Adventures of a 30V 2.8 TB change...
05-29-2004, 09:03 PM
#1
AudiWorld Expert
Thread Starter
Adventures of a 30V 2.8 TB change...
Yes it was a challenge, yes it was time consuming, yes it was trying, but yes it was fun in the end. The weather was awesome...75 degrees and sunny. Comfortable to get stuff done. Having experience doing my own 1.8T TB/WP made this seem less daunting. We also used a few other helpful write-ups Benfica09 found.
Everything went so smoothly in the beginning. Bumper came off, A/C moved out of the way, Radiator removed and lock carrier disconnected...just like the 1.8T.
One little problem...the damn allen bolt that wouldn't want to come out of the fan clutch housing. It was conveniently rounded. We didn't have the right tools to get it out. After spending 3 hours trying different methods we called it a night.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010026-vi.jpg">
The next morning we went to get some industrial strength drill bits to get it out. Rui begins the procedure.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010019-vi.jpg">
What took 3 hours and minimal results last night, took 15 minutes and maximum happiness. Victory will be ours! Rui removing the fan housing.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010029-vi.jpg">
See the bolt still sitting there. It threaded out easily by hand after that.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010032-vi.jpg">
The remaining shavings and head. See the screw lying there on the lock carrier.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010035-vi.jpg">
We celebrated for a bit and then ate lunch. We then began the real work. Cam sprocket holder thanks to RKA was used.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010038-vi.jpg">
Serpentine tensioner and TB tensioner in the pics. TB tensioner was pinned to relieve pressure after squeezing the pin back down.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010039-vi.jpg">
We took the TB off and a few pulleys. We then gained access to the WP. Applying downward pressure to the serpentine tensioner gave access to the cover holding in the thermostat.
<img src="http://images5.fotki.com/v69/photos/1/131573/985188/P1010045-vi.jpg">
New WP installed.
<img src="http://images5.fotki.com/v69/photos/1/131573/985188/P1010053-vi.jpg">
A bit of wrestling and finagling but the belt made it back on. We cranked the cams one revolution to make sure it was ok. Harmonic dampener pulley being resintalled.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010055-vi.jpg">
More wrestling to get the covers on but bolts are being tightened and everything almost buttoned up.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010058-vi.jpg">
Everything back in place. We then reattached the AC/Radiator/Bumper/connections with ease.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010065-vi.jpg">
We also changed the coolant temp sensor. He was given the (incorrect) green one. He eventually got the correct blue one. We re-used the stock clip since it was metal. Notice the new ones get the cheap plastic.
<img src="http://images5.fotki.com/v68/photos/1/131573/985188/P1010064-vi.jpg">
We then refilled the coolant and used a few tricks to prevent air pockets. We fired it up and she was alive! The plastic TB covers were rubbing for a few moments against the cams and pulleys until they reseated (or ground away heh) properly. The car definitely sounded smoother and quieter. I could hear the Supercharger whine now. ;-)
Cleaning up the pulleys also helped a lot. There was a ton of rust/dust on one of them. I'm sure he gained back 3 to 5 HP from the cleaning alone...heh. It took a while but we finally got the thermostat to open and get the whole system cooling properly. Test drive was good and the car's engine purred quietly. *phew*
Initial test reports were positive. Cooling was doing it's job and oil temps dropped too. I am tired but it was good. I recommend leaving a LOT of time to do a TB. It may go fast (less than 5 hours) or it may not but if you leave plenty of time and do not allow frustration to set in, it is very doable.
Everything went so smoothly in the beginning. Bumper came off, A/C moved out of the way, Radiator removed and lock carrier disconnected...just like the 1.8T.
One little problem...the damn allen bolt that wouldn't want to come out of the fan clutch housing. It was conveniently rounded. We didn't have the right tools to get it out. After spending 3 hours trying different methods we called it a night.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010026-vi.jpg">
The next morning we went to get some industrial strength drill bits to get it out. Rui begins the procedure.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010019-vi.jpg">
What took 3 hours and minimal results last night, took 15 minutes and maximum happiness. Victory will be ours! Rui removing the fan housing.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010029-vi.jpg">
See the bolt still sitting there. It threaded out easily by hand after that.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010032-vi.jpg">
The remaining shavings and head. See the screw lying there on the lock carrier.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010035-vi.jpg">
We celebrated for a bit and then ate lunch. We then began the real work. Cam sprocket holder thanks to RKA was used.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010038-vi.jpg">
Serpentine tensioner and TB tensioner in the pics. TB tensioner was pinned to relieve pressure after squeezing the pin back down.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010039-vi.jpg">
We took the TB off and a few pulleys. We then gained access to the WP. Applying downward pressure to the serpentine tensioner gave access to the cover holding in the thermostat.
