Print Page | Close Window

New W8 Owner

Printed From: The W8 forum
Category: Registration
Forum Name: Introduction
Forum Discription: New members, please introduce yourself here.
URL: http://www.w8forum.dk/forum_posts.asp?TID=5553
Printed Date: 13-Dec-2018 at 16:11
Software Version: Web Wiz Forums 9.56a - http://www.webwizforums.com


Topic: New W8 Owner
Posted By: Uberhare
Subject: New W8 Owner
Date Posted: 16-Nov-2017 at 04:39
Hello!

New W8 owner here - located close to London, Ontario. I just purchased a pair of W8s - 2004 Wagon & 2003 Sedan (for parts). I jumped in with both feet, bought a wagon that needed a transmission (auto) then found a parts car.   Wagon is fairly clean with new headlights.

My plan is to rebuild the converter while it`s apart, then install into the wagon.   Parts car as a low cylinder (75PSI), but otherwise a clean car. Too bad it`s only a sedan. If I didn`t have my own hoist, I don`t think I`d even consider this mess!

https://flic.kr/p/CQ9QFd"> https://flic.kr/p/CQ9QFd - 22791734_10159515331250072_4551240897248455943_o by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

https://flic.kr/p/21cCnXs"> https://flic.kr/p/21cCnXs - 20171106_173123 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

Progress so to date:

https://flic.kr/p/21wKMMo"> https://flic.kr/p/21wKMMo - 20171114_215359 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr



Replies:
Posted By: JayTheSnork
Date Posted: 16-Nov-2017 at 05:08
welcome to the madness!


Posted By: Michel
Date Posted: 19-Nov-2017 at 20:59
Nice garage my friend!
I'll love to have a car lift like yours, perhaps my ceiling is too low..

-------------
W8-2003-270kKm, Moonrock Grey, Tiptronic, still Running well...   


Posted By: SeaHunt
Date Posted: 19-Nov-2017 at 22:48
very cool :)


Posted By: eddycooper
Date Posted: 20-Nov-2017 at 20:20
Cool!

Nice to see someone else with the ambition to look after one of these cars properly. If you think about selling pieces from your parts car, post them up here. The W8-specific parts are hard to find!


Posted By: Uberhare
Date Posted: 21-Nov-2017 at 00:42
Had a bit of an issue removing the tq converter bolts.   They required at 12pt 16mm thin wall socket. So I made one....

https://flic.kr/p/GN3tmx"> https://flic.kr/p/GN3tmx - 20171117_202715 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

https://flic.kr/p/21DE3gY"> https://flic.kr/p/21DE3gY - image-20171117_202938 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

https://flic.kr/p/ZDmu3u"> https://flic.kr/p/ZDmu3u - 20171119_000708 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

I can't believe how many bolts were missing in the front end of the Wagon when I took it apart. Front bumper was only held on with 4 screws (2 each side) to the fender liner! Sadly it was a VW dealer who last had it apart for new headlights. Engine/trans is half way out of the 2nd car now. Hope to be driving it next week.   I did find a converter rebuild shop within 15 minutes of my house.   He even had one from a TDI on the bench to show me inside.

It is certainly nice to have a warm(ish) shop outback where you can work at your own pace. I'm running out of space though, it looks like a W8 explosion of parts right now.   Decided to check compression on the "good" motor while it was warm and freshly backed inside. 150 across the board, nice and even. (spec is 145-189) It was supposed to have had chains, waterpump, and tstat done within 15K. I'm wondering if it was a used engine installed. Doesn't seem as clean as the rest of the car, and I can see damage on some of the belt pulleys likely from a crash.   




-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: JayTheSnork
Date Posted: 21-Nov-2017 at 02:52
how many miles are on the "good" motor?


Posted By: Uberhare
Date Posted: 21-Nov-2017 at 03:48
220k KMS.

Almost ready to pull!

https://flic.kr/p/21G4dWJ"> https://flic.kr/p/21G4dWJ - 20171120_213431 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: JayTheSnork
Date Posted: 21-Nov-2017 at 03:53
with 145-150k miles on it, I'd be checking the chains and guides since you're pulling it.



Posted By: Uberhare
Date Posted: 21-Nov-2017 at 03:57
They were apparently done 15K ago. Along with waterpump, thermostat and balance shaft belt.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: JayTheSnork
Date 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.


