1. Sam Bateman

    Sam Bateman New Member

    Joined:
    Nov 25, 2009
    Messages:
    2
    Car:
    1996 VW Passat TDI
    I am the new owner of a 1996 Passat B4S with between 120,000 and 150,000 miles (depending on who you believe). Didn't get much service history with the car so I'm basically starting from scratch. I plan to replace the timing belt, tensionizer, serpentine and V-belts, water pump, vacuum hoses, etc. as outlined in the extremely informative how-to's on this web site.
    The one system that I didn't see much info on overhauling is the cooling system. This car still has what appears to be the G-11 coolant in it and the hoses don't seem to be on the verge of failing but nowhere near new either.
    I'm thinking that while the system is opened for the water pump replacement, it would be wise to replace the thermostat and as many of the hoses as possible. I'm planning to go back with the G-12++ coolant so a complete flush will be done before refilling.
    Does anyone have any first hand experience with what order the hoses and such should be replaced? Since I didn't see any how to's for this I'm assuming that the factory hoses hold-up pretty well?
    I need your advice based on your history with these cars.
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  2. chittychittybangbang

    chittychittybangbang Administrator

    Joined:
    May 23, 2007
    Messages:
    21,873
    Car:
    2006 Jetta TDI
    Location:
    CT
    http://myturbodiesel.com/1000q_how_to/a3b4/coolantflush.htm

    Look through this. You will need to do the procedure listed for full flush to get all the old G-11 out. G-11 and G12 aren't compatible. So flush with water before filling with coolant.

    The weakest factory hoses are probably the ones at the back of the engine near the EGR cooler. They're exposed to a little more heat being next to the exhaust manifold and turbo. Otherwise the hoses hold up pretty well. I replaced the Y-shaped hose under the injection pump because I installed a coolant heater (there's also a writeup for that). If you have a fuel leak on the injection pump it will drip onto that hose and diesel fuel melts rubber hoses. Any other hoses that you replace would just be preventative maintenance, I can't think of any specific weak spot.

    Also look through the new owner checklist. It should bring the car up to current maintenance. While you are replacing all the hoses also inspect all the wiring for chafing, rubbing, or cracks.

    Also check the harmonic balancer pulley. If it's original because the original design tends to chirp. There's a wirteup for it in the "how to" section.
  3. Sam Bateman

    Sam Bateman New Member

    Joined:
    Nov 25, 2009
    Messages:
    2
    Car:
    1996 VW Passat TDI
    Thank you CCBB.
    Since I posted the original post I have been in touch with the VW dealer that serviced this car and have gotten some copies of the service records.
    The turbo gave-up the ghost at about 70,000 miles and was replaced. Seems like a mighty early failure to me. Is this anywhere near the normal life span of a turbo?
    Other than worrying about what maintenance needs to be done, I'm thouroghly enjoying driving this car. Drove it 316 miles pack from PA and used 6 gallons of fuel. Wow! I can get used to this....

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