The "What did you do to your B4 today" thread...

TDIDaveNH

Left Lane Coal Roller at Large
Joined
Feb 17, 2009
Location
North Conway, NH
TDI
1997 Passat TDI x2 1984 Buick Century 4.3 diesel
Wrapped up more fun sessions of B4 repairs:
Upgraded to an 02J shifter, replaced the exhaust system with new from turbo to rear axle, updated the turbo oil drain line since the original was getting pretty crusty, New CV shaft on the passenger side to compliment the driver's side one put in a few months before, new flange seal as well since it was leaking a bit and the inner boot was torn since getting it on the road about 30K miles ago. Let's see...engine oil change, transaxle oil change with Redline MTL, replaced the cigarette lighter with a dual USB port and replaced the AC/Recirc button backlight while it was apart. Also swapped out the untouched original 327K mile injectors with DLC520's from DBW new Bosch glow plugs and a couple custom stainless braided brake hoses from HEL performance going from the body to rear axle since nobody makes them anymore, at least ones that fit properly.


Yes, that is the original tan carpet under the black.




It was easier to add a 3rd bolt and a sleeve as a spacer for securement that trying to fabricate something to tie into the 2 threaded holes topside.


This is not up as high as it can go....it sits about 3/8" below the floor with a foam gasket I made when I did my first 02J shifter conversion years ago since to go up all the way, puts too much of a bend on the cables right as they exit the box.


I was impressed with these hoses, cost about $118 shipped for the pair and had them in a week. I ordered some SS hoses from ECS and after paying twice for them I still didn't have them after 6 months. When they did show up, they were for a Mk4. Whatever.


You can build these exactly to your specs on the helperformance.com website. They fit good this time. Length is only available in whole centimeters, for these lines I could have used 1/2cm less but it worked out in the end.


My first time around I ordered them a couple centimeters too long, even though they fit, the bend was terrible, as terrible as the next two pictures.


This was the worst hole, the slide hammer I had for years could only remove the #1 injector, the rest no way. I vacuum out the holes before moving on to slide hammer the others.


Lots of scrapping with sharp pics like a dental hygienist to get the scale off then finish with a plethora of dremel rotary wire brushes and brake kleen, aero kroil, vacuum and compressed air, napkins, Q-tips and whatever else it took. I use a 1/4" dia rubber stopper in each hole that I sink below flush that can be retrieved with a set of long needle nose pliers to prevent anything from getting into the cylinders.


This is what it took to get the remaining 3 injectors out, if the weight were any less it may not have happened. I had to stop after the 1st injector and put it all back together and drive to storage to retrieve the big set seen here.

Ready to pull the plugs and bolt down some money.


Done. The glows despite no anti-sieze came out good, only one had to have it's threads chased with a modded old glow plug.
 
Last edited:

Benjamis

Veteran Member
Joined
Jan 17, 2021
Location
Due east of Cincinnati, Ohio
TDI
1996 B4V 1Z 321k
Had the rain leaking in the rearmost side windows of my wagon, I pulled the upper trim off the top of the windows on the inside and all the nuts were loose. I tightened em up and after several downpours, no leakage. The whole 'air' inside the vehicle is rather... dry. Quite nice. Now to figure out the intermittent leakage coming down the pillar on the driver side below the dash, I fixed it once before but a few years later it's back at it..
 

TDIDaveNH

Left Lane Coal Roller at Large
Joined
Feb 17, 2009
Location
North Conway, NH
TDI
1997 Passat TDI x2 1984 Buick Century 4.3 diesel
Installed a modern radio with a 90's aesthetic this evening. Used a Blaupunkt Madrid 200 series...it's probably 1/8 the weight of the original. It's nice to be able to make and receive calls without the use of earbuds and I now have 3 USB charge ports. There is a version that will accept CD's but not this one, nice and simple with an aux port and bluetooth.


 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
Installed a modern radio with a 90's aesthetic this evening. Used a Blaupunkt Madrid 200 series...it's probably 1/8 the weight of the original. It's nice to be able to make and receive calls without the use of earbuds and I now have 3 USB charge ports. There is a version that will accept CD's but not this one, nice and simple with an aux port and bluetooth.
I like this idea. But I want to find one that looks period correct and has the correct color display to match the cluster. You can change the color on some head units, but not on the Blaupunkts that I've seen.
 

