The Black Pearl

After a morning of downpours, the dogs got walked and with more rain on the way, it seemed like a good time to spill some coolant (I caught most of it in a bowl!) and tackle the leaky pipe seal going into the pump.
The job was going quite well until it wasn't. This was the easiest way to extract the housing, who else hates those "flat" hose clamps?
So now I need to repair that bleed spigot.
Its not just FSI's that cook their coolant fittings, an 83°C stat is fitted and this is all original 2002 parts. Rotten O ring on the pipe had failed.
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Can you internally sleeve the fitting with brass tube then rebuild the exterior with the broken parts and epoxy?
 
I think that I'll tap a thread into the housing and make a new spigot to suit.
Quicker and cheaper than a £35 housing +£17 postage from Germany for a "LST" branded one, whoever they might be...
 
It appears to be ok. I suspect that the bleed spigot had been strained or bumped before, the coil pack is non-original (Delphi) so a clumsy mechanic may be to blame.
 
You are probably right re the clumsy monkey. Although now with these cars the heat soak cycles have probably made a lot of the cooling systems "fragile" both plastic and metal. It is annoying that as these parts are reaching their ultimate life OEM replacements in many cases are no longer available.
 
Stat housing repaired. Drilled 3mm with an M6 threaded spigot to maintain some wall thickness and I can always go up to M8 if it plays up.
I have replaced the rotten lower seal on the original pipe with two o-rings, if it seals ok it can stay as it is in A1 condition ;) if not I'll fit the Birth replacement. I will install it with red rubber grease on the seals.
Strange thing, the housing is the original 2002 part, with a conventional thermostat (only 83°C?) but the housing has the inner molding features for the small capsule type thermostat, however none is fitted.
Has it been removed or is that for FSI's only?
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Leaking roof update. Since dropping the headlining and despite some heavy overnight downpours, there is no sign of wet or even damp in the car.
I dont understand how it has stopped leaking, but the headlining and trim isnt going back in until its been trailered to Staines for a full OSS refurb!
 
The drains were all fully connected and clear of blockages? Leaks from the tailgate rubber seal at the top. Good choice to have the OSS "professionally" refurbed. Are you having your own refurbed or exchanging it??
 
That is a very good solution to the broken spigot. I wonder is something similar could be done to the notorious "Y" pipe if there is enough material to support it?
 
audifan said:
The drains were all fully connected and clear of blockages? Leaks from the tailgate rubber seal at the top. Good choice to have the OSS "professionally" refurbed. Are you having your own refurbed or exchanging it??
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As far as I can tell the drains are now clear. Kleynie will be taking my money in due course, local to me. I am not fussed about originality, I just want it watertight and working.
 
VAG fool said:
Stat housing repaired. Drilled 3mm with an M6 threaded spigot to maintain some wall thickness and I can always go up to M8 if it plays up.
I have replaced the rotten lower seal on the original pipe with two o-rings, if it seals ok it can stay as it is in A1 condition ;) if not I'll fit the Birth replacement. I will install it with red rubber grease on the seals.
Strange thing, the housing is the original 2002 part, with a conventional thermostat (only 83°C?) but the housing has the inner molding features for the small capsule type thermostat, however none is fitted.
Has it been removed or is that for FSI's only? View attachment 80426View attachment 80427View attachment 80428
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Hi there
Where did you source the M6 threaded spigot as could do with the same repair!
Thanks
 
Perhaps you could make parts for those that do not have a lathe. Work out a price then consider offering parts service. ONLY a suggestion.
 
I hadn't considered that tbh. Crazy busy what with work, home and cars at the moment.
I'll look into it and start a fresh topic
 
Thursday night was a rapid refit of the big coolant pipe and the thermostat housing. I can confirm that using red rubber grease on the pipe seals makes the job almost easy, allowing the pipe to be gently levered back into the thermostat housing once the latter is bolted in place, then the clip goes in from below.
Refilled with coolant and apart from an apparent airlock in the heater (which eventually cleared) no leaks so far...
Saturday is going to be the first big club-related day since buying this car. Clue: she's on a trailer for a little hop round the M25 ;)
 
I'm a very happy bunny and also relieved that I returned the trailer in the same shape that it was borrowed!

(I also got in some much-needed trailer reversing around corners practice)
 
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