Posted By: GS535i
Date 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.

-------------
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


Posted By: Uberhare
Date 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,04 Phaeton W12, 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


Posted By: Uberhare
Date 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,04 Phaeton W12, 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


Posted By: eddycooper
Date 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...



Posted By: GS535i
Date 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 ;) ))

-------------
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


Posted By: Uberhare
Date 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,04 Phaeton W12, 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


Posted By: GS535i
Date 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


Posted By: Uberhare
Date 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,04 Phaeton W12, 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


Posted By: GS535i
Date 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


Posted By: Uberhare
Date Posted: 26-Nov-2017 at 00:59
My parts car has that "feature".   I actually bought a replacement temp sensor, but grabbed the wrong one of the shelf.   I expected it to be the green one, not grey. Maybe next time :)

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: JayTheSnork
Date Posted: 26-Nov-2017 at 03:56
fans running all the time can also be caused by the front CTS being bad; been there and resolved it.


Posted By: Uberhare
Date Posted: 26-Nov-2017 at 05:26
It's back on all it's mounts!

https://flic.kr/p/DKgYAE"> https://flic.kr/p/DKgYAE - 20171125_213023 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

This little guys were a PITA:

https://flic.kr/p/DKgYbw"> https://flic.kr/p/DKgYbw - 20171125_115502 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

Fixed the downpipe while it was apart:

https://flic.kr/p/ZMHR5Q"> https://flic.kr/p/ZMHR5Q - 20171125_161615 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr

Guess I'll be doing some A/C work too:

https://flic.kr/p/21QgXLE"> https://flic.kr/p/21QgXLE - 20171125_213532 by https://www.flickr.com/photos/uberhare/ - uberhare , on Flickr



-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 28-Nov-2017 at 23:34
It's ALIVE AND WELL!   

A few more gremlins along the way:

https://flic.kr/p/21TGwJG"> https://flic.kr/p/21TGwJG - 20171126_152623 by https://www.flickr.com/photos/uberhare/ - uberhare

This next one was the real kicker....I damaged the speed sensor wires during the divorce of engine/transmission and had to repair the connector at the bottom. I assumed it was a bad splice and spent considerable amount of time redoing that repair first. Like laparoscopic surgery with it in the car! Found the corrosion at the ECU when I was going to pin it out. Cleaned up everything and she came to life!

https://flic.kr/p/21VMvXq"> https://flic.kr/p/21VMvXq - ECU_wires by https://www.flickr.com/photos/uberhare/ - uberhare

What's in my driveway right now:
https://flic.kr/p/21TGwnQ"> https://flic.kr/p/21TGwnQ - PassatCollection by https://www.flickr.com/photos/uberhare/ - uberhare

https://flic.kr/p/21VMvkd"> https://flic.kr/p/21VMvkd - Passat_Outside by https://www.flickr.com/photos/uberhare/ - uberhare

9 litres of trans fluid
8.5 litres of oil
16 litres of coolant
1 litre of p/s fluid (and another one later to flush out the wrong fluid that was in there)

What an adventure, I would NOT want to do it again. I could have probably converted it to a TDI in less time.   It drives really nice now, but I am underwhelmed with the performance. I expected more to be honest, it's not much faster than my 6spd manual TDI @ 25PSI.   It would be nice to drive another one to see if it's where it should be.   Looking for a 6speed manual now for it. I've decided I don't like the automatic after all the work.


-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: eddycooper
Date Posted: 30-Nov-2017 at 18:38
A manual swap isn't as straightforward as it should be for these cars:
- Final drive ratio is different. So you'd either need to change the front diff in your new 6-speed (not easy) or take the rear diff from your parts car too.
- If you get a 6-speed from another W8 it'll have an oil pump and lines that got a cooler in the radiator. Might easier to get one from another car without the oil pump.
- Exhaust piping is different. Might just be a difference of support locations, but for some reason there are different part numbers.


Posted By: Uberhare
Date Posted: 30-Nov-2017 at 23:11
Lots of items that are different....I'd pretty much need a parts car:

Driveshafts (x3)
flywheel/clutch
shifter assembly
cooler lines
pedal/hydraulics etc

I've done this on a TDI Passat in a day (albeit a very long day), but it was pretty straight forward on that car. I'll just live with the auto for now unless a parts car pops up for the right price. I could probably do the swap using B5 S4 parts too.


