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Discussion starter · #61 ·
Repair of a leak in the boost circuit.

Intake manifold removed without too many problems. You have to be methodical.

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Then, the part that interstest us

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The references below are the correct ones, by which I mean very up to date, because on my 2001 model, I have a few variants, where it is written "ECO" on them. Audi would have made some savings at the time with lower quality components ...?

The end of 06A-103-213-F broke during dismantling. The plastic was probably too old.

I ordered everything, except 06A-133-789 which looks ok, and also because it is not cheap ...

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Discussion starter · #63 ·
At random during an inspection, I noticed that I had an almost bent cooling hose, at the engine outlet.

Probably a bad reassembly after an operation ...

Side view

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Front view

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I found the image below. We can see that this hose (the small one below the arrow) passes on the other side of the water outlet box.

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After draining the coolant, I was able to reposition it.

That's done.

By the way, I should be able to do a big clean ...

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Discussion starter · #64 ·
We then go to the engine support on the battery side.

I found the engine to move a lot, especially at idle.

Luckily, I was able to get my hands on a new part at a very good price.

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Tightening torques (in N.m):

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It is advisable to replace the screws when changing. Not having ordered them beforehand, I reused them with a little red loctite threadlocker.

We make room, then a little clean.

Obviously, during the replacement, the motor is supported from below!

The operation is not very complicated in itself. You have to remove the air box to gain access.

Attached is a link to an illustrative video.


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And hop !

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Well it was not luxury!

After the left support and the anti-torque rod, it remains to do the one on the timing side, during a next operation.
 
Discussion starter · #65 ·
And finally, the rack silent-block 1J0 422 884 A

Considering the small difference in price, I took powerflex here, generally more robust and easier to mount.

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To access it, you must remove the right wheel.

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We see it, held by a sort of horseshoe, held by 2 screws under the subframe.

You also need 2 screws at the top because this horseshoe holds a protective carter and a hose.

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To remove it, it's a bit of a hassle. I had to trick and poke holes in it. It made it easier for me to take it out. Here is once everything removed.

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Then, reverse operation to reassemble.
It's easier with powerflex and PTFE grease ...

And here.
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Tightening torques:

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Discussion starter · #66 ·
The rack bush was the first part of the overhaul of the power steering system

On the menu, change of oil and gaskets on the olive which is connected to the pump (where the numbers 14, 15 and 16 are on the first board) ref N 0138487 as well as the gasket of the fault switch. pressure (N ° 31 on plate 2) ref N0138115.

This is the only place on the circuit where it is a little greasy.

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Discussion starter · #67 ·
While waiting for my parts order, cleaning the intake manifold. Briochin (product for cleaning the ovens) and nylon brush + toothbrush, then WD40 to finish.

Before
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After
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Then, in the turn of the injectors

After some research, I got to know a very nice person, who offers cleaning (or descaling in the worst cases) in an ultrasonic bath + control of the quantities injected.

Some photos during the operation

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Result: no seized injector, and injected flow rates very close to each other, whatever the operating point.

Final result

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Milky_Way said:
We continue with the V71 recycling component which brings up the following message:

Address 08: Auto HVAC Labels: 8N0-820-043.LBL
Controller: 8N0 820 043 A
Component: TT-KLIMAVOLLAUTOMAT D03
Coding: 00040
Shop #: WSC 01236
VCID: 28237BA3DBEB
1 Fault Found:
01274 - Air Flow Flap Positioning Motor (V71)
41-10 - Blocked or No Voltage - Intermittent


So, we disassemble by following info found on these links and this youtube video

https://forums.audipassion.com/topi...opic/157486-tuto-defaut-01274-climatronic-capteur-g113-et-volet-v71-defectueux/
http://evren-yurtesen.blogspot.com/2017/07/golf-mk4-variant-v68-temperature-flap.html


The extracted part. OEM Ref: 1J1 907 511A

View attachment 1

Without much surprise, broken gear.

Hi what symptoms did you get with the V71 fault, the reason I ask is my ac packed up and i keep getting this code now. I just wonder if you did not get any AC when this was faulty.

cheers
 
Discussion starter · #69 ·
ryanmtt said:
Milky_Way said:
We continue with the V71 recycling component which brings up the following message:

Address 08: Auto HVAC Labels: 8N0-820-043.LBL
Controller: 8N0 820 043 A
Component: TT-KLIMAVOLLAUTOMAT D03
Coding: 00040
Shop #: WSC 01236
VCID: 28237BA3DBEB
1 Fault Found:
01274 - Air Flow Flap Positioning Motor (V71)
41-10 - Blocked or No Voltage - Intermittent


So, we disassemble by following info found on these links and this youtube video

https://forums.audipassion.com/topi...opic/157486-tuto-defaut-01274-climatronic-capteur-g113-et-volet-v71-defectueux/
http://evren-yurtesen.blogspot.com/2017/07/golf-mk4-variant-v68-temperature-flap.html


The extracted part. OEM Ref: 1J1 907 511A

View attachment 1

Without much surprise, broken gear.

Hi what symptoms did you get with the V71 fault, the reason I ask is my ac packed up and i keep getting this code now. I just wonder if you did not get any AC when this was faulty.

cheers
Hi
I was foggy in the car in rainy or cold weather
The air conditioning went on well when I pressed the button
 
Discussion starter · #70 ·
I reduce my list of missing / to be replaced parts

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By the way, protection of the haldex harness with duct tape, as originally

Before
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After
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Cleaning / inflation / treatment (dressing) of the spare wheel

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Final result. Fine !

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Discussion starter · #71 ·
Receipt of my order

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We start with the most tiring ...

