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-   -   BHW Balance Shaft Module replacement (http://forums.tdiclub.com/showthread.php?t=233651)

Lug_Nut March 6th, 2009 12:46

Quote:

Originally Posted by oilhammer
We hear about the total BHW figures for cars sold in North America, but are these more common proportionally in Canada like other TDIs?

Reason is, while I have serviced quite a few of these, most have come from great distances. There are only 4, including my own, that I see regularly in the STL area proper.

I know I read somewhere once that VW sales of TDIs in the US were less than 6%, but in Canada it was more like 30%. But the US total vehicle sales is likely exponentially higher than Canada's. So, are there actually MORE total TDIs in Canada, or is it just a higher percentage but fewer total cars. And, where does the BHW equipped Passat fit into this?

18,102 BHW Passats in North America (and two 1999 AWD GLX TDI! :eek: )
5,051 in Canada or 53.9% of the 04, 05 Passats.
13,061 in USA, or 12.3% of the 04, 05 Passats.
http://mysite.verizon.net/vzerziy1/s...on_numbers.xls

johnboy00 March 6th, 2009 13:11

Quote:

Originally Posted by Lug_Nut
18,102 BHW Passats in North America (and two 1999 AWD GLX TDI! :eek: )
5,051 in Canada or 53.9% of the 04, 05 Passats.
13,061 in USA, or 12.3% of the 04, 05 Passats.
http://mysite.verizon.net/vzerziy1/s...on_numbers.xls

My car is one of only 42 in the Country in that configuration!

USA 2005 GL Variant TDI Tip FWD SILVER, REFLEX SILVER ANTHRACITE Leatherette 42

Who's got one of the rare ones where only 1 was produced in that configuration?

KALaBenne March 6th, 2009 13:38

Quote:

Originally Posted by sschnath
The service manager mentioned that the VW tech rep for this area happened to be in while the BS work was underway. Apparently he was "fascinated" by the work being done and made copies of some of the documentation I had supplied them with (Thanks again Oilhammer and MOGolf). And after all the letters to VW, he knew nothing about this prior to his visit. I hope he spreads the word within VW.

'Fascinated' because he had no clue that engine or those parts even existed. I hope Oilhammer and MoGolf are ready to sue them for copyright infringment when their instructions show up in the hands of VW service techs.;)

I guess mine is rare, because it doesn't show up on the list:eek: . Actually it's probably because either I have the paint color wrong or they do.

When I looked up the paint code that was in the trunk, I got the color called 'urban grey metallic' but on vortex it says 'silverstone grey'

Anyone know wich name is correct? the code is LD7W

over here it says LD7W is urban grey also.

If it's silverstone grey then I have one of 52 in the US with 13 more like mine in Canuckistan:D

aja8888 March 6th, 2009 15:10

Nice ride!
 
I took the Passat on a 250 mile run down the highway (I - 10) today to Louisiana. This was actually the first real steady highway speed run since the major balance shaft job was done. It was early morning and I had the A/C on low and the radio off and was crusing between 65 - 80, depending on where the State Troopers were. The engine is so much more quiet at highway speeds than before and sounds crisp on a quick acceleration up to 80 from say 60.

I have to say I am pleased and feel justified that the job was done when I did it. RI_TDI can vouch how loud my engine was next to his a couple of months ago when we met one Saturday morning. Steve Glover said he heard me coming a 1/2 a block away from his shop.

If you have one of these BHW's, I urge you to get this upgrade done when you can afford it. It's like a different car (and won't crater on you).

One happy camper for hopefully 100,000 more miles....:D

oilhammer March 6th, 2009 17:38

Just finished another one today. Once again, night and day difference. Amazing how QUIET the engine is from outside the car afterwards. Sitting at a warm idle, it is nearly as quiet as the CBEA common rail engine, just the faint sound of the uber-high pressure PD injectors.

sschnath March 7th, 2009 06:08

Quote:

Originally Posted by oilhammer
...Sitting at a warm idle, it is nearly as quiet as the CBEA common rail engine, just the faint sound of the uber-high pressure PD injectors.

I can't say that mine is that quiet now. With my mileage I don't think I should expect it to sound like new. Certainly much, much quieter than before. But I'm hearing more than the injectors. I'm also still hearing a slight rattle that I need to investigate further.

It's subtle so I'm not going to put any money into chasing it down. Even though I've got a rebuilt timing area, new BS, new belts, there's still a lot of things that haven't been replaced so I suppose I'll have to wait until it gets louder or stops functioning to track it down. At least I know it's not the balance shaft!

DickSilver March 7th, 2009 06:25

[quote=sschnath]I can't say that mine is that quiet now. With my mileage I don't think I should expect it to sound like new. Certainly much, much quieter than before. But I'm hearing more than the injectors. I'm also still hearing a slight rattle that I need to investigate further.

