First major service on a VW

[DWV]

I just got my bug about 6 weeks ago, I got it with 79k miles on it and have been told by everyone that I needed to do the t-belts and then some.

I just ordered this kit yesterday, and I will be doing the install next Thursday - whenever I finish. LOL

http://www.mjmautohaus.com/catalog/p...oducts_id=2412

Any last words of wisdom before I begin this journey???

[Lnzbug]

Pat yourself on the back for doing this before it breaks. What kind of book are you using as reference? I hope you have some sort of manual to help you. When John did my rebuild he also had me take pictures before he took something off so he could make sure the right wire or hose went to the right place when he put it back together. Good luck and take your time.

[PostO]

Get a Bentley Service Manual for reference. Good to see that kit has a water pump with metal impeller unlike the plastic POS that VW puts in at the factory.

[DWV]

I don't have a manual, and probably won't get one. I've never worked on a German car before however I have done plenty of work to American and Jap cars. I feel confident I can jump in there and get this knocked out.

If I must, I can jump on my bike and run down to the Autozone 2 blocks away and pick up a haynes.

[Lnzbug]

Originally Posted by DWV

I don't have a manual, and probably won't get one. I've never worked on a German car before however I have done plenty of work to American and Jap cars. I feel confident I can jump in there and get this knocked out.

If I must, I can jump on my bike and run down to the Autozone 2 blocks away and pick up a haynes.

You could also go to the library just to have it on hand. My hubby has also done belts before and he was happy he had the manual. Why wouldn't you want to be prepared? These cars are little buggars for repairs.

[LadybugEwa]

Originally Posted by DWV

I don't have a manual, and probably won't get one. I've never worked on a German car before however I have done plenty of work to American and Jap cars. I feel confident I can jump in there and get this knocked out.

If I must, I can jump on my bike and run down to the Autozone 2 blocks away and pick up a haynes.

See, the thing is just because you know American and Japanese cars doesn't mean you'll be able to 'figure out' the VW without first breaking something on it. Dubs are just different, and I've had mechanics stumped with its weirdness a couple of times. A Bentley manual is a great investment.

[05yellowbeetle]

I found a great list of instructions on either here or vw vortex for changing out the water pump & timing belt. My '98 blew up the water pump (impeller cracked and quit spinning) at 60K in May, but I sold it and bought an '05 with 10K miles, so I don't have to worry about that for a long time.

[DWV]

Ya, i've read the vwvortex DIY several times, as well as some Audi sites. I got my parts in the mail, so tomorrow I still start on this project.

Thanks for all the help/posts and I'll provide pics of the operation!

[Yurko]

Originally Posted by DWV

Ya, i've read the vwvortex DIY several times, as well as some Audi sites. I got my parts in the mail, so tomorrow I still start on this project.

Thanks for all the help/posts and I'll provide pics of the operation!

well, the manual is nice because it has all the torque specs, and while the DIYs on Vortex are very helpful, they don't give any beetle-specific info. I would highly recommend getting the manual, or at least download the .pdf from that russian website.

Some tips you might find helpful:

Go ahead and pull the intercooler, as it will give you more room to work. I went ahead and cleaned mine out.

getting the belt off isn't so bad. just make sure your engine is well supported when pull the mount, and you won't be able to get it completely out like you can on some other 1.8T VWs, so just work around it.

Compressing the tensioner with the screw is probably the biggest PITA on the removal side. I would recommend getting a ratcheting wrench like the craftsman cross-force to make it easier.

a 10mm deep socket was invaluable, as was the wobbly extension I had for it.

Many of the DIYs out there say that you should bolt the tensioner down before you put the belt on. I couldn't get the belt on with it already bolted down.

I wasted 2 or three hours trying to shimmy the belt on with the tensioner tightened, and what ended up working for me (disgustingly easy I might add)was to have the tensioner mounted, get the belt on save for the top, disconnect the tensioner (it will stay in the little area it bolts to), slide the belt on, and then bolt down the tensioner.

When you pull the factory water pump, try not to break it off inside, as I did and I think a piece of it made its way to my heater core and caused a leak.*

Also, when you pull the water pump, have a drain pan handy, as more coolant is going to come out.





*The heater core is one thing you do not want to mess with if you don't have to, and you will need a bentley for that, but it still doesn't tell you everything you need to know.

[AzDivr]

Originally Posted by Lnzbug

You could also go to the library just to have it on hand. My hubby has also done belts before and he was happy he had the manual. Why wouldn't you want to be prepared? These cars are little buggars for repairs.

A little insurance to make sure you have the info if you need it and it doesn't cost a thing. Just don't grease it up.

[beetlejuice]

And, by the way, I don't believe Haynes publishes a manual for the New Beetle. I've been looking.
b

[05yellowbeetle]

actually, Haynes made the first manual for the beetle. I had a '98 - '00 for my '98.

[DWV]

I ended up getting a Haynes book after all. I figure if I don't use it now, I probably will need it someday.

Well i got everything out except the timing belt pulley. I didn't have an allen wrench big enough to remove the bolt in it. I'll just wait till tomorrow to pick one up. So far everything is going well, not a hard job at all, just time consuming.

One thing I'm surprised about, the waterpump is in flawless condition! And i could tell that someone has at least pulled the pancake tube out before, cause the hose clamps were a little off. I'm wondering if some one has replaced the pump already and not done the t-belt cause it was obviously original.

The belt actually ripped while trying to remove it.

[DWV]

Originally Posted by Yurko

Many of the DIYs out there say that you should bolt the tensioner down before you put the belt on. I couldn't get the belt on with it already bolted down.

I wasted 2 or three hours trying to shimmy the belt on with the tensioner tightened, and what ended up working for me

That was the best advise I've read so far! That belt was just not going to go back on any other way. Although I have to pull it all back off again cause my crank pulley is off by about one tooth... At least with this loose tensioner method I know its easy to re-do.

Thanks Yurko

[Yurko]

Originally Posted by DWV

That was the best advise I've read so far! That belt was just not going to go back on any other way. Although I have to pull it all back off again cause my crank pulley is off by about one tooth... At least with this loose tensioner method I know its easy to re-do.

Thanks Yurko

glad I could be of service!