The self-adhesive pads of the trunk stops. Ref 8N0827771

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On the left side, she was no longer even present

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Final result, after cleaning, installation and refitting of the plastic cover

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Then we take care of the sticker with the tire pressure instructions. The ref is directly on the sticker.

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Yes, we are in the detail, but the goal is not only to be consistent with models with 18 inches.

It is also to have the values of pressure, without looking everywhere!

Before. The old one has held up well for 20 years!

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Cleaning operation including the cap and the chute, with an APC (I use All Clean + from Chemical Guys) and a brush, after removing the sticker with a razor blade + acetone.

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It's clean, it's beautiful

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A shutter at the front right ref 803803583A

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Discussion starter · #72 ·
Replacement of the breather hose, softened by time, no doubt. It is suspected of crashing during severe depressions.

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Then we move on to the power steering circuit.

Replacement of the seals and cleaning around the pressure sensor, on the AD pump

References a few posts above

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It was greasy and dirty. Even if it means replacing DA oil, we might as well raise any doubt about the sealing.

Draining an AD circuit is a first for me.

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Ready to receive new oil

Hoping to get a more smooth steering than before

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To tighten the sensor seal ring to 15 N.m, I first took my "marks" by putting the dynamo wrench in the vice, just to know how to dose.

The circuit is now nickel, with the replacement of the silent block of PowerFlex rack, some seals and the oil change.
 
Milky_Way said:
ryanmtt said:
Milky_Way said:
We continue with the V71 recycling component which brings up the following message:

Address 08: Auto HVAC Labels: 8N0-820-043.LBL
Controller: 8N0 820 043 A
Component: TT-KLIMAVOLLAUTOMAT D03
Coding: 00040
Shop #: WSC 01236
VCID: 28237BA3DBEB
1 Fault Found:
01274 - Air Flow Flap Positioning Motor (V71)
41-10 - Blocked or No Voltage - Intermittent


So, we disassemble by following info found on these links and this youtube video

https://forums.audipassion.com/topi...opic/157486-tuto-defaut-01274-climatronic-capteur-g113-et-volet-v71-defectueux/
http://evren-yurtesen.blogspot.com/2017/07/golf-mk4-variant-v68-temperature-flap.html


The extracted part. OEM Ref: 1J1 907 511A

View attachment 1

Without much surprise, broken gear.

Hi what symptoms did you get with the V71 fault, the reason I ask is my ac packed up and i keep getting this code now. I just wonder if you did not get any AC when this was faulty.

cheers
Hi
I was foggy in the car in rainy or cold weather
The air conditioning went on well when I pressed the button
pretty much what i am getting cheers, loving the build so far btw :D
 
Discussion starter · #74 ·
Once the power steering has been drained and the bubbles removed, we move on to the main thing:

The cleaning / reassembly of the intake facade, covered with a thick layer of sludge, caused by the faulty hose of the network under the manifold.

Here, we can already see more clearly. Brush, brush, Briochin, WD40 and brake cleaner and ... courage.

To avoid trouble, I plugged the various openings.

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On dismantling, a few balls of sludge fell into the intake ducts.

So I preferred to think about a solution to find them. It works as well as at the dentist!

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Hose network rebuilt, joint plane cleaned, gasket installation. it takes shape.

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The collector is ready. He received new inserts to hold the engine cover (ref: N 908 47501)

And new hoses to join the fuel pressure regulator, and the N249.

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Before reassembling everything, I changed a few old sheaths

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Once everything was in place, I repeated a leak test. The circuit can withstand more than 1 bar without problem. On the other hand, the pressure drops slowly, the air escaping through the gauge. I imagine that the circuit cannot be tight enough to hold pressure for several minutes?

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One all in place

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And it starts straight away!

I don't know if these are the injectors ultrasonically cleaned and the boost circuit redone, but the sound of the exhaust is more hoarse than before

You just have to drain the cooling circuit, following the repositioning of a bent hose (probably an old intervention)
 
Discussion starter · #75 ·
Before installing the air box, I remembered that I needed to adjust the gearbox linkage.

A quick check our in my book, everything is played at the level of the selector above the gearbox, and the lever, which must be immobilized with a 5 mm diameter drill

Verdict: it's really night and day! Guidance is much more precise.

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As long as we do, cleaning and treating the lever gaiter, which is in rather good condition for 20 years!

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No need to access the gearbox side, we can put the freshly spoiled air box back.

I was looking for an efficient and dry filter (without oil)

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Discussion starter · #76 ·
Before his first turns of the wheel after more than a month of hiatus, one last touch: the covers behind the steering wheel

The opportunity also to change 2 broken quick fixes and add a missing screw on the large cover below.

Before
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After
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Discussion starter · #78 ·
Small release report after all that. It's better but not as blatant as I imagined.

It pushes a little more, we hear more the exhaust (I can't wait to change for something more rewarding, but I have to control my budget), the airbox (certainly the effect of the pipercross filter) and the dump valve, but I still find it very linear. There is no "butt kick" effect

The turbo thrust manifests itself a little before 3000 rpm, which I left a little late in view of the official curve below, even if I am well aware that we are on a 20-year-old turbo ...

So I always wonder if she pulls out all her power.

With VCDS, now, only one fault code, always the same, which I have to take care of.

1 Fault code found:
17748 - Capt. position AAC (G40) / crankshaft (G28) Incorrect assignment
P1340 - 35-00 -
Tests passed: 0110 0001

By searching in the invoices, I have trace of a change of the chain of camshafts and of the tensioner associated with 116 000 km, 2 000 km after the change of the distribution kit + tensioner + water pump + accessories belt + all hydraulic inlet / exhaust valve lifters.

The last change in distribution was made at 156,000 km. Maybe a bad timing?
 
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