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Discussion Starter #21
Finally got to remove the EGR cooler.


A hose pulled from a Passat 1.8T that was chopped at the junk yard. I had to cut it down a little more to get the kinks out of the system without modifying the stock hose

Notice the nice black hard coated aluminum hose barb :)

I rotated the old hose around 180 degrees to mate up with the new heater hose, while doing that I noticed this little connector, its a soft rubber insulation and the connector is a spade connector, the female side.


Its a tight bend, but there are no kinks where the two mate up


New hose on the heater core - that was a pain to fish through!


And clean.


You wouldn't believe it, but a person can actually find a place to stand in a passat engine bay!


Jon
 

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Discussion Starter #24
Well after the car had 57k on it, it went till about 85k where the first timing job was done at the dealer - incorrectly, a complete hack job, so yes, replace plates and top off the water, add a little green antifreeze when appropriate. Yup, reconditioned battery. I'll be getting a new battery from the VW dealer soon.

Did the timing job on it, just got back from greengeekers place(tdi club trusted mechanic). Timing job done, new water pump, thermostat, belts, hammer mod, etc. He did an excelent job.
He pointed out that those connectors(found a second one) were for other options or something.

Jon
 

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Discussion Starter #25
Ahh(not my engine code), I feel much better. Timing job complete! Nick did a great job on it and I learned a lot.
Nick decided that he'd do a write up on how to do the timing job on a North American AHH, that will follow shortly ;) I'm kidding. Here are a few pictures:
step 1, remove front end:




We found that the viscous coupling pulley would not budge! we went to Menards to get a strap wrench, no such luck, so we got some 5mm bolts, a 3 foot 1x.25 steel flat and made a custom 3 foot spanner wrench. Without a welder or the proper tap, the bolts had to be wedged in and held in place by the awesome assistant(me).



That short ratchet did nothing, a cheater was required, and even then, it took a lot to get it to budge.

With that off, we were able to get the serp tensioner off and the water pump out.



Thank you Volkswagen for the unique pump!
we found that the O-rings for the pump and the thermostat were totally chewed up, must have gotten smashed at the factory - according to the records, it hasn't been replaced.

New belts on


From there, everything was put back together. Nick adjusted the IQ, IP timing, did some logs and I made it home safely with the multifunction display reading 53MPG when I got home(~30 miles).

btw, that connector I posted a picture of is nothing, just an option I don't have I guess.

Enjoy the pics!

Jon
 

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I guess it's too late to easily replace the whole hose but the power steering reservoir hose connection is a common leak.
 

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Discussion Starter #28
Quick update, I got a CAT fuel filter and lubrication specialists adaptor(from a local tdiclub member who stopped using his) to swap into my car, I plan on purging the injectors and then install it when I finish that. If you look at the pictures above, the fuel filter is a screw on type, its a M16 thread on there I guess and I've been searching and haven't found an adequate replacement. I could put one from any north american TDI into there but I went for the upgrade.

Its looking more like a proper clutch replacement will be a 1.8t clutch setup, once I confirm that I'll feel more comfortable about getting a higher torque tune.

Jon
 

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Discussion Starter #29
Just a shot to show how things are progressing:

I added a battery cover from a B5.5 and finished the EGR Delete.

Also, I confirmed a rumor:

Confirmed, factory 11mm IP!


the 414 in the bosch part number designates the 11mm IP


Jon
 

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Yup, reconditioned battery. I'll be getting a new battery from the VW dealer soon.
No I've never heard of reconditioned batteries either, not for automotive use.

I wouldn't bother with the VW dealer for a battery Jon unless you fancy paying an extorsionate price. There should be plenty of places that sell auto batteries? ;)
 

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;) According to ETKA the rear main seal is 028103171b, the same one as for 1z/ahu engines.

There was a switch from the rubber lip type seals to the teflon type seals.
 

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passat tdi

hey i saw your thread and i was woundering if you would like to sell the passat i am a huge fan of passats more for the tdi ones
 

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Discussion Starter #36
That is pretty cool, I too am a big fan of the B5 platform(vw and audi).

You're going to have to pry this one out of my hands if you really want it.

Jon
 
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