Abacus

That helpful B4 guy
Joined
Nov 10, 2007
Location
Relocated from Maine to Dewey, AZ
TDI
Only the B4V left
How is the sound? Almost every aftermarket radio I’ve found has really crappy and tinny sound, no matter what I try. I need a new one for the wagon, which I’ll be driving more after moving my daily driver back to Maine until late fall.
 

TDIDaveNH

Left Lane Coal Roller at Large
Joined
Feb 17, 2009
Location
North Conway, NH
TDI
1997 Passat TDI x2 1984 Buick Century 4.3 diesel
I didn't really do my homework on selecting this....saw it on a social media reel and decided to buy one since it had an aux port and USB and looked like it belonged in a B4 dash. I didn't know it had bluetooth and can pair with a cel phone at the time. Green display color would be great but it's not a deal breaker for me. I know some of the higher end Blaupunkts have illumination color that you can change and really dial it in exactly since you're adjusting various primary color amounts. This particular model the color is not adjustable as far as I know.

The sound is fine for me, I-red lacks rear speakers and has only the 4 up front. I listen to audiobooks and podcasts mostly so I barely notice the lack of kick. The headunit has a cheesy little equalizer which can switch between 4 different sound modulations: pop, rock, classic, flat or off. I keep it off since it sounds the best to my ear. My mechanical standards are high, but my electronic standards are low so I'm easy to please.
 

Mcgink

Veteran Member
Joined
Oct 15, 2004
Location
South of Boston MA
TDI
I-Red,"The Passat formerly known as Harlequin" 97 B4, a non VW GTDI too
IIRC, I-red had functioning speakers in all 4 doors and the 2 on the dash. Likely original though.
 

Mcgink

Veteran Member
Joined
Oct 15, 2004
Location
South of Boston MA
TDI
I-Red,"The Passat formerly known as Harlequin" 97 B4, a non VW GTDI too
I'm using one of these in my FL buggy for Bluetooth audio/phone connectivity. I like to stream music. The audio system in is integrated with the climate controls and would be a big $$ job to upgrade. Oddly, the car has hands free phone connectivity but no audio. As usual, I'm having picture posting issues :rolleyes:



 
Last edited:

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
New engine oil and filter, plus fuel and cabin filters in my B4 Sedan. And this happened:

It's getting a timing belt this week at Kraftwerke. Filled it with fuel, too. 47.6 MPG on the last tank, all local driving. Not to shabby.
 

Mcgink

Veteran Member
Joined
Oct 15, 2004
Location
South of Boston MA
TDI
I-Red,"The Passat formerly known as Harlequin" 97 B4, a non VW GTDI too
Nice to see that it's officially broken in now at 300K mi. Nice to see it's getting proper care too just like I-red is in TDIDave's capable hands.
 

gboss

Active member
Joined
May 24, 2010
Location
NJ
TDI
(2)1997 Passat, 2014 Golf
I like this idea. But I want to find one that looks period correct and has the correct color display to match the cluster. You can change the color on some head units, but not on the Blaupunkts that I've seen.
It looks like some of the Blaupunkts now have adjustable colors, at least the Frankfurt and Bremen now do.


e.g.:
COLOR (FARBE)
Setting options R (red), G (green), B (blue): create
your desired colour by changing the brightness
values of each colour (possible 16x 16x 16 colours,
each colour intensity can be changed by 16
increments).
 

Chungus

Well-known member
Joined
Jul 23, 2022
Location
Vancouver
TDI
B4 Wagon
After locking my keys in the trunk one too many times, finally installed keyless entry and brought this car into the 21st century

 

TDIDaveNH

Left Lane Coal Roller at Large
Joined
Feb 17, 2009
Location
North Conway, NH
TDI
1997 Passat TDI x2 1984 Buick Century 4.3 diesel
Needed to replace the right inner tie rod end so ended up doing them both along with new outers as well...since why not. I did the outer ends and boots about 10 months ago when the transaxle was out and the right inner showed no play. I was reminded how difficult it is to set the boots correctly and get the band crimped with the transmission in.





Left output seal was leaking so I did that, and it made access to the driver's steering boot a tad easier even though I crimp it from the side along the length of the tie rod but need the tool access for boot & clamp positioning.



