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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old May 17th, 2017, 14:51   #16
peiphil
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That tool holds the bsm in the correct position during the install but you wont need it for the delete option !
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Old May 28th, 2017, 14:39   #17
philshizle
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Got the pedals installed today and the clutch pedal switch f36 (blue one) does not come in contact with the clutch pedal. It is maybe a 1/4" out. I couldn't find any way to adjust ithe in the service manual. Any idea what could be causing this?
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Old June 22nd, 2017, 11:59   #18
burnercan
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I'm also getting ready to attack the BSM delete and am sort of looking forward to taking an air hammer to that stupid thing. After reading lots here about the various methods of removing the crank sprocket, I'm a bit unclear about the air hammer procedure.

Does the sprocket need to be broken/cut/dremeled or otherwise suitably abused prior to laying the hammer to it? Or can I skip all of those steps and just go straight to the hammer?

Last edited by burnercan; June 27th, 2017 at 08:18.
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Old July 5th, 2017, 15:54   #19
papasmurf
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I used an air hammer to move mine off of the crank. I should have removed the bearing cap because doing it my way, I put some dings in the crank. luckily it was not where the seal rode.
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Old July 6th, 2017, 05:34   #20
mgoff5000
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Look, I'm not gonna get in the way of anyone and air tools but the modified puller worked great for me and I don't think it put the crank at any risk at all.
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Old February 18th, 2019, 06:17   #21
AllenAlic
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I did these two task at different times on the ground. I would definitely say pull the motor and trans. Removing the front core gives so much room to slide the unit out and you have a nice chance to repair the coolant flange and anything else’s that might be amiss. Here is a link to when I did the BSM delete. I cut the sprocket and it just slid off.
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Old February 18th, 2019, 08:02   #22
PickleRick
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×2 on cutting the sprocket with a fine cutting wheel on a side grinder. I don't have a need for these tight spaced. 2 or 3 jaw pullers in my shop, i would have had to borrow one and i cant grind down borrowed tools.
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Old February 19th, 2019, 20:21   #23
vwztips
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Remove the #1 crank bearing cap and put air hammer to rim of toothed pulley. 5 secs and its off. The delete kit i get from Bora includes the cap replacement bolts
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Old February 26th, 2019, 16:04   #24
y22man
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I Did this job in the month of November and December. I pulled the motor and transmission out as one unit. I then remove the automatic transmission. And installed the clutch and transmission. It was way easy and I was able to pull the motor and trans in the bout the same time as it would take just the trans out the bottom. It was a lot easier with the motor out of the car. Did this job in the month of November and December. I pulled the motor and transmission out as one unit. I then remove the automatic transmission. And installed the clutch and transmission. It was way easy and I was able to pull the motor and trans in the bout the same time as it would take just the trans out the bottom. It was a lot easier with the motor out of the car.

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