Stormy the B4V

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
While performing my typically fruitless B4 Passat search on a Saturday morning in May, I stumbled upon a fresh ad for a storm grey B4V. It was imported in 2009 and spent its previous days in California and then Washington. The seller had converted it to GLX leather and done some routine maintenance. It was last tagged in 2016 but the seller had run the car every few months to ensure nothing atrophied etc. The front doors were entirely non-op so you had to crawl through a back door to get into it. Rear brakes seized, all brakes rusty etc. HVAC is non-op so I’m hoping once that gets fixed I will have working AC.

https://flic.kr/p/2q58GAx
https://flic.kr/p/2q5dnaT
https://flic.kr/p/2q58HHH
https://flic.kr/p/2pRUc5B
The car was located near the coast so I sent my dad to check it out. After a quick glance at the dog legs and floor pans, I knew that the purchase was a no brainer. While he was checking it out, they were able to toss a battery on and drive it onto the trailer despite the mostly seized rear brakes.

There’s some typical California sun fade on the paint but it’s definitely better than dealing with a rot box!

My parents came up to visit and were able to squeeze Stormy and the BHW donor onto one trailer for the 600 mile trip east.

https://flic.kr/p/2q58Kva
While my dad was up, he helped remove both rear doors so we could drill the door latches from the B pillar side to manually trip them. This is what came out on both sides.

https://flic.kr/p/2q5eDfZ

The goon barn is filling up!

https://flic.kr/p/2q5fbrC

For now, I’m consolidating all my best parts from the 3 cars and the spares pile onto this one and trying to fix the bugs so that it’s a good runner. I’ll be swapping this stock exhaust for the 2.5” SS one from the purple car but I’ll be adding a muffler this time! This car received the freshest turn signals, GLX fogs, and the euro fog light switch. I have a pair of mk4 alloy rear calipers to replace the seized ones as well. With my spare 1Z I got for the purple car, it came with a smattering of spares which included an MFA cluster so that will go in this car as well since I was finally able to get my hands on the MFA signal stalks. The green goon came with a GLX leather wheel and E code headlights so those will get swapped and find a home on Stormy as well. I’ll be keeping my eyes out for leather mk4 seats to replace the GLX ones since I don’t like how high these sit compared to my retrofitted mk4 seats in the purple car. The heated seat controls will be pilfered from the purple car as well before its sale.

https://flic.kr/p/2q5eDLU

Last week, I picked up a plus front subframe so that’s hanging out in the job jar for when the rest of the necessary work is done. Unfortunately, the brakes had been pilfered from the part out already but I have a set of Audi 2 piston G60 calipers from back in the day when I had my Audi 90Q. I also grabbed a pair of the Corrado G60 brackets for the G54/280mm option.

I’m chuckling as I write this since this sounds more and more like many “dream b4v” build ideas. At least this chassis is worthy of putting some nice parts on vs my purple B4v!

I still dream about a power build but for now I have my hands full. Once this and the green goon are together and operational then I can clean up, unload the purple car, and shift gears back to the Allroad project. :)

Stay tuned!
 

starrd

Veteran Member
Joined
Nov 24, 2003
Location
Canada
TDI
1996 Passat
Nice looking Passat and in great shape. Jordan, if you want/need the MFA cluster mileage corrected or want the tach working for a 4 cylinder with the proper TDI diesel tach faceplate, I can do that for you. No signal converter required.
 
Last edited:

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
Thanks for the offer Don. It’s all set up for TDI already though so I should be good. I’ve tested the cluster (without all the widgets) in the green car and it does the basic functions including glow plug light. I was able to get an oil temp sender and I have the ambient air temp sender but haven’t connected them all up yet.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
BHW swap you say…
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
MD
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
Just to help you with your upgrade to 11" brakes, you can use the calipers or just the brackets from any 11" G60 or VR6 car. Brackets and the calipers are the same between the VR6 and G60.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
I wear looking homeless in my mk3 as a badge of honor…
I do as well but my other half appreciates the badge a lot less than I do!

