Re: Sics Consolidated Faded Moderns Thread - 2003 E320 & 2006 Golf Mk5 GTI
Posted: Fri Feb 16, 2024 12:26 am
Absolutely peeing it down tonight. I'm not sure why, but I decided to get going on this.
Even my cat was watching on in bemusement as I worked out in the rain.
Anyway pulled the alternator out. Wasn't a bad job. I have just realised I didn't mark which way the aux belt went. Maybe I should replace it while I'm there now?
Alternator date code is 2006. Almost certainly original to the car. Impressive that it's lasted nearly 200k. However the one way clutch on the pulley is locked solid and not functioning. I don't know how important it is for a petrol?
I do have the tool somewhere to remove a one way pulley. Hell knows where it is. I think may even have a new pulley for a TDI A4. Probably the same as what is on this.
Anyway I'm going to pretend it's okay for now unless I find said pulley + tool.
With the alternator out of the way, access really isn't that bad.
Most difficult bit was trying not to round one of these stupid triple spline bolts. Found an M5 in my Rolson bit set that I bought from Maplins years ago. Not the best quality but far better than a cheap set I got off eBay a few years back. I reckon I need to invest in some better quality Triple Spline sockets. These stubby ratchets are very handy for getting into tight places too.
With the thermostat visible, I pumped up the reservoir again. Pretty clear that the thermostat housing is fubar.
I'm really hoping that the Behr/Mahle will be better quality. This doesn't look that old a thermostat either.
No idea why it chose now to fail. I think it was just a bit of bad luck - especially considering where it failed.
I carried on removing bits ready for a thermostat change when it arrives. The intake charge pipe hose was a bitch to remove. It would have been a lot easier if I jacked the car up to begin with and realised no amount of struggling would get over that I've missed a torx screw on the bottom.
While I had access to it, I removed the throttle body for a clean. I suspect this came off much easier than I'll get back on. It's mounted inverted on the intake manifold with the fixings not visible. Removing it does however give even more access to the thermostat area.
I'll give this a good scrub tomorrow. Will have to remember to reset the adaptions on it too. It's date coded as original too, so possibly this has never been off or cleaned. I'm tempted to take the cover off the side and inspect for wear on the potentiometer resistive tracks. Given the mileage, I fully expect the tracks around the idle position to be very worn.
Decided to start undeleting the PCV.
Again while I had bits removed, it made replacing the main pcv cam cover to crank cover hose really easy. I wasn't intending to replace this as it was looking difficult access until I removed all these bits. However I'm glad I have, as the old had gone very brittle and snapped in half while moving it.
Inside all this is NASTY. Stank pretty bad. I'm really not a fan of PCV deletes. All this should be sucked into the manifold and burnt off, rather than accumulating in the cam/crank case and oil.
Removing the PCV delete plate was just a case of four torx.
Then replace the gasket as I have a new one.
You need to get the right pcv valve as there are two different setups on these engines. Get the wrong one and you'll have a big vac leak. Basically it comes down to whether there is a one was valve in this PCV or the one on the rear of the turbo.
I'm not actually sure which I need, so I went with the one with. At least I can cut out the valve if I don't need it. The check valve on this is the blue thing on the left.
The rear pcv check valve is in this hose joiner with the Audi logos on in the middle of this picture. Thing is, I don't want to remove this hose as I don't want to break anything. So I'm assuming it doesn't have one.
New pcv all bolted down with new screws supplied in the packet.
Looking at the engine, it did pass my mind that I was only £150 in parts and only an hour or so needed to go further in and replace the cambelt while I'm here...
It's tempting but I'd rather wait till spring (only a month away) when the weather warms up.
Not least right now I'm absolutely soaking wet after working out in the rain all night...
Even my cat was watching on in bemusement as I worked out in the rain.
Anyway pulled the alternator out. Wasn't a bad job. I have just realised I didn't mark which way the aux belt went. Maybe I should replace it while I'm there now?
Alternator date code is 2006. Almost certainly original to the car. Impressive that it's lasted nearly 200k. However the one way clutch on the pulley is locked solid and not functioning. I don't know how important it is for a petrol?
I do have the tool somewhere to remove a one way pulley. Hell knows where it is. I think may even have a new pulley for a TDI A4. Probably the same as what is on this.
Anyway I'm going to pretend it's okay for now unless I find said pulley + tool.
With the alternator out of the way, access really isn't that bad.
Most difficult bit was trying not to round one of these stupid triple spline bolts. Found an M5 in my Rolson bit set that I bought from Maplins years ago. Not the best quality but far better than a cheap set I got off eBay a few years back. I reckon I need to invest in some better quality Triple Spline sockets. These stubby ratchets are very handy for getting into tight places too.
With the thermostat visible, I pumped up the reservoir again. Pretty clear that the thermostat housing is fubar.
I'm really hoping that the Behr/Mahle will be better quality. This doesn't look that old a thermostat either.
No idea why it chose now to fail. I think it was just a bit of bad luck - especially considering where it failed.
I carried on removing bits ready for a thermostat change when it arrives. The intake charge pipe hose was a bitch to remove. It would have been a lot easier if I jacked the car up to begin with and realised no amount of struggling would get over that I've missed a torx screw on the bottom.
While I had access to it, I removed the throttle body for a clean. I suspect this came off much easier than I'll get back on. It's mounted inverted on the intake manifold with the fixings not visible. Removing it does however give even more access to the thermostat area.
I'll give this a good scrub tomorrow. Will have to remember to reset the adaptions on it too. It's date coded as original too, so possibly this has never been off or cleaned. I'm tempted to take the cover off the side and inspect for wear on the potentiometer resistive tracks. Given the mileage, I fully expect the tracks around the idle position to be very worn.
Decided to start undeleting the PCV.
Again while I had bits removed, it made replacing the main pcv cam cover to crank cover hose really easy. I wasn't intending to replace this as it was looking difficult access until I removed all these bits. However I'm glad I have, as the old had gone very brittle and snapped in half while moving it.
Inside all this is NASTY. Stank pretty bad. I'm really not a fan of PCV deletes. All this should be sucked into the manifold and burnt off, rather than accumulating in the cam/crank case and oil.
Removing the PCV delete plate was just a case of four torx.
Then replace the gasket as I have a new one.
You need to get the right pcv valve as there are two different setups on these engines. Get the wrong one and you'll have a big vac leak. Basically it comes down to whether there is a one was valve in this PCV or the one on the rear of the turbo.
I'm not actually sure which I need, so I went with the one with. At least I can cut out the valve if I don't need it. The check valve on this is the blue thing on the left.
The rear pcv check valve is in this hose joiner with the Audi logos on in the middle of this picture. Thing is, I don't want to remove this hose as I don't want to break anything. So I'm assuming it doesn't have one.
New pcv all bolted down with new screws supplied in the packet.
Looking at the engine, it did pass my mind that I was only £150 in parts and only an hour or so needed to go further in and replace the cambelt while I'm here...
It's tempting but I'd rather wait till spring (only a month away) when the weather warms up.
Not least right now I'm absolutely soaking wet after working out in the rain all night...