VanGogh Broken VW Engine Block Fix Kit for MK5 BRM TDI

Abby

Active member
Joined
Jun 17, 2012
Location
NJ
TDI
2006 Jetta TDI
Has any used Diesel Geeks VanGogh Broken VW Engine Block Fix Kit for MK5 BRM TDI?

i understand that you need to unbolt the EGR cooler from the block and the 2 hard lines to the EGR. Do you need to diconnect the 2 rubber coolant lines, or is there enough flex room to install the repair kit?

Thanks
 

Abby

Active member
Joined
Jun 17, 2012
Location
NJ
TDI
2006 Jetta TDI
It's nice to have friends

I have a friend with a shop with a lift. One of his mechanics guided us through and helped with the installation of the Diesel Geeks VanGogh Broken VW Engine Block Fix Kit.


Here are some of the things we needed to do to install it:
  1. support engine from above
  2. remove Alt, A/C Compressor and radiator fan assembly
  3. unbolt/remove bracket, part # 038 903 143 AF , OURS WAS BROKEN where the engine monut bracket is attached, from the block. This carries the Alt, A/C comp and also provides anchor point to to support the engine
  4. put car on lift
  5. remove bracket between the Cat and the block
  6. undo the 2 hard line connections for the EGR gases, save the gaskets
  7. remove the 4 bolts that attach the EGR cooler to the block
  8. we left the 2 coolant hoses connected, were able to move the cooler just enough, it was tight, but we still had just enough wiggle room to get the new bracket in place. The bolt that went into the unused/existing bolt hole was the most challenging part.
  9. Reconnect the 2 EGR Hard lines
  10. attach the 4 small bolts that hold the cooler to the block
  11. re-mount the bracket between the Cat and block
  12. replace 038 903 143 AF, our was broken
  13. re-install A/C Comp, Alt and Fan assembly
  14. reinstall anything else you may have undone to get access
  15. double check your work
  16. have driving your car again
Steps 5 through 11 took us about 5 hours over 2 nights
 
Last edited:

A5INKY

Vendor , w/Business number
Joined
Sep 4, 2007
Location
Louisville, KY
TDI
2006 Jetta TDI, 2002 Eurovan Westphalia VR6
Why on earth remove the accessories and their bracket? The engine mount bracket will come out entirely for a TB change without touching those things. Can't imagine why they would be in the way.
 

Abby

Active member
Joined
Jun 17, 2012
Location
NJ
TDI
2006 Jetta TDI
Edit

See revised # 3
3. unbolt/remove bracket, part # 038 903 143 AF, from the block. OURS WAS BROKEN where the engine monut bracket is attached as a result of the failure of the threaded hole in block that broke away. bracket, part # 038 903 143 AF carries the Alt, A/C comp and also provides anchor point to to support the engine
 
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