Just another quick update, this has been lifted from another forum, I actually did the work at the end of January:
Well, recently I've been pretty busy with the car, sorting things out. I've managed to find the time to recondition my recently-acquired calipers and carriers which have allowed me to fit 280mm discs. I've also fitted braided hoses, new fluid and renewed almost all of the suspension components with 'just' the top mounts and steering rack left to replace to sort out a handling issue. As well as that I've fully serviced the engine, with new consumables (oil, filter, plugs, leads, cap, rotor arm) and also changed the cambelt and tensioner just to be on the safe side.
Here's a few pics:
Reconditioned bearing housing/hub with new wheel bearing:
New front calipers etc:
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I've also ordered three new engine mounts from AVS as the original ones are getting very tired now, especially the front one. While having a look at the work that I'd need to do to replace the mounts, I noticed a damaged wire leading to some sort of sensor at the front of the block, behind the oil filter. Further investigation revealed that its the crank position sensor, pretty crucial in keeping the engine running. I contemplated trying to repair the wire in-situ, but then decided I best take the sensor off and have a look at the job in hand. To get to the 5mm cap-head bolt securing the sensor to the block I had to remove the radiator fan and its cowling, as well as the front engine mount and its bracket. I then was able to get the bolt and sensor out easily, and found it looking like this:
Bit of a mess really
The wires are twisted around each other during manufacture for some reason, but 13 years exposure to heat (running near the block) has damaged the insulation and made it very brittle, meaning I'm unable to strip the wires back to fresh insulation and re-solder new sections in. I got as far back as the sensor itself but there's no chance of repairing it. The insulation is fine up near where it plugs into the engine loom as its well away from any heat source, but it doesn't help at the sensor end unfortunately. So its new sensor time, and for part number 037906433A I think I'm looking at around £150 from VW. Replacement sensors are listed on eBay but they're non-genuine and with crucial engine sensors I prefer to stick to genuine OE. Oh well! At least the front engine mount is off now
I've managed to borrow a car from work for the couple of days it'll take for VW to get the sensor in, and then I'll fit it this week. Its a good job really, as the missus and I are heading up to Scotland next sunday for a week away driving in the C, and it would have been a bugger if the sensor had failed when I was up there.
Plenty more to come as I replace the steering rack, rear axle bushes, fit the Mk4 calipers, do the rear wheel bearings and new discs/pads etc - all good fun
