[William Richardson]

Thanks for the reply,
After doing some research it seems to be that I can revert the entire system back to a booster/master configuration using OEM parts. So instead of a 92 with a 92 oem brake system it will be a 92 with an 89 oem brake system. The car is in fantastic shape with 120k on the clock and no rust I would hate to junk it or pass the problem along.

[William Richardson]

The amount of time required varies greatly depending on experience and could be prolonged due to issues that arise. If you have not tackled the job before give yourself a weekend to do it. Take your time and do your research. Also, Check compression across all cylinders; if two cylinders next to each other have low compression compared to the rest of the engine this could indicate a warped head.

[William Richardson]

Timing chain guides could be worn out but we need more information. Does it grind all the time? Does it grind when you are sitting in park or driving?

[William Richardson]

Grease: When moving parts need lubrication

Threadlock: Use on fasteners that have the same metal type as the material you are fastening to, i.e. steel bolt in a steel hole.

Anti-seize: Use on fasteners that have a different metal type than the material you are fastening to, i.e. stainless bolt in an aluminum hole. When you use anti-seize you always want to use a locking washer to prevent the fastener from backing out. The use of Anti-seize is for the prevention of dissimilar metal oxidation which occurs when two different metals come in contact.

Be careful with grease though, make sure you are using the correct grease for your application and know how much to apply. General Purpose grease is fine for mating splines but should not be used for wheel bearings. Also, if you are using your vehicle for offroad purposes i would recommend marine grease to help keep moisture out.

[William Richardson]

If you cant verify if it was replaced I would replace it. If it fails engine damage is inevitable since its an interference engine. Here is an excellent write up on timing belt replacement for that engine: http://www.blauparts.com/vw_timing_belt_replacement/28l30v/howto/how_to_replace_vw_passat_timing_belt_installation_guide.html

[William Richardson]

Do you have a sub/amp setup installed? If so, this would cause the voltage fluctuations as well and I would install a capacitor to relieve the stress on the electrical system. Audio amplifiers are alternator killers.

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