pictures to update the thread.

You may have noticed the original pictures I have a Blaupunkt cassette player and this comes with a 6 CD changer in a bot compartment. Well on collection day my friend gave me a Pioneer headunit, nothing brilliant but a lot more updated than this. So I ordered some headunit pins from ebay and they arrived today.





Unfortunately for me, the plugs are different as I first thought. My mate has the adapter and is sending it down for me.

I still have my KillAllWipers bung to go on. Because I left it so long the sealant has set. Fail on my behalf. It's waiting anyway.



Got a great deal on a PD130 inlet from Chris Oakman on the Facebook page. Not sure if hes on here or not?

On arrival...



Gave it a clean with a microfiber and some brake cleaner today...





Will be going over it again soon with some APC and brushes - also ordering a new gasket from Darkside before install.

One thing that bugged me since getting the car were the security stickers on the 2 front windows. These were horrible to take off as they were very sticky and very brittle. Strange how a bit of sticker removal makes me happy.







I am aiming for some progress soon. Just been very busy. Updates soon with cambelt change and service.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Removed a aftermarket old useless 6cd changer. Also cut out the towbar wiring, can probably tidy this up better at a later date for sure and also dropped part of the towbar. I need to replace the crash bar for a standard one at some point but it's now being degrandaded.







Also removed the rear wiper motor and arm. Blanked off the washer fluid pipe by melting the end rather than a screw, see how it holds out.. Removed the rear badges, a sticker and the rear bumper sticker / protecter also.. #:-s

With some thinners and some compounding it will do for now, I am going to buy a machine polisher around chirstmas time and start learning some techniques.















Also wiped the top plastic trim down while the trim was out it was a bit grubby..


GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Changed the batteries in both my key fobs today.



[url=https://flic.kr/p/MH9UbM]




dannyDC2

7,543 posts

168 months

Friday 2nd December 2016
quotequote all
I'm one of the weirdos who loves threads like this so keep the updates coming!

I had my aux belt snap on my A4 too the other weekend, then my mates went on his passat. PDs are dropping like flies wink

Mine's on 235k, yours must feel fresh as a pup!

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
So undertook some work yesterday and time to bore you with some photos.

Time to carry out a change on the cambelt, waterpump, thermostat, coolant, snubmount, oil and filter, air filter, pollen filter. We didn't get round to changing the fuel filter.



How we started off anyway..



Can also see the headlight fading and moss in the indicators.







I have ordered some APC and a brush etc but it never arrived in time (my fault) but I did have a cloth and some shampoo with me to give a few bits a wipe down along the way.





First off the front end started coming off and we dropped the coolant out the system while removing more parts.





While being on UKPassats I have picked up that the snub mount requires changing. Upon removal I can clearly see why. I changed to a rubber option from the V6 TDI.





Some buildup around the the inlet..



We got everything off..



Replacements..



Timed and locked in and parts put in place ready for the belt



Quick test and thankfully all running smooth.



Engine off and carry on with the rest of the work..

Old air filter was dirty..



Pollen filter was a PITA to change. Clearly well overdue. Had a 2012 stamp on for a guideline..



For some reason the thermostat housing just would not come out without moving the alternator. But needs must, I have seen it be done without moving the alternator with little room so I'm not sure what happened here.



As the car was being put back together, greased up the crash bar knob for the snub mount to be placed on and slotted in place.

Upon driving after work completion, I can feel a slight difference in gear change but mainly, previously in traffic while in gear I could tap the throttle and the gearknob would judder, this has now been eliminated which makes the change worth it for me.



Heres a final shot. The bay was cleaner but after putting everything back together it all got dirty again so I will wait for my APC to arrive and some cloths. Will help when the EGR is out along with some unnecessary pipes has gone and a new clean inlet is in.