<img src="http://images5.fotki.com/v69/photos/1/131573/985188/P1010045-vi.jpg">
New WP installed.
<img src="http://images5.fotki.com/v69/photos/1/131573/985188/P1010053-vi.jpg">
A bit of wrestling and finagling but the belt made it back on. We cranked the cams one revolution to make sure it was ok. Harmonic dampener pulley being resintalled.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010055-vi.jpg">
More wrestling to get the covers on but bolts are being tightened and everything almost buttoned up.
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010058-vi.jpg">
Everything back in place. We then reattached the AC/Radiator/Bumper/connections with ease.
<img src="http://images6.fotki.com/v79/photos/1/131573/985188/P1010065-vi.jpg">
We also changed the coolant temp sensor. He was given the (incorrect) green one. He eventually got the correct blue one. We re-used the stock clip since it was metal. Notice the new ones get the cheap plastic.
<img src="http://images5.fotki.com/v68/photos/1/131573/985188/P1010064-vi.jpg">
We then refilled the coolant and used a few tricks to prevent air pockets. We fired it up and she was alive! The plastic TB covers were rubbing for a few moments against the cams and pulleys until they reseated (or ground away heh) properly. The car definitely sounded smoother and quieter. I could hear the Supercharger whine now. ;-)
Cleaning up the pulleys also helped a lot. There was a ton of rust/dust on one of them. I'm sure he gained back 3 to 5 HP from the cleaning alone...heh. It took a while but we finally got the thermostat to open and get the whole system cooling properly. Test drive was good and the car's engine purred quietly. *phew*
Initial test reports were positive. Cooling was doing it's job and oil temps dropped too. I am tired but it was good. I recommend leaving a LOT of time to do a TB. It may go fast (less than 5 hours) or it may not but if you leave plenty of time and do not allow frustration to set in, it is very doable.
05-29-2004, 09:12 PM
#2
damn.
stratocaster1422 and I did stace's SC'd 2.8 30V a few months back, I think from start to finish it was like 7 hours? And that included a Wendy's run and a trip to autozone.
Sounds like this one was a bitch - how'd that bolt get rounded? Just by you guys trying to get it off?
Sounds like this one was a bitch - how'd that bolt get rounded? Just by you guys trying to get it off?
05-30-2004, 05:26 AM
#4
Member
Join Date: Oct 2001
Posts: 3,749
Likes: 0
Received 0 Likes
on
0 Posts
i can sleep easy now that the WP is done! thanks again for the help Digi
just a few struggles, but success is ours! =)
before doing this, my coolant temps were staying in the 114 range for the past week or 2. basically the first tick mark past normal on the gauge. So I was getting nervous, since it was the original waterpump @ 104K miles. (that's another story all together)
Once we started, the job really isn't that bad. Everything is straight forward, just take your time. Its much more intimidating when reading about it.
If it wasn't for that snag with that last hex bolt holding the fan clutch assembly, the entire job would have been very smooth. The problem we had was our hex socket wasn't long enough to reach inside the housing to properly seat. So we tried it with a set of hex keys, but we just couldn't get enough torque on it. And sure enough, it began to strip. We then tried cutting a hex key and putting it in a socket(basically made our own.) It was too late though, the bolt had lost its edges. We then tried hammering in a torx bit. This almost worked. =) Final solution was, if we can drill off the head of the bolt, it should relieve all the tension, and we can slide out the housing.....and it worked!! A 5/16 inch DeWalt metal bit made quick work of it! =)
Having someone else around is key. Having another set of hands,eyes, & thought process is always needed,(thanks Digi) and it doesn't hurt that he's done this before, so he knew some tricks.
Overall, it was a great way to spend a Friday night & Saturday, with a friend & wrenches! =)
And you really learn more about how this engine works.
I want to give another big thanks to Digit@lex. Couldn't have done it without your wrenching & support. Also, thanks RKA for lending me the cam bar. I can't imagine doing the V6 without it. It was very helpful.
The car is running great! Coolant temps are normal, even the oil temps have dropped. I'm very happy to have this done with and out of the way.
thanks again guys.