Lined the toe up as close as I could get it, which was pretty damn close...It's nice not having to run a dedicated set of sacrificial tires waiting to get onto an alignment rack.



Finished up the session with a change of tires, going from bologna skins to a $100 set of barely used snows from marketplace. Still more work to do before a proper alignment can be done, then new summer tires go on.
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
Picked up my sedan today at Kraftwerke after a timing belt service. Things went slightly sideways, as during the service on of the bolt tabs broke off the A/C compressor. Then Chris couldn't get the high and low pressures to read correctly, finally discovering the receiver/drier had died. But now it's all good.

Biggest improvement, however, is the new engine mounts. Far, far fewer harmonic noises and vibrations transmitted to the seat and steering wheel. And it's quieter. Best benefit is it shifts better, especially from 4th to 5th, which was a bit tricky before despite multiple linkage adjustments. I guess having the drivetrain in the right location matters.
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
Gave my ride just a bit of minor TLC yesterday. Topped off the tires, oil, and coolant. Got a soapy rag and a bucket and cleaned out the door jambs, underside of the hood, and the core support. Vacuumed and cleaned the interior. We'll be taking a road trip from Kentucky to Colorado next month and I need to figure out if I'll be over my oil change interval by the time I get back. Really looking forward to taking pics of the car on top of Pike's Peak!
 

BoiseTDI

Veteran Member
Joined
Sep 21, 2007
Location
Germany
TDI
2002 Jetta Wagon - Sold, 96 Golf - SOLD
If you ever feel the need to get rid of one let me know. =) That is an amazing find.

Collected a 3rd B4V today. Found an ex California car down near Vancouver and rapidly adopted it. It’s the cleanest one in the fleet by a mile! It’s mostly sat for the last 8 years so there are a few things that need TLC but it’s a great successor.


https://flic.kr/p/2pRUc5B
 

alanack

Veteran Member
Joined
May 10, 2022
Location
Rhode Island
TDI
1998 Jetta
Replaced clutch master and slave cylinder.
Literally impossible to bleed.

Purchased a reverse bleeder per a my vw guy.
Bleed in like 3 minutes.

Pedal is better than ever
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
I suppose this is only tangentially related to my B4, but I refreshed my Harbor Freight cargo rack with some fresh paint and reflective tape. (Thanks to @TDIDaveNH for his second-to-last 2" hitch receiver.) I bought this used for $50 a couple years back and immediately put spot welds all over it to help stiffen it up. The "paint" that was on it faded rather quickly, so maybe the Rustoleum I brushed on will look better for a while longer.

20240531_183405.jpg
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
Also finished up renewing a set of headlamps for myself today. I've had the angel eyes for several years, and they were never great to begin with. But now on top of the inability to adjust their direction and a chip in one of the glass lenses, one of the high beams has a short in the wire somewhere and I'm tired of fooling with them. So I'm going back to the basics in an effort to make it better. I think I have 4 or 5 of each OEM headlamp, so I picked out the nicest ones, cleaned them, polished the lenses, and glued them back together with Sika polyurethane adhesive. Now just waiting on my LEDs to arrive.

Also, does anybody know the best tool for adjusting the horizonal position on these? Phillips 3 is too big, Phillips 2 is too small. Maybe a JIS of some kind?

20240601_133730.jpg

20240601_133117.jpg
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
And done. Right off the bat they're aimed MUCH better than the Angel Eyes were. The built-in levels really help.

20240602_153615.jpg

I didn't catch this when I first installed them, but the vertical adjustment gear on the back side of the housing had stripped in the middle and was spinning. I was able to gently pry one off another housing, drill it out large enough to slide over the metal screw, and then drop fill it with thin CA glue. Good as new again!

20240602_145621.jpg
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
Hit the ground running with my engine mounts today. It makes a really bad clunking noise whenever I go over rough spots in the road and has been getting worse over the past year or so. The rear engine mount wasn't so bad to remove, but the rear trans mount was the absolute worst. Bolts were hard to reach with anything, and I had to pull the aluminum bracket to get the mount out of the frame.

Hopefully this will make things go smoothly for our road trip next week. When we get back I'm planning on starting the turbo swap and clutch.

20240613_174905.jpg
 
Top