Thread: What happened to your D3/D4 today?

Originally Posted by BradC

I found I had to remove the fuel return line. There's a bit that is clipped into the passenger side of the valley. Once I removed that (I suppose the manual terminology would be "repositioned") I pulled the separator forward and rotated it clockwise. It dropped into the space previously occupied by that fuel nipple thing and just slid out. Only took me 3 hours to figure it out.

I moved everything out of the way that i could but still wont come out, got the front bolts of the pump out at least so i might just leave it there until the pump is ready to come out.

After yesterday's short drive of 105kms and 1 hour of dirt road I lay on the drive way and hosed underneath the back of the car as it's going to my mechanic for new rear airbags and suspension arms/bushes tomorrow. It definitely needed it as the grey concrete was brown afterwards.

Originally Posted by loanrangie

I moved everything out of the way that i could but still wont come out, got the front bolts of the pump out at least so i might just leave it there until the pump is ready to come out.

There is a very specific position that it can be popped out. Still clashes but can be forced out.

I took this photo at the exact position that worked on my D3. Very repeatable once I found the exact spot.

Finally got it out and new pump is in, of course I seem to have lost the only 1/4" drive 10mm I had so will have to wait until tomorrow to torque the tensioner and close it up.
That right rear pump bolt is a doozy.

Yeah, I sacrificed my favourite 10mm socket to the rear of the pump also. Those rear bolts are a "challenge". After that job I bought a tiny 1/4" pneumatic air ratchet on a whip hose in case I ever had to get in a space like that again. For me the real bear was torquing up the tensioner bolt. My smallest torque wrench just fit, but one click at a time.

Don't make my mistake and pull the pin on the tensioner before you have the belt perfectly aligned on the pulleys. Mine was over the edge on the pump side and I had to walk it back on with screwdrivers so I could get the remainder of the belt housing back on the top of the pump.

I've considered several times the purchase of a battery ratchet, but I have air and the pneumatics are so much smaller for the same torque. No battery to swing around.

I've got the job tomorrow of replacing the a/c dryer on my old D4. I'm hoping to lean the radiators back enough to unbolt the condenser to raise it to get access to the bolt in the bottom of the dryer, hoping to not have to remove the whole pack.

Originally Posted by Graeme

I've got the job tomorrow of replacing the a/c dryer on my old D4. I'm hoping to lean the radiators back enough to unbolt the condenser to raise it to get access to the bolt in the bottom of the dryer, hoping to not have to remove the whole pack.

It can be done. Fiddly but doable.

Originally Posted by BradC

Yeah, I sacrificed my favourite 10mm socket to the rear of the pump also. Those rear bolts are a "challenge". After that job I bought a tiny 1/4" pneumatic air ratchet on a whip hose in case I ever had to get in a space like that again. For me the real bear was torquing up the tensioner bolt. My smallest torque wrench just fit, but one click at a time.

Don't make my mistake and pull the pin on the tensioner before you have the belt perfectly aligned on the pulleys. Mine was over the edge on the pump side and I had to walk it back on with screwdrivers so I could get the remainder of the belt housing back on the top of the pump.

I've considered several times the purchase of a battery ratchet, but I have air and the pneumatics are so much smaller for the same torque. No battery to swing around.

Bought a set of 10mm sockets so hopefully I don't lose them all, torx bolts are pita but I was able to use a combination of bits to get into that limited space. After that it's plain sailing.