& thanks for the great write-ups
before doing this, my coolant temps were staying in the 114 range for the past week or 2. basically the first tick mark past normal on the gauge. So I was getting nervous, since it was the original waterpump @ 104K miles. (that's another story all together)
Once we started, the job really isn't that bad. Everything is straight forward, just take your time. Its much more intimidating when reading about it.
If it wasn't for that snag with that last hex bolt holding the fan clutch assembly, the entire job would have been very smooth. The problem we had was our hex socket wasn't long enough to reach inside the housing to properly seat. So we tried it with a set of hex keys, but we just couldn't get enough torque on it. And sure enough, it began to strip. We then tried cutting a hex key and putting it in a socket(basically made our own.) It was too late though, the bolt had lost its edges. We then tried hammering in a torx bit. This almost worked. =) Final solution was, if we can drill off the head of the bolt, it should relieve all the tension, and we can slide out the housing.....and it worked!! A 5/16 inch DeWalt metal bit made quick work of it! =)
Having someone else around is key. Having another set of hands,eyes, & thought process is always needed,(thanks Digi) and it doesn't hurt that he's done this before, so he knew some tricks.
Overall, it was a great way to spend a Friday night & Saturday, with a friend & wrenches! =)
And you really learn more about how this engine works.
I want to give another big thanks to Digit@lex. Couldn't have done it without your wrenching & support. Also, thanks RKA for lending me the cam bar. I can't imagine doing the V6 without it. It was very helpful.
The car is running great! Coolant temps are normal, even the oil temps have dropped. I'm very happy to have this done with and out of the way.
thanks again guys.
& thanks for the great write-ups
05-30-2004, 06:50 AM
#5
about the metal vs plastic clip...
<i>The resin clip replaced the metal one. The metal clip's square wireform could not be manufacturered to be completely flat. This caused the clip to press into the sensor/cooling housing eventually causing the housing to crack. With such a crack coolant will spew out...not good. This happenes especially at cold temps. Get the strong resin clip to be safe</i><ul><li><a href="http://forums.vwvortex.com/zerothread?id=941359">http://forums.vwvortex.com/zerothread?id=941359</a</li></ul>
05-30-2004, 07:22 AM
#6
AudiWorld Super User
Join Date: Feb 2003
Location: Orlando, FL
Posts: 6,451
Likes: 0
Received 0 Likes
on
0 Posts
The Frog, my bro and I could have had Frog's done in under 4..
But we had to work that day and we were kinda tired, so we worked one evening and came back the next day. I borrowed the 30V cam bar from work, but since it doesn't fit the 12V, we had to make one. It worked though, and the cams, TB and WP went in flawlessly. He rechecked it at work with the 12V bar and the timing was dead on.
Now at work I am doing cylinder heads on a Passat 30V cause the owner didn't read the label that states "Change toothed belt every 60,000" and yet its still under powertrain warranty. Kinda messed up if you ask me.
Now at work I am doing cylinder heads on a Passat 30V cause the owner didn't read the label that states "Change toothed belt every 60,000" and yet its still under powertrain warranty. Kinda messed up if you ask me.
05-30-2004, 08:41 AM
#7
AudiWorld Super User
Join Date: May 2001
Posts: 18,200
Likes: 0
Received 0 Likes
on
0 Posts
nice work....
it's getting to be that time for me. but seeing this pic scares the be-jeebies out of me... don't know if i'm brave enough...
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010019-vi.jpg">
<img src="http://images6.fotki.com/v78/photos/1/131573/985188/P1010019-vi.jpg">
Trending Topics
05-30-2004, 08:56 AM
#8
AudiWorld Expert
Thread Starter
Yeah, the job itself wasn't long. We took our time and wiped stuff down.
It was a nice day. The part that killed us was the rounded bolt. We spent 3 hours messing with it since we didn't have the proper bits to drill it out once it was rounded.
The proper thing would have been to use a long allen socket instead of an allen key and vice grips...that caused it to be rounded off. That bolt was clamped on tight though.
The proper thing would have been to use a long allen socket instead of an allen key and vice grips...that caused it to be rounded off. That bolt was clamped on tight though.
05-30-2004, 08:59 AM
#10
AudiWorld Expert
Thread Starter
hehe, don't be scared. It's really straightforward...
Once Rui and I got the bumper off and I showed him to separate the AC/Radiator/Lock carrier, it was all just bolting and unbolting pieces. To be honest, I've had a harder putting some excercise equipment together. It looks scary once you take a step back but while you're doing it, it's very logical.