@G60ING I read a bunch of threads and I have both options. B4 VR6 brackets for G54s or the Audi 200 Girling G60 2 pot brakes. Based on the weight of the G60s and the small master from the non-ABS B4, I think I will go for just the brackets on the existing G54s. Either way, I’ll have 280mm brakes 🙂
 

d24tdi

Veteran Member
Joined
Jan 6, 2019
Location
MT
TDI
BHW x3, BEW x2, ALH x2, AHU, 1Z, AFB, AKN, BCZ, BDH
This is gonna be a nice one! :cool:

Can't beat starting with clean/straight/dry sheetmetal. Just about anything else is worth dealing with if you've got that on your side......

Michelin rubber is always a sign of a car owned by someone who was trying to take care and not skimping on the good stuff!

Quite the haul with two cars plus the heavy trailer. That load would have gotten some attention from the DOT commercial vehicle enforcers down here on this side of the border. Must be a little more relaxed on the freer side up there. :) Great loading dock setup too, zero incline for getting those cars on there is nice.
 

turbodieseldyke

Top Post Dawg
Joined
Jun 6, 2010
Location
Free Mustache Rides
TDI
Big ol' honkin' tdis
That load would have gotten some attention from the DOT commercial vehicle enforcers down here on this side of the border. Must be a little more relaxed on the freer side up there.
I've seen 2 cars being towed by a single car/pickup in Texas i think. A towing B with a tow bar or dolly, with B dead-pulling C with the same setup. More than once, on the interstate, making me think it was legal.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
I’ve been making small bits of progress amid the busyness of life. Recently, I poured concrete and am in the final stages of getting a 2 post hoist going which will significantly improve any of these car related projects! :)

Stormy now has a fully functional MFA!
While I was under the dash, I found a disconnected ground which ended up fixing the HVAC fan so that was a nice easy fix.

https://flic.kr/p/2q9nLqD
I was able to swap out all the yellowed front end lights with fresh ones from the auto wreckers and installed a euro fog light switch thanks to a switch swap from the green goon. I still need to swap the headlights out for the euro ones but that’s a later project.

https://flic.kr/p/2q5eDLU
I received my Leatherique conditioner so I’ll be reconditioning the leather seats as soon as the weather warms up here again.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
Hasn’t seen the road yet… she does have a new tbelt as of tonight though so it’s getting closer.

I need to finish going through the rear brakes, swap SS exhaust from the purple car over, and ditch the chaxles in favour of the OEM ones from the purple car as well. The purple car already donated a clutched alternator to the cause.

Through the last 2 hot weeks of august, I did a 2 stage Leatherique on the interior and it’s cleaned up a bunch for sure but there are still a couple tough spots. With any luck, I’ll be able to get it on the road next week.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
I’ve stalled out a little on progress. I found a bad front wheel bearing so I need to get the front hubs machined to be dual pattern for 4x100/4x108 so I can run the nice wheels without spacers. I have rear rotors that have been dual drilled as well and one has made it onto the car to replace a bad wheel rear wheel bearing.

I was able to orbital sander the front rotors (they’re only worn 0.1mm) and one of the rear rotors to clean up the rust. I replaced one of the rear e brake cables and calipers (with a mk4 one) to remedy the stuck caliper issue. All the brake slides are lubed up and the ebrake works smoothly.

The SS exhaust is on and what a sweet and quick job that is with v band flanges! 😍
I ended up cutting the factory exhaust near the rear axle so I could remove it without dropping the rear beam.

Lovely condition underneath for something with 500,000k on it.

https://flic.kr/p/2qh6kDo
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
I got a day plate for the old girl today after getting new wheel bearings on all around with the 4x100/108 hubs. No more front wheel poke and fender interference! 🙂

It drives pretty well and seems to pull decently hard. I’ll put some more miles on it and some fresh fuel later today after tweaking the timing. I was pretty close after doing the belt but it’s not bang on!

https://flic.kr/p/2qjtxgx https://flic.kr/p/2qjnLEN https://flic.kr/p/2qjnLFE
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
After a couple shakedown runs, it was clear I was losing coolant through the overflow tank seam. I swapped out the tank from the Goblin for the meantime and ordered a new one. All excited to go test it out, I fired up the car again and realized there was now a newer, darker puddle under the car. The oil cooler gasket let go too so that's on order and I'm waiting on parts again... :(

I pulled the Euro lights from the Goblin and installed on here since it needs DOT lights for inspection and this one needs some serious headlight help.