You may also notice some black caps from an Audi A3 (Coolant, Oil & Brake Fluid)



I will tackle the EGR and vacuum pipe removal shortly. I still need to carry out the fuel filter change we just ran out of time and I never took any photos of the oil & filter change.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Couple of deliveries at work...

[url=https://flic.kr/p/MMVMGw]

[url=https://flic.kr/p/MQX2vH]

DA Polisher, glass sealant (plan on using this on the headlights after restoring), pads, microfibers, APC, tar & glue remove, brush etc..

Also a Recaro young sport front facing seat for my little one to jump in to in a few weeks time as her rear facing seat is getting a bit small.

Purchased this from Halfords. Nothing amazing. Bluetooth (Music & Phone calls, can install microphone as and when I please), AUX, CD & Radio. Cheap and cheerful. I can actually listen to music now.



Changed the cage over, which I'm actually struggling with. I have managed to secure the cage in place but I need help securing the actual head unit in to the cage. Any advice would be great for the best way to go about this. Guess climate control unit out and maybe a couple of buttons?



As you can see it hangs out slightly and doesn't quite click in place?



Will get a picture when it's lit up at night on my camera when I next do some work.

[u]Tracking[/u]

Something that bugged me for ages. The steering was almost straight but the steering wheel was out of line majorly.

Took the car in to work and had it tracked, wheel was centred etc etc and everything was rectified.





Everything was tightened back up and 1 minute down the road my wheel is wonky again but it's now pulling. Oh and I have lost a hub cap lol.

Any advice regarding the steering will be great, it's bugging me.

Had my ambers turn up so I can now get ready with the headlight restoration smile

1 even came in a tired looking VW box.


GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Had my car scanned a couple weeks ago by a friend, got it emailed over to me yesterday.

Anyone feel to shed some light on the fault codes feel free.

There is an issue with central locking but this work was carried out from VW a fair few years back looking at a receipt.

There seems to be an issue where sometimes when I push the lock button more than once without realising the alarm goes off. Not always though.

As for the mirrors, not quite sure if the heating elements work but when I switch the dial to R and adjust when reversing, both mirrors move. This doesn't happen when on L.

Also this document says my engine code is AJM where as the label in my car say ATJ?

Thanks.

[b][center]Monday,26,September,2016,18:51:00:62939
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.0.0
Data version: 20130910


VIN: License Plate: W732RNE
Mileage: 146260km-90881mi Repair Order:









Chassis Type: 3B - VW Passat B5 (1997 > 2005)
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


Mileage: 146260km/90881miles


Address 01: Engine Labels: 038-906-019-AJM.lbl
Part No: 038 906 019 BK
Component: 1,9l R4 EDC G000SG 1061
Coding: 00002
Shop #: WSC 05311
VCID: 61C9430FEBBC7116FBD-4A9C

No fault code found.
Readiness: 0 0 X X X



Address 03: ABS Brakes Labels: 8E0-614-111-ASR.lbl
Part No: 8E0 614 111 AH
Component: ABS/ASR 5.3 FRONT D10
Coding: 00012
Shop #: WSC 05314
VCID: 64C74A1BF4AE643E10B-5000

No fault code found.



Address 08: Auto HVAC Labels: 3Bx-907-044.lbl
Part No: 3B2 907 044 C
Component: CLIMATRONIC C 0.7.0
Coding: 05000
Shop #: WSC 05311
VCID: 224B0C03AE3A2A0EA27-51D0

No fault code found.



Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 6Q0 909 605 B
Component: 05 AIRBAG VW5 0003
Coding: 12341
Shop #: WSC 05311
VCID: 3663C05312B2A6AE7EF-4A3A

No fault code found.



Address 17: Instruments Labels: 3B0-920-xx2-17.lbl
Part No: 3B0 920 922 A
Component: B5-KOMBIINSTR. VDO V25
Coding: 05445
Shop #: WSC 05311
VCID: 1E3338F39A420EEE86F-5000

Subsystem 1 - Part No: IMMO
Component: IDENTNR: VWZ7Z0X2173671
IMMO-IDENTNR: VWZ7Z0X2173671

No fault code found.



Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00004
Shop #: WSC 05314
VCID: F0EFB64BB056489EE43-5000

1 Fault Found:
01044 - Control Module Incorrectly Coded
35-00 - -



Address 46: Central Conv. Labels: 1J0-959-799.lbl
Part No: 1J0 959 799 AH
Component: 3R Zentral-SG Komf. 0001
Coding: 04096
Shop #: WSC 05311
VCID: 8407EA9B94EE443E30B-4A3A

Subsystem 1 - Part No: 1J2959802D
Component: 3R Tõrsteuerger. FS0002r

Subsystem 2 - Part No: 1J2959801E
Component: 3R Tõrsteuerger. BF0002B

Subsystem 3 - Part No: 1J4959811D
Component: 3R Tõrsteuerger. HL0002r

Subsystem 4 - Part No: 1J4959812D
Component: 3R Tõrsteuerger. HR0002r

4 Faults Found:
01135 - Interior Monitoring Sensors
36-10 - Open Circuit - Intermittent
01134 - Alarm Horn (H12)
49-10 - No Communications - Intermittent
00943 - Heated Exterior Mirror; Driver Side (Z4)
35-00 - -
00944 - Heated Exterior Mirror; Passenger Side (Z5)
35-00 - -

End ---------------------------------------------------------------------[/center][/b]

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Heres a before photo from a earlier workload day..



Used my new machine polisher from Slims Detailing. Along with some Megs cutting compound and some other 3M products. Used 1200, 2000 & 2500 wet and dry to went sand my headlights and this was the outcome.





Used some G Techniq to seal them, maybe not the best stuff to use it is for glass but it included a sealant and a residue remover.



Stuck my genuine ambers in..









Opted for some Philips Extreme Vision, albeit brighter they are too yellow for my liking and will be replaced for some Diamond Visions.



Made a mess in the engine bay and on the whole car with compound everywhere, wiped down the engine bay fine with some APC but the car needs a good clean. Gonna give this particular item a few goes over.



Next up was to do my rear brake hoses and caliper seal kit. Upon removal of the wheels (hadn't taken these off previously) it was evident a new set of discs and pads was required and a new caliper on the N/S/R. I will change the O/S/R in due time to match.





Bosch supplied an original refurbished part which is fine by me.



Brake hoses from TPS which only the N/S/R was fitted, the other side didn't fit.



All fitted back & bled.



I then drove the car to Telford & back for Ultimate Stance which was about a 400 mile round trip and the car ran faultlessly and ticked over the 92,000 mile mark and is well on the way to 93,000.

Monday my 57mm Darkside Developments EGR delete kit arrived and my Forge silicon corner reducer arrived also. All ready to go on the previously picked up PD130 inlet. This will all be going on in the next couple of weeks.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Purchased these from a friend.

Genuine Audi S-Line alloys 18 x 7.5J all round.

They require 2 tyres to make them legal although the two tyres on there that are pretty new are budgets. They also will be refurbished.

In no rush to get them on but sooner the better.



came to the car a few mornings ago and was greeted with such...



Managed to get it in at work and have a look.

Drainhole was already clear under the battery and there were no signs of leaking around pollen filter area. Gave it a blast and hoovered up the water on top of the carpet for now.





Also the bottom of the windscreen under the scuttle panel was horrendous, gave this a clean out.



Chucked in a couple air con bombs while I was at it.

Ordering new pollen filter housing and seal thanks to parts numbers from Gaz. Will lift the carpet to hoover that hopefully tomorrow.

Yesterday I travelled up to Milton Keynes to see Am from BladeIce to do a photoshoot on his E series X5 for Ilovebass.

Teaser Pic.



