I've been lurking around this forum here and there ever since taking possession of my Dad's old 2000 Passat GLX 4Mo when he upgraded to an A6 back in 2012. Needless to say, I love the fact that this resource exists for these cars. It makes working and tinkering on them soooooo much easier. It also nice to know that there are a few people out there that are as nutty about this stuff as I am.
Anyway, the car has been a spare car for me ever since my Dad upgraded. It spent some time as my daily driver shuttling me back and forth to and from work. Eventually, the dreaded cam seal oil leaks got the best of me, and it pulled it into the garage to change them and the whole PCV system out. That was... TWO years ago. :| House projects and well... life.. seemed to get in the way at every turn. Things have settled down a bit now, and over the last few weeks I have been able to put some time into bringing the car back to life.
Those few weeks have been an adventure trying to figure out and understand a few of the stumbling blocks I had run into that made it easy to work on other items on my 'to do' list rather than the Passat. In that time, i've kinda been all over the VW/Audi forum universe looking for advice and feedback, and have been inspired by a lot of the build threads I have seen out there. With that in mind, I wanted to scratch out a little piece of the internet for myself to document the work that I have, and will be putting into this car... so here we are! Yah, i know... a stock Passat maintenance thread, you might be thinking... Why bother?? This is definitely not going to be anywhere near as entertaining as a Stage III S4 build or anything like that, but just a spot to record what I have done, and to hopefully get some feedback from you kind folks if you see me taking steps in the wrong direction. I see the work that I put into this car as a way to take the limited mechanical skill set I have now and build upon it. I've always had a thing for the B5 S4, and am thinking one of those might be in my future someday. So, I figured a B5 V6 4Mo Passat would be as good of a 'practice' car as any!
So first... a little bit of background on the car.
My dad bought the car new in the summer of 2000. It had been a demo car, and had about 500 miles on it when we took possession in August. I wish I had more pictures of it back in the day... but, here's the original window sticker:
Anyone have any idea why they thought they had to call out the '1000r rack and pinon steering'? Sure sounds fancy!
Here is the earliest pic I could find... from a Pacific Coast Road trip in 2004 after I graduated from university. Yep... its blurry. Apparently we didn't take a whole lot of photos of it!
Its got 134k on the clock as it sits today. I dunno what it is about it, but I've always had a real strong sentimental connection with this car. It's not like it was the first car I learned to drive on or anything like that. I had long moved away to college by the time my dad bought it. Its certainly not exotic or even overly fancy. I've always just thought it to be quite competent transportation with nice clean lines. Additionally the interior bits were/are top notch as well. In my opinion, this was as good as VW ever got at building solid interiors. All the Passats I have been in since feel cheap in comparison, which in a way is a bit sad and disappointing.
Since taking posession, i was able to do a few things. I found some aeroblade wiper arms in the classifieds and installed those... Also found some OEM HIDs and popped those on... horrible pic to follow:
The internals of one of the HIDs was busted by the time it got to me from the seller. I did a makeshift repair at the time, but the adjustment is no longer working, so I need to get back in there an tinker with it some more.
I came out one morning and the rear drivers side window had a golfball size hole in it , so the door came apart for a replacement to go in:
Then, I bought a house that had a real garage, and I was finally sick enough of the Cam Seal issue to think about doing something about it. Into the garage the passat went, and disassembly commenced:
But not before finding this little guy:
And that was two years ago.
Fast forward to today, as mentioned previously, I'm taking a different tactic with the repair work. This is going to become a 'learning car' where I can repair and fix at my own pace (obviously... )
I'm still working on the passenger side head, and after running into a few stumbling blocks getting the Cam Chain Tensioner compressed (the compression tool fitting threads stripped out, see here ) , I was able to get it and the intake cam out of the car.
Next steps will be cleaning up of the passenger side head before I slap the seals and gaskets back in. (A new CCT is on its way to me from GAP). Anyone have any thoughts on anything additional I should check while I have the intake cam out? Anything I should look for on those valve lifters? Anything to look for as far as abnormal wear on the camshaft itself? Where can i find specs to check the cam lobe diameters? I didn't see anything in the bentley that discussed this, but maybe I just missed it.
Additionally, does anyone have the part number for the bolts for the camshaft bearing caps? I managed to 'tweak' a few of them when taking out the intake cam, and they won't be going back in the engine. I've heard conflicting things about these depending on which post I have read... either 1) they aren't available... or 2) they aren't individually available unless you are buying a new head. I find that ridiculous. Dinking around on Audizine, I was able to find this part number: WHT002015, in the B6/B7 S4/RS4 forum. Its a long shot given that the engine in that application is totally different (4.2L V8), but it's all I've got thus far, and maybe they have similar cam caps... I don't know... I've thought about just ordering one to see if its the same.
Its been neat taking apart the intake cam and cam caps, seeing the level of detail/fit and finish it takes to construct these parts, all the small oil passages drilled into the caps etc. If you can't tell, this is the first time I've done any major engine work.
OK... so as previously mentioned, a new CCT is coming from GAP, and I have ordered the 'deluxe' timing belt kit as well. I figured that I would just get that one out of the way for another 90k while I'm in here tearing up all this stuff on the front end, and since I'll be taking the cam pulleys off anyway to replace the seals etc etc. Vacuum lines are all getting replaced while I'm in here too. The old ones are quite beat up, with their exteriors fraying etc. I haven't vac tested them so they might be functionally fine, but with 15 years and 134k on them, I figured it would be a good idea. I'll be checking the functionality of all the solenoids as well. I'll hopefully remember to keep this up with my progress as I try to get this thing back on the street.
Once all that is done, there is still plenty to do... A short list:
- Heater Core
- Engine Mounts
- Suspension Components (haven't even begun to think about this one)
Yikes.... I just have to keep remembering this is an adventure
More to come!