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  #101 (permalink)  
Old 12-18-2015, 05:41 AM
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California; will always have some of the highest prices in the USA, thank CARB for that!😫


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  #102 (permalink)  
Old 12-20-2015, 06:28 PM
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Default Cha2ga's Fusca Tdi

190k mile service.
Oil (Rotella T6 5W40) and Mann filter.
Inspection on suspension, axles, hoses, etc. All looks great.
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  #103 (permalink)  
Old 02-06-2016, 02:59 AM
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Alternator wasn't charging at proper voltage. I was getting 12.8-13.1 volts output. Not an easy job to r&r. Remove serpentine belt. Had to disconnect AC clamps so the hose was loose in the engine bay. Leave the AC lines connected to the compressor. Unbolt and support the compressor. Remove large radiator fan. Place cardboard into the fan opening to protect the radiator. Remove serpentine belt tensioner. Remove alternator. Everything is done from below.
$143 to rebuild alternator locally.
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  #104 (permalink)  
Old 02-06-2016, 03:01 AM
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  #105 (permalink)  
Old 02-06-2016, 03:03 AM
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They put the wrong pulley on. Should be a six groove pulley with spacer. I think this is the Passat pulley that they put on.

The correct pulley is this one.
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  #106 (permalink)  
Old 02-06-2016, 03:04 AM
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New pulley installed and the alternator now back on the car and about 500 miles on it. Works great.
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Old 02-06-2016, 02:22 PM
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Glad they fixed that issue, mang. Glad to hear the bug running good, 500 miles strong.
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  #108 (permalink)  
Old 07-18-2016, 11:53 PM
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Last tank. Still getting 700. Getting close to 200k.
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  #109 (permalink)  
Old 07-18-2016, 11:54 PM
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Put my first sticker on. Brian Walters is the man at making stickers!
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  #110 (permalink)  
Old 07-18-2016, 11:58 PM
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Default Cha2ga's Fusca Tdi

Having a new alternator clutch pulley; makes a big difference, I went through a bunch of belts and screeching noises, before I figured out my clutch pulley had seized! Much smoother and quiet belts, compared to a seized one!

What kind of volts; is the alternator putting out, after the rebuild?

Also, why a rebuild over buying new? Was it strictly more cost effective or availability in your area? All of the of the auto electric shops; that used to rebuild electrical parts in my area, have closed! I have been researching a rebuild kit for my 120 amp Valeo alternator; good DIY videos on YouTube, it looks like it could be a fun DIY project!


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Last edited by billymade; 08-27-2016 at 01:56 AM..
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  #111 (permalink)  
Old 07-19-2016, 12:16 AM
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Billy it did make a huge difference. About 20k miles before this, I replace the timing belt. At that time I replaced the idler pulley and the tensioner on the serpentine drive belt as well as the timing roller components.

14.1 volts at idle with as much system load as I could make (lights, rear defroster, etc).

I have always had alternators rebuilt. I have a 2000 Chevy Blazer with over 100k on a rebuilt alternator and 220k total miles. So I saw no reason to drop $475 for a Bosch rebuild. In fact I would prefer the Valeo new one (idparts) for about $200, last time I checked. All the tdi's are 120Amp as well.
I looked at the kits and agree on the diy worthiness. I actually rebuilt the large radiator fan at one time.
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  #112 (permalink)  
Old 07-19-2016, 12:53 AM
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I looked at diy's and tried to fix my small fan but it had back/forth play and I destroyed it trying to take it apart. These newer cheaply made parts; are not always rebuild/repair friendly! In the older parts of the past; everything had fasteners and could be assembled/disassembled easily, not so
Much anymore. I bought a new made in China VDO fan and replaced it; no problems so far.


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  #113 (permalink)  
Old 08-27-2016, 01:21 AM
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I reached the 200,000 mile mark this week. I can say that it has been a fun car. It took some effort to get maintenance caught up and correct the neglect from the prior owner. I can truly say that I will drive this car anywhere. If you have followed this thread you know the amount of effort, time, and money I have spent on this car. I
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  #114 (permalink)  
Old 08-27-2016, 01:29 AM
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Service 200,360 miles.
Oil Mobil1 0W/40
Oil filter Wix 57210
Air filter Mann c37154
Cabin filter Mann CUK2962
Fuel Filter Mahle KL147D
Wiper Bosch icon 21A drivers
Wiper Bosch Icon 19B passenger
PowerService silver to prime fuel filter
Rotate tires
Inspect drivetrain
Inspect exhaust

Note the oil filter in the first pic is not for this car (it's for my daughters Passat 3.6).
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  #115 (permalink)  
Old 08-27-2016, 01:48 AM
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Default Cha2ga's Fusca Tdi

I installed gauges. All the parts are listed below but even better is the wiring diagram a few pictures down with all the parts listed on it.
Gauges are VDO Vision Black
VDO 310-151 EGT
VDO 150-104 BOOST
VDO 350-104 OIL PRESSURE
VDO 360-001 sender 80psi oil pressure

Blue LEDs are from 42 Draft Designs


Last edited by cha2ga; 09-30-2016 at 01:53 AM..
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  #116 (permalink)  
Old 08-27-2016, 01:48 AM
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  #117 (permalink)  
Old 08-27-2016, 01:49 AM
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  #118 (permalink)  
Old 08-27-2016, 01:49 AM
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Old 08-27-2016, 01:49 AM
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  #120 (permalink)  
Old 08-27-2016, 01:51 AM
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