---------------------------

I don't remember who did your BS module, so my questions are not directed in criticism. Two things that anyone installing the new geared BS module needs to be very sure of:

Were all the bolts properly torqued?

In particular, was the idler gear held tightly against the two other gears and properly torqued?

Getting back in even to check these things means near-total dismantling of the job.

volkswagendude March 7th, 2009 07:55

Quote:

Originally Posted by oilhammer
Just finished another one today. Once again, night and day difference. Amazing how QUIET the engine is from outside the car afterwards. Sitting at a warm idle, it is nearly as quiet as the CBEA common rail engine, just the faint sound of the uber-high pressure PD injectors.

If one was to compare a brand new BHW engine (o mileage) with chain, VS the exact same brand new engine with the gear assembly replacement...I'm assuming that the geared one would still be quieter right?

2004PassatTDI March 7th, 2009 08:23

Glad the BS is over.
 
Got mine done last week at Fast Enough Performance in Lexington Kentucky. Thanks Dick Silver for recommending the shop and the lift from the airport. It was a pleasure meeting you! With 60,000 miles on the clock, foot on the brake at a stoplight, the steering wheel vibrated a bit more than I recall when it had 45,000 miles. Air gauge and CD cases have not been buzzing in the door pockets either.

All the belts, water pump, brake/transmission fluids changed too. I have to say that visually there was no excessive wear (at least what I consider to be excessive) on the sprokets. I’m glad the upgrade was done.

I also had the resonator and muffler replaced with a same diameter straight pipe. Muffler and resonator weight is 15 and 25 pounds respectively. Edit: http://www.youtube.com/watch?v=m4XgJFi6kdQ . Droning...a little at about 60MPH. Just have to drive fast enough to outrun the sound!

Now to replace the glow plugs.

oilhammer March 7th, 2009 08:27

Quote:

Originally Posted by volkswagendude
If one was to compare a brand new BHW engine (o mileage) with chain, VS the exact same brand new engine with the gear assembly replacement...I'm assuming that the geared one would still be quieter right?

Absolutely. My car had 1.7 miles on it when we got, brand new, and it is without a doubt smoother and quieter now at 84k miles than it was then. I cannot even hear my wife pull in the garage anymore. The sound of the electric door opener, a good one, drowns out any TDI sounds. :)

myULSD March 7th, 2009 17:27

So you got it done. Lucky bastage. I'm trying to figure out if my Power steering pump or alternator pulley is bad.

How does that new exhaust sound? Any droning on the highway?



Quote:

Originally Posted by 2004PassatTDI
Got mine done last week at Fast Enough Performance in Lexington Kentucky. Thanks Dick Silver for recommending the shop and the lift from the airport. It was a pleasure meeting you! With 60,000 miles on the clock, foot on the brake at a stoplight, the steering wheel vibrated a bit more than I recall when it had 45,000 miles. Air gauge and CD cases have not been buzzing in the door pockets either.

All the belts, water pump, brake/transmission fluids changed too. I have to say that visually there was no excessive wear (at least what I consider to be excessive) on the sprokets. Iím glad the upgrade was done.

I also had the resonator and muffler replaced with a same diameter straight pipe. Muffler and resonator weight is 15 and 25 pounds respectively.

Now to replace the glow plugs.


Lug_Nut March 8th, 2009 15:50

Quote:

Originally Posted by volkswagendude
If one was to compare a brand new BHW engine (o mileage) with chain, VS the exact same brand new engine with the gear assembly replacement...I'm assuming that the geared one would still be quieter right?

It is a different sound.
I'm no longer as certain as I was immediately post replacement that the gear whine that I now hear is louder than the chain was. Remember: Mine at the TDIfest was commented on as being much quieter than most. I only had evidence of a loud chain system the last 2 miles before the swap.
The difference between the geared drive and a quiet chain was fresher in my memory a month ago and back then my opinion was the chain, before the tensioner broke, was quieter than the gears.
I still hear the soft whine of something that wasn't there before the swap, so I presume it to be the gears. I may be aware of it because it might be 'louder' than my quiet chain had been, or it might be because it is just plain different. For whatever reason I am aware that it is not the same as it was before.

DickSilver March 8th, 2009 16:32

Since the gears are helical: that is, the teeth are ground on a spiral, or helix, pattern, there is very little meshing noise from the teeth.

Lug_Nut March 9th, 2009 05:07

"Very little meshing noise" yes, but there is something different from the very little chain noise I had prior to tensioner breakage. Which was the lesser noise? Which was the greater? That is no longer certain in my mind. They are that close.
Suffice it to say that the gears will be very unlikely to become louder than the very little noise they produce now, but the chain system, even without tensioner fracture, would only become louder and louder.

aja8888 March 9th, 2009 07:26

Quote:

Originally Posted by Lug_Nut
......... but the chain system, even without tensioner fracture, would only become louder and louder.

......Until things go completely *silent* and you have to call a tow truck to get the mess off the road......:eek:


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