Well as some of you know, I ground the Passat out last week, and I've got the wonderful job now of replacing the sump. Not an easy job as you have to drop the subframe and hold the engine up with a hoist.

So, as the front needed dis-assembling for that, thought I'd do the cambelt, water pump, clean the boost pipework, sort out the cross tube that was showing signs of rot (metal boost pipe that runs the width of the car), clean all the areas of ****e that have accumulated etc etc.

However, taking the front end of has revealed a rotten radiator also :thumbdwn:

Also going to replace the drivers heated seat mat, broken rear ash tray, fit a W8 interior light and replace the alloy wheel centre caps.

Bill for parts is looking at £900!!!! :( So on top of the windscreen it needs, thats nearly a grand. Still, should be good for another trouble free 100k miles.

The good thing about having an estate, is you have somewhere to store the parts!!! :P

A few pics of todays progress...

PMSL at the parts in the boot , they always take up so much space when they are not attached to the car

at least you are not scared to have a go , and get B@lls deep on a job Tom , good work

Respeck!

If that was me, I would need a bale of duck tape to put it all back together!

Who's been a busy little boy then eh!!

May as well whip the turbo off and do the VNT vanes while you're there

May as well whip the turbo off and do the VNT vanes while you're there

Yeah, good point. And the EGR too.

Will carb cleaner get the majority of ****e off?

Thanks Stu for the heads up on the engine support - Screwfix have one on offer at £34.99!!! My local hire place wants £22 for a weekend, so I'll be buying one methinks!

As for balls deep - you ain't kidding mate. Saying that though, its all relatively easy as long as you are methodical, just a little bit daunting.

Not a lot more I can do now until the parts arrive.

Nice work Tom, Wish i had the bottle to takle jobs like that.

I used a gallon of Parafin to do the VNT Vanes when I did them.

I used a gallon of Parafin to do the VNT Vanes when I did them.

Cheers for that, will pick up some from work tomorrow. May even do a guide if I can be arsed to take photos, lol.

Phew

Methodical or what

lol bless ya!

Good luck with the work though, looks like your going to be busy for a little while

should be good for another trouble free 100k miles.

.

keep up tom my sisters V-Reg 1.8 A4 is at 217,000 she's only selling it as they want a bigger car for the baby!!!!

she's only selling it as they want a bigger car for the baby!!!!

how big is the baby , i'd of thought the A4 would be more than adequate :confused:

blimey talk about getting stuck in there nothing like fixing your own car though. i just hope you dont end up with the amount of "spare bolts" i had after doing a engine swap!!

Hmmm, this is getting scary.

The turbo was a pig to get off, but alas its here, on my desk. Its soooo friggin heavy.

Thing is, now its off, what do I do with it?

And had my first "mishaps". Firstly I snapped the oil feed pipe as the union was siezed... :( Looks like a pig to swap as where it meets the block isn't really accessible. The other thing being snapping the plastic leg that actuates the EGR. That ain't going to be cheap for sure. :(

Hmmm, this is getting scary.

The turbo was a pig to get off, but alas its here, on my desk. Its soooo friggin heavy.

Thing is, now its off, what do I do with it?

And had my first "mishaps". Firstly I snapped the oil feed pipe as the union was siezed... :( Looks like a pig to swap as where it meets the block isn't really accessible. The other thing being snapping the plastic leg that actuates the EGR. That ain't going to be cheap for sure. :(

those oil feed pipes are pigs , check the spindle for play before strip down , as there is no point doing anything if the turbo is f00ked

have a look at the pics in this thread http://www.briskoda.net/forums/maintenance-performance/de-coking-tdi-engine/89753/

basically there are 4, 10mm headed bolts to remove to access the inside of the turbo , no need to mark the position as there is a pin to locate the 2 halves

how much play should there be?

there maybe a little bit , as the oil will take up some it when the engine is running , we usually work on , if the vains are touching the casing it needs renewal , someone might have a different view on that though

Doesn't seem to be much play at all, only a smidge, a tenth of a mm maybe. Certainly doesn't touch the case.

The fins look a bit battered though, I'll let the pics do the talking

Looks like something has been through there mate.

The oil feed pipe isn't too bad and it's about £26 IIRC.

You can't buy the black actuator seperately - it's the whole EGR, so you need to find a used one.

It'll cost you a fair bit in new gaskets too.

how big is the baby , i'd of thought the A4 would be more than adequate :confused:

noo a v reg a4 saloon quite small just like a mk4 golf inside also you can't put the rear seats down unless you've got the se version. My octavia although similar in the rear seat size has a huge boot.

However he picked his t5 up today its like a garage in the back!!!! huuuggeee space, also he kept up with me on the way back :thumbdwn: may have to get a chip:thumbup:

While you have the front off check the alternator pulley is free wheeling. Easiest way to do that is hold the pulley at the front and then with a this screw driver you should be able to turn the cooling blades in the alternator one way. If you cant the pulley is goosed and requires a new one.

Okie dokie, will do Ross.

Thinking about getting the turbo reconditioned as preventative maintenance, but only if its cheap enough.

Grrrr.

Well, I've source a radiator, £56 all in from my local Wilko.

Still on the hunt for an EGR actuator... been offered a couple second hand, but photos show that despite having the same part number (bar the revision letter) that they look nothing alike. Have put a plea out on here and UK Passats, but no luck yet. Pinged Skospares an email too.

Think I'll get a cambelt kit from Silverwagon on eBay, £77 including postage for a genuine kit.

Want a metal impellored water pump, think I'll get one from my local independant who normally looks after me.

The cross tube is back from the powder coaters, and looks STUNNING!!! Looks too good to be hidden away. Ho hum. Not bad for £30.

So I'm still to source a sump and all the little bits like nuts, bolts, seals and gaskets...

Intercooler, turbo, inlet manifold and all pipework is all cleaned up just lovely now though!!

Bought an engine support, but before I remove the subframe I'm going to hire an engine crane/hoist for a weekend to see if I can remove the sump by lifting the subframe. Got to be worth a go.

Alternator pulley is fine, thank God. At nearly £100 for a replacement I hope it stays fine for some time too!!

Bought a second hand correct EGR valve on eBAY for £72 + £5 postage. I can sell mine on though (less the actuator) and make most of that back I hope.

Cambelt is ordered through Silverwagon on eBAY, £77 all in for a genuine kit - VERY good value.

About £100 worth of bits ordered from vagparts, and the other £300 odd of bits have been ordered from my local Skoda specialist - they normally look after me.

Still, don't expect to have all the bits til late next week, will most likely have next Friday off and get it done so I can drive to work on Sunday!

3 weeks without a car hasn't been as bad as I thought it would be though, and I've saved a fortune on diesel by calling in favours!

Total bill for parts and the tools I've bought will be just shy of £800, but for the work I've done thats not too bad.

Heated seat repair, and the mods I wanted (W8 light etc) will have to wait for the forseeable though.

It will certainly have been an experience Tom. Well done mate.