Various Automotive Repairs

I will only very briefly discuss key points of more interesting repairs, and omit basic ones (oil change, brakes, shocks, etc). These all take place on a Mk4 Golf. VWvortex and tdiclub are inavaluable references. UK-mkivs and Pelican Parts also often prove useful. Of course, YouTube videos can help clarify certain tasks as well.

Replacing door latch

The door latches have a tendency to fail due to the microswitches inside them. Replacement is not difficult, but key points include:

• The door lock operates only if the window motor is connected
• The plastic door trim is easily removed but the metal door panel beneath it is attached with plastic rivets. These must be snapped off
• The latch assembly is held in place by a triple-square M8 screw, NOT a Torx. A set of triple-square bits comes in handy for other VW repairs
• Removing the window sounds dauting but they are very strong and unlikely to break with due care. However, ensure that they are fully seated back into the plastic brackets upon reinstallation, or they will not fully open
• The trunk latch is an entirely different (but very ingenious) system, and failure is usually due to corrosion of the cast aluminum. Replacement from VW is extremely expensive as the new lock has to match the key. The latch is very hard to remove from scrapyard cars without breaking. A suitable part may however be ordered off alibaba, and comes with a new set of keys, but only includes the metal part. Non-metal latch parts can be purchased inexpensively from VW, and a regular plumbing o-ring may be used to seal latch against the trunk door.

Replacing A/C compressor clutch

This is conceptually simple, but actually very frustrating due to the limited space. It would likely be preferable to drop the compressor, but that requires discharging and recharging the A/C gas, and must be done in a professional shop. At that point, I would be inclined to replace the compressor rather than fight the snap rings. Key points include:

• Removing the alternator is very simple and allows a little more space
• Removing the old pulley can be done with a mallet and a screwdriver, but would be easier with a puller
• There is a point where the pulley needs to be immobilized. A specialized tool exists, but channel locks can be made to work too
• Snap ring pliers are required to remove and reinstall the snap rings. However, these can be extremely challenging to reinstall, and this took me several days, with the pliers and a screwdriver to push the ring into place as well. By far, the worst part of the job
• The serpentine belt belt tensioner can be raised with a flat wrench to allow for belt removal and reinstallation

Replacing radiator

These radiators have an unfortunate tendency to be corroded by road salt, and spring a leak. Replacement is time-consuming but straightforward. Repair is mostly pointless, as new ones are rather inexpensive, and the corrosion tends to be extensive. keeping track of the various bolts is important due to the number of parts that have to be removed. Coolant does have to be drained, and should be replaced with new coolant. Some of the hoses may be a little stiff and hard to remove/reinstall. It may be a good idea to replace the thermostat while the coolant is drained.