-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 02-Dec-2017 at 01:26
So my story does not end here....After driving the car long enough to warm up the fluid this happened:

1 Fault Found:
17125 - Torque Converter Clutch
            P0741 - 35-00 - Stuck OFF / No Power being transferred

Lovely. After reading about the captive clutch on this unit, no wonder it is so problematic. Some info can be found here on the Sonnex website: https://www.sonnax.com/tech_resources/57-revisiting-the-captive-clutch

0.040" of movement in the spring plate with 0.030" of material (friction surfaces). After 0.010" of wear the lockup no longer works. I am quite surprised no one has come up with a replacement/better spring plate for this unit. I talked with a local European transmission specialist and he tells me very few re-builders can get this one right every time. I bet that plate gets worn and fatigued causing much of the rebuild problems. It doesn't seem to be available either.

If I had not driven the parts car I would have blamed the valvebody and been tearing into it right now.   So, out to the shop for round 2.......



-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 22-Dec-2017 at 03:43
After taking a few weeks off from this I'm back at it.   7.5 hours so far and it's just about ready drop back into the car. Another hour of tinkering and it should be back in the bay.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: GS535i
Date Posted: 23-Dec-2017 at 23:45
That's fast - assume that there must be an interesting story on the 2nd TC rebuild ;) .... what was done differently to avoid a 3rd teardown?

BTW, Best of the Season!!

-------------
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


Posted By: Uberhare
Date Posted: 23-Dec-2017 at 23:58
First rebuild was purchased so I wouldn't have to do this a 2nd time! Figured out afterwards I was given a TDI converter (& it slipped), so I got my original one back but rebuild. Fingers crossed! I'm hoping to finish it tomorrow just in time for Christmas.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 28-Dec-2017 at 04:45
All good 2nd time around. It's a beast in the snow!   Under 20 hours the 2nd time around....

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 28-Jan-2018 at 23:16
Made it 2500K now. Cam position fault bank 2 just came on. Guess I'll be trying the "shock therapy". If not at least I have a parts engine.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: JayTheSnork
Date Posted: 30-Jan-2018 at 04:48
which cam adjuster is the impossible one to get unless you pull the engine?


Posted By: GS535i
Date Posted: 05-Feb-2018 at 00:15
The 'shock therapy' is a good deal, and frequently works ----- until you find one of the 4 solenoids that is obviously stuck - no 'click'.

At that point, it is not much more work to pull the valve cover and remove the offending solenoid for a cleaning & flush of the bore.

Did this once w. success, described here http://www.w8forum.dk/forum_posts.asp?TID=5457&KW=&title=camshaft-adjuster--p0021-fix-success - http://www.w8forum.dk/forum_posts.asp?TID=5457&KW=&title=camshaft-adjuster--p0021-fix-success

-------------
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


Posted By: Uberhare
Date Posted: 05-Feb-2018 at 03:40
So far the problem has not come back. It cleared itself the next time I started it, so I reset the codes. I imagine it will come back eventually.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 24-Apr-2018 at 01:42
Jinxed it. Last week I was thinking how wonderful this car has been!   My son took it to work Saturday and prompty brought it back with a plume of smoke in trail.    It looked like something catastrophic let go inside! Turns out one of the injectors stuck wide open. Good thing I have a parts engine laying around. They were seriously stuck in the head.   Almost didn't think it was going to come out in 1 piece!   Running like a champ again.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: orangeokie
Date Posted: 25-Apr-2018 at 01:51
Great story. Cam Adjusters still OK?


Posted By: Uberhare
Date Posted: 25-Apr-2018 at 03:49
Originally posted by orangeokie

Great story. Cam Adjusters still OK?


Not going to answer that question in fear they might be listening.


-------------
04 Passat W8 Wagon,04 Phaeton W12, 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


Posted By: Uberhare
Date Posted: 02-Oct-2018 at 01:35
Winter is just around the corner, time to get this one out again! It was hardly driven over the summer. Phaeton W12 kept me busy.

-------------
04 Passat W8 Wagon,04 Phaeton W12, 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



Print Page | Close Window

Bulletin Board Software by Web Wiz Forums® version 9.56a - http://www.webwizforums.com
Copyright ©2001-2009 Web Wiz - http://www.webwizguide.com