In return he was very kind to give me a set of Gladen M-165 component speakers which I will get fitted ASAP. Just need to get some autoleads adaptors and some sound deadening. Didn't get the tweeters out for the photo ha.


anonymous-user

54 months

Friday 2nd December 2016
quotequote all
nice car ive had a few b5 audis but never a tdi.

i own a Octavia tdi 130 which are a great engine. my coolant temp drops slightly below 90 but never had any issues so not a problem really, i'm not going to change anything. i changed my aux belt at cambelt change as it looked ropey, a lot never do.

Will you remap it?


GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
So today I put on my new PD130 inlet, Darkside EGR delete, Forge 57-51mm reducer and carried out some vacuum simplification. Bit more confusing for me and my friend than I thought as I've not done anything like that before.

Anyway got the recommended Mr Muscle oven cleaner out...





The gunk that came out while pressure washing was unreal. Gave it 2 goings.



Came out good enough internally.





Also gave a scrub with some APC before painting.

Heres a couple photos of what was being removed.





A brief comparison between the two...



The additional parts going in, can also see the new inlet gasket.



Taped up some holes.





Straight after a coat of paint. Looks wet here but it is in fact satin black.



PD115 inlet, EGR unit & corner pipe removed. Very dirty.









Blanking plate & gasket going on.



Comparison between the 2 manifolds.



All fitted, was a bit dark at this point.



When the front end off comes off at some point I will then remove the vacuum reservoir.

Can't really say I feel much of a difference low end, I think I can feel a slight difference mid range but this could just be a placebo effect.

Another job off the to-do list though and happy with it.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
Cleared the 93k miles a little while back.



Got the tyres taken off the S-Line wheels..



I'm not going to drop them off to my friend to paint, and while I'm there I will be collecting this..



My carrera road bike rebuild :mrgreen:

Picked up my LUK flywheel from Chris at the weekend so need to get some free time to get this completed.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
dannyDC2 said:
I'm one of the weirdos who loves threads like this so keep the updates coming!

I had my aux belt snap on my A4 too the other weekend, then my mates went on his passat. PDs are dropping like flies wink

Mine's on 235k, yours must feel fresh as a pup!
Ha I've just chucked up a few more updates!

Have some more coming in the next week or so regarding clutch / dual mass etc.

I'm working my way close to 94k now which is minor in the great scheme of things.

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
The Spruce goose said:
nice car ive had a few b5 audis but never a tdi.

i own a Octavia tdi 130 which are a great engine. my coolant temp drops slightly below 90 but never had any issues so not a problem really, i'm not going to change anything. i changed my aux belt at cambelt change as it looked ropey, a lot never do.

Will you remap it?
Well I got this car on the belief if it being a PD130, was only a day or 2 before collection I was informed the b5 only came in PD115 so I kind of wish I went for an A4 saloon PD115 B5 but hey ho.

Mine was dropping but since doing the coolant flush, thermostat and waterpump I've had no issues. Just annoying how long it takes to reach 90.

I will certainly be mapping the car but I have just stuck a PD130 inlet on and have a few more bits to stick on before I bother getting it mapped.

anonymous-user

54 months

Friday 2nd December 2016
quotequote all
The b5 passet came with tdi pd 130 engine. The audi a4 didn't. you can even get the b5 tdi 130 4 motion.

the audi a4 s line steering wheel is a nice feel and shape if you look at changing it.

Edited by The Spruce goose on Friday 2nd December 17:21

GrantB5

Original Poster:

572 posts

88 months

Friday 2nd December 2016
quotequote all
The Spruce goose said:
The b5 passet came with tdi pd 130 engine. The audi a4 didn't. you can even get the b5 tdi 130 4 motion.
B5.5

Not B5

My engine code ATJ is the highest power out put PD that they made in this range for B5. Most were PD100 and a few PD110. Let alone 4 motion ha

lel

395 posts

123 months

Friday 2nd December 2016
quotequote all
What a handsome looking car, I too love these kind of threads so I look forward to more updates smile

Cracking photos too!