Operation Bora Body

[beale187]

I haven't investigated completely yet but my puddle light stopped working and interior motion alarm button stopped working after I d/c the battery when installing my CAI, thought this may have caused. Will have to dig deeper.

re fuel pump, I believe this is correct. When I open my door I can hear an ever so slight hum which I assume is the pump priming.

[PranK]

So, quite the update.

I finally decided to get an A/C guy out to look at my system. Especially as it would appear that the lack of A/C pressure was stopping my fans from working.

He immediately found a massive leak and replaced 4 O-Rings. On charging with fresh gas however my pressure switch just collapsed and released all the new gas. Luckily he had a spare, genuine VW, pressure switch and fit it. Charged the system up and not only do I have beautiful cool air, I have working fans!! This has been such a bastard to get fixed and its really the last step before the car is drivable again.

So, on Sunday I wired up the resistor fan fix and I also replaced my horn with new Hella items as mine stopped working a while back. Jeezuzz the new horns are seriously loud!

I put another radiator flush in and ran the car for around 30 mins. Fans stayed on and the bay was noticeably cooler than on previous radiator flush attempts. I have some fresh G13 and distilled water to go in this weekend.

The front is still off the car and I'll take great joy in putting it all back together this coming weekend.

[PranK]

I'd love to know why my images are upside down.

[PassionGarage]

looking good man just did the whole read

[PranK]

looking good man just did the whole read

Thanks mate! Hopefully not too boring.

My latest update is a frustrating one; when I put my compressor back together with the new clutch coil, I tightened it too much. This meant that it worked for 15 mins before siezing and falling to pieces.

I now have a replacement compressor (A Zexel as opposed to a Sanden - but assured it will fit). I just need A/C guy to come back and flush so we can fit and then refill.

So close! Would love to have it on the road for Summer as its been over a year now since it died.

[PranK]

So, I can confirm that the Sanden compressors are exchangeable with Zexel.





So, had to drain coolant, fit Zexel compressor, then got system re-gassed with a new drier.

THEN, believe it or not, my small fan stopped working. I almost put the car back together with the fan not working, I was so jack of it.

I left the car for a few hours and watched the cricket, the time away made me less angry and I thought I'd try to fix it myself.

It ended up being a seriously easy fix, one of the fan bushes had stuck in its housing, so I doused the whole thing in WD40 until everything moved freely and put it back together. I used Permatex Steel Weld to epoxy the fan back together (you need to use brute force to break the fan apart). Then I put it back together and it all worked again. Hallelujah.

You can see the stuck bush in the pic below.


That means that on Sunday, it went for its first drive in 6 months or so. It was so awesome being able to drive it again, I've missed it a lot. The brakes felt like ****, the disks were a little rusty so hopefully that will just get better once I start driving it more.

Also, the battery is done. It wont hold charge longer than 2 or 3 days.

Its totally filthy and the interior is full of spiders webs, so the whole thing will get a really good clean over chrissy / ny.

[beale187]

nice write up man, on a side note how's your a/m headlights holding up? Any fading?

[PranK]

nice write up man, on a side note how's your a/m headlights holding up? Any fading?

Oh I took them off ages ago. I gave my stock ones a good sand and polish and they came up well enough to put them back on.

[beale187]

Didn't like the look? Or they started to fade also?

[PranK]

I liked the look a lot, but they were cheap and the light wasn't great from them. I find Bora headlights terrible at the best of times, those ones made it even worse.

What are your headlights like?