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I suspect at some stage Frank's previous owner noticed that Frank had some overheating issues. So they used a bottle of the Stop Radiator Leak goop. Which is something you only resort to when you're selling a car, as it literally eats a cooling system alive.

When we touched Frank's radiator hoses, and squeezed them, it felt like we were squeezing a bag of potato chips.

B1 VW Passat cooling system

 

B1 VW Passat cooling system

 

B1 VW Passat cooling system

All the hoses were coated with orange rust particles.

 

B1 VW Passat cooling system

And as you can see, they were bulging.

 

B1 VW Passat cooling system

The radiator was in a terrible state.

 

B1 VW Passat cooling system

As were pipes connected to the radiator

 

B1 VW Passat cooling system

 

B1 VW Passat cooling system

The water pump had turned into swiss cheese

 

B1 VW Passat cooling system]

The remains of the after market air conditioning system Frank once had were still there, including this steel bracket, so we unbolted that.

 

B1 VW Passat cooling system

The engine mounts were looking sad too, and needed replacing.

 

B1 VW Passat cooling system

Old engine mount in middle, two new ones on either side. When we replaced the engine mounts with new ones, the engine sat up approximately one inch higher than it had before.

 

B1 VW Passat cooling system

One bolt had snapped off and required removing.

 

B1 VW Passat cooling system

Gotcha

 

B1 VW Passat cooling system

So here we have the new ingredients. New hoses, brake lines, water pump, water pump housing, wormbands and radiator.

 

B1 VW Passat cooling system

Found these on Ebay US, new inner steering ends. Considering how worn out most of Frank's replaceable parts are, it couldn't hurt to replace those, right?

 

B1 VW Passat cooling system

The only one left in Australia, one B1 radiator mount. Of the ones in Frank, the one under the radiator was completely shot, the one on the side useable.

 

B1 VW Passat cooling system

Got this from Ebay US but I think it might be for a LHD car as its outlets are on the wrong side for Frank. Could use a mirror image of this! So we went to the Golf parts instead.

 

B1 VW Passat cooling system

Part of the hoses that came out of Frank. Note the sparkplug on the end? That was used merely to plug up the hose!

 

B1 VW Passat cooling system

It smelt bad too

 

B1 VW Passat cooling system

So much orange goo everywhere!

 

B1 VW Passat cooling system

New and old water pump housing.

 

B1 VW Passat cooling system

 

B1 VW Passat cooling system

All new sensor, new (used) radiator.

 

B1 VW Passat cooling system

The old front indicator cable covers were very dry and housing spiders. So we fished some other used ones out of a box, not as dry and sad looking.

 

B1 VW Passat cooling system

Painted the fan shroud, replaced the fan blade as the old one was torn, and painted the pulley cover.

 

We got a new thermostat too. The one in Frank wouldn't open until a naked flame was on it, turning it red hot! We'll need to run several flushes of coolant through the system to ensure all orange residue is gone. But Frank fires up and the fan works properly now :D

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