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New W8 Owner

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JayTheSnork View Drop Down
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  Quote JayTheSnork Quote  Post ReplyReply Direct Link To This Post Topic: New W8 Owner
    Posted: 21-Nov-2017 at 04:59
doesn't look like the accessory belt tensioner has been replaced; but then again, Ottawa winters can be brutal.
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 21-Nov-2017 at 21:01
Lookin' good - brings back a lot of memories .... most of them bad! ;)

Be very critical of any exposed wire harness, especially on the firewall side: guys who have been in there previously have a habit of leaving chaffed insulation, especially on the smaller gauge wires. I found a couple to repair that would have forced a motor drop if they failed in service.
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 22-Nov-2017 at 01:22
Yes - very good idea. I found a few wires that are cracked I will repair before reinstalling.   Used tranny is bolted up with the reman converter.   Sorry no pictures, but just about ready to reinstall. I just have to swap the engine mounts over (current ones are very toast, one fell apart when we lifted the engine off the subframe!) and reinstall the starter. Hopefully have it driving next weekend.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 22-Nov-2017 at 01:35
One more thing to note - this car had the T55 torx bolts for the torque converter, just like every other 01V I've taken apart.

Looking for a source to buy just the pulley on the tensioner. VW has replaced it with the complete unit ($$$$$). The 2 idlers I can source through aftermarket cheap enough though. So the front end may have to come back off later when I get that sorted.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote eddycooper Quote  Post ReplyReply Direct Link To This Post Posted: 22-Nov-2017 at 05:03
I also couldn't find a source for just the tensioner pulley when I did my water pump earlier this year. I just ended up leaving the old one in. I think you could replace it from the front without pulling the bumper off, but it would be tight.

Another "while you're there" item with the engine out would be oxygen sensors, particularly the upper ones. Then again, if it ain't broke...

This car will give you a new appreciation for tools that are suited for tight locations...

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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 24-Nov-2017 at 01:22
Originally posted by Uberhare

One more thing to note - this car had the T55 torx bolts for the torque converter, just like every other 01V I've taken apart.

Looking for a source to buy just the pulley on the tensioner. VW has replaced it with the complete unit ($$$$$). The 2 idlers I can source through aftermarket cheap enough though. So the front end may have to come back off later when I get that sorted.


I have a spare tensioner assembly, and the pulley bearing is 'smooth'.

So, there are two options .. #2 being that I could mail a pulley your way; however, a better option #1 might follow as I just pulled the T40 pivot bolt from the pulley, and the bearing looks to be replaceable.

The bearing is 35mm/15mm od/id, and is 25mm wide, with an 8mm id bore insert pressed into the inner race ( for the pivot bolt). The bearing is marked INA-08, and pulley is designated INA F 230590-300 or p/n 07D 109 244 A

Piece of cake to press in a new bearing - IF one can be found ... or put that lathe to work to faux fit a shell around another sourced 'conventional' bearing.

( all the timing belt idlers and tensioners for the Porsche 928's can be 'refreshed' with $10 bearings vs the $100/each new parts, so I've pressed in quite a few ;) ))

Edited by GS535i - 24-Nov-2017 at 01:24
03 Variant W8 silver on black TIP
00 Variant white 1.8T 5sp
96 993 C4S midnight blue/cashmere
90 535i blk/blk 5sp
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 24-Nov-2017 at 04:52
Thanks for the dimensions, you beat me to it!   I'm going to see if i can source a bearing first. I have spare unit from the parts car, so I have something to play with.

Found some more spare parts today! Pickup another set of headlights, taillights, cluster, rad fans and a bunch of modules. Going back for the brakes and wheels. It was kind of sad, car was pretty clean and the owner trashed it parting it.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 24-Nov-2017 at 21:49
BTW, there is a parting seam in the middle of that pulley .... there may be two 12.5mm wide bearings inside vs one 15mm??

If there is a front badge on the grill of the latest parts source, I could help in finding an accommodating home :)

Agree that any shallow head allan/torx/triple sq bolt would be the ticket for the flex plate: recall them being at least 10.9, if not 12.9 hardness.
03 Variant W8 silver on black TIP
00 Variant white 1.8T 5sp
96 993 C4S midnight blue/cashmere
90 535i blk/blk 5sp
928 5sp
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 25-Nov-2017 at 06:28
I'm sure the grille is still there. I hadn't even thought about it at the time!

Going to try for a marathon tomorrow. I think I have everything I need except time :)
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 26-Nov-2017 at 00:48
If you have pulled the fans, follow the harness back to retrieve the control module: it is sometimes implicated in the 'turbo fans' deal, wherein the fans decide to run @ max speed even after the ignition is turned off.

As a caveat, my experience with that phenomenon ( which many experience) is that replacement of one or both of the coolant temp sensors works, usually the most awkward one under the throttle control valve [my preferred fix is simply disconnecting the battery for a min or so - works every spring .... no logic, it just works]
03 Variant W8 silver on black TIP
00 Variant white 1.8T 5sp
96 993 C4S midnight blue/cashmere
90 535i blk/blk 5sp
928 5sp
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