In the meantime, I have to align the car since it's a little off after doing the front wheel bearings.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
Been away for work and vacation but managed to get the oil filter gasket and overflow tank replaced and all is well.
Great read here about removing the threaded shaft to avoid fighting with coolant and hoses.

The Euro lights are fantastic… sure glad I have those.

Farmer alignment went well and the wheel is straight so I can’t complain.

I’m assuming it’s due for an intake cleaning but I figured I would do an intake cleaning coupled with weight reduction and flow improvement so I got a BHW/PD136 intake. Pulled the actuators for spares for my BHW and will build piping to suit a drop in replacement on the 1Z.

Next up is an oil change, fuel filter change and then hopefully pack on a few miles while the Goblin gets some floor lovin’.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
Scratch the next plans…. Looks like the next item up is the head gasket!
It kept blowing coolant from the overflow tank. If I drove granny-like and downshifted for hills, I could preserve coolant somewhat but its time is up. Judging from the coolant bottle evidence, this isn’t a new issue but probably got exacerbated by sitting for ~8 years with green coolant. I retorqued the head bolts (all to 90 ftlbs and only a couple moved) and then added 45*.
I have a spare OEM 2 hole gasket from my spare 1z care package so it’ll get put to good use. I’ve wanted an excuse to do a head bolt upgrade at some point so now is my chance…. I have some slender high strain 4140 HTSR collars designed to allow PD150 or 160mm 12.9 SHCS to be used. Pics to come once there’s something concrete!
I have the car in the shop now so I just need to muster some motivation to get it all apart again.

https://flic.kr/p/2qtXpsv
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
Until I did my homework, I assumed it was just degradation products from the green coolant but alas…
 

Lug_Nut

TDIClub Enthusiast, Pre-Forum Veteran Member
Joined
Jun 20, 1998
Location
Sterling, MA. USA
TDI
2015 GSW 6M in S trim the other oil burners: 1967 two stroke Sonett 1988 Bolens DGT1700
The 1996 used G11 as factory fill, and that was green as I recall.
Maybe incorrectly recalled.
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
My other B4V has the Smurf coolant. I thought I saw another post about coolant colours… :p
Once this mess is settled, I’m planning to use the modern coolant after a flush.

Lug nut, you need to see an eye doctor. G11 is BLUE!!!:eek:

 

Steve Addy

Top Post Dawg
Joined
Aug 7, 2002
Location
Iowa
TDI
97 Mk3
The 1996 used G11 as factory fill, and that was green as I recall.
Maybe incorrectly recalled.
The G11 was classified as 'green-blue' but my memory says it was actually closer to blue. Closer to what BMW was using back in the early 90's etc. I used to have some around but with nothing that used it I'm sure I tossed it in the Chevy diesel at some point....that's the destination for all non-pink or non-purple coolant remnants.

Steve
 

JordanTr

Veteran Member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V x2, 2006 Dmax, 2005 Allroad, 2005 BHW
For a while I’ve been looking at Matt’s 02S thread and thinking how wonderful a 6 speed would be… especially one with a Wavetrac in it. Ever since doing my homework on diffs many years ago, I’ve wanted a Wavetrac. Flash forward 15 years ago to this weekend and I was able to find a mk7 1.8TSI 0A4 5 speed (RTW) with a wavetrac already installed. It was from a Malone tuning test car and allegedly has “chatter” noises but the clutch also had issues so we will see if there are any issues within the trans. I was able to dump the oil before purchase and it didn’t look too sinister so I am optimistic. It goes smoothly into and out of all gears. I’m going to flush, filter, and bench test the trans before I bust into it on an exploratory mission. Worst case, I harvest the wavetrac for an actual 6 speed! I couldn’t walk on by for only $400!
The 0A4 has 3.39 final drive compared to the 02A CTN 3.16. The gear ratios are different too so the overall ratios are still TDI friendly. 1st/second are lower than the TDI trans (~7%), 3rd is the same, and 4th/5th are taller by ~6%.
I’ll need to tee up with @caffeine for the 02S goodies kit to be able to install it.
The trans in the car is a little rough getting into and out of 4th and 5th gear so this will be a nice fix for that as well as fixing up the shift feel. I sure miss the 02J shift setup that went with the purple B4V!

Hopefully get through the head gasket job and then I can collect some parts and make some time to get this in. It is definitely slippery road szn up in Canada now.
 
Top