Jetta roll on bedliner paint and other repairs

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Hello Folks,
I'm new to this forum and to diesel cars, but this summer i bought myself a little toy project - 2005 Jetta Wagon 1.9 TDI BEW. I went for summer vacation and just recently found some time to work on it.
I'm no mechanic or big DIYer, but beside breaking few stuff - so far so good. I would like to ask few advises on how to replace parts, so any suggestion or corrections will be greatly appreciated.
When I've got my new/old Jetta I decided to bedliner the whole car in color "read my lips" from "MonstaLiner", anybody did this kinda roll-on painting job before?
Secondly the car was in not to bad of the shape except grinding noise coming from driver side front suspension. This issue I solved - driver side CV axle joint failed (replaced)
Anyways, I needed to pass the safety inspection so I required to fix few things like replace E-brake cables, brakes, hazy headlights etc., but I went ahead and order buncha parts cause I want to keep the car for few more years and maybe give it to my daughter.
so here is the list~
Initial Cost - $500 (CAD)
Mileage - 321 076 km
MonstaLiner Paint - $700 (USD$582.08)
2 Gallon kit - Read my Lips color
1 Gallon kit - Black
1 Quart - Silver chassis saver
1 Quart - Black chassis saver
1 Quart - S8 Multi-Temperature Reducer
6 Extra rollers
Work Done:
  • Rear Bilstein Shock, strut top stop & dust boot, lower shock bolt & nut replaced (x2)
  • Rear E-Brake cable, e-brake clip (x2)
  • Rear Hub/Bearing assy, rear splash shield (new/painted chassis saver), rear brake disc & pads, ABS sensor and screw(x2)
  • Rear brake caliper cleaned and painted, rear caliper bleeder screw w/ dust cap, rear brake line aluminum washers/seals (x2)
  • Rear driver side rocker panel end rust repair/weld
  • Front Bilstein Shock and coil spring, strut mount w/ bearing & upper spring seat, dust boot & bump stop replaced (x2)
  • Front wheel steering knuckle & hub cleaned/painted (chassis saver), front wheel bearing replaced (kit) (x2)
  • Front splash shield (new/painted chassis saver), Brembo front brake disc & pads, front brake hose (x2)
  • Front brake caliper & caliper slider holder cleaned & painted (caliper paint / chassis saver), slider pins w/rubber boots (x2)
  • Front CV Driveshaft w/ joints, ball joint, inner & outer tie rod; control A-arm w/ bushings, sway bar link/bushing/clamp (x2)
  • Flushed w/ XADO - Total Flush & drained engine oil, changed oil filter and fuel filter, replaced oil cooler O-rings, cleaned oil cooler
  • Removed Intercooler for oil drainage and cleaning
  • Removed Roof rack & disassembled front grill for MonstaLiner paint
  • Replaced Stereo Head unit from stock to Sony WX-900BT
  • Cleaned rusted areas for chassis saver
  • Took off plastic from side mirrors, ready for paint
Work I want/needs to be done:
  • (Currently on this job, missing tool T#10050) Replace Timing Belt/Tensioner/Roller/Water Pump/Thermostat with O-ring & housing
  • Replace Serpentine Belt Tensioner/Serpentine Belt/
  • Flush/replace engine coolant (with G13), flush/bleed brake fluid (DOT 4)/Fill engine with oil (5W-30)
  • Replace headlight lens with glass, custom LED HALOs, upgrade 9007 bulb to GTR Lighting LED (3rd gen)
  • Replace lower front bumper grills with Fog lights, upgrade lighting control switch to automatic
  • Replace speakers, install amp and subwoofer, door logo lights
  • Replace interior and exterior light bulbs with LED
  • Remove wax/oil from whole car, rough up paint for MonstaLiner tape off non-painting area
  • Take off hood, front fenders, doors, front and rear bumpers, move them to paint area
  • Paint car body and taken parts, 2-3 coats
  • Install new mud flaps
  • Replace broken windshield spray nozzles
  • Remove door handles before painting (need help on that one)
  • Spray rubberized coating under wheel well fender liner
  • Clean EGR valve
I live up north in Canada (Manitoba) so the closest dealer or good shop is about 1000 km away so I have no choice but do it myself. I've got parts from germanparts.ca or germaneom.ca and ebay and shipping ain't cheap but I am already committed lol
I would appreciate any help/advice
Thanks
Oleh
 

maxmoo

Veteran Member
Joined
Jan 19, 2011
Location
Lakefield, Ontario, Canada
TDI
2000 golf, 2001 golf, 2000 beetle, 2003 wagon, 2004 golf, 2004 jetta, all diesels
Welcome aboard!

wow....you're biting off a lot at once!

A little advice from someone that has made enough mistakes over the years to learn a thing or two....

- A quality timing belt kit is crucial if you don't know the history of previous maintenance.

- Using the correct oil is also critical in a BEW engine....full synthetic 5w40 505.01 spec or better....
http://forums.tdiclub.com/showpost.php?p=4852411&postcount=3

- Owning and learning to use a vcds diagnostic tool is mandatory to properly diagnosing and maintaining these cars.
 

mjydrafter

Veteran Member
Joined
Jul 12, 2015
Location
dsm, ia
TDI
2004 Jetta Wagon
  • Remove door handles before painting (need help on that one)
  • Clean EGR valve
Find a thread on door latches for the handle removal, it's a real process. Not super difficult but there are few "gotchas" The threads with pics will explain.

EGR is simple, pull electrical connector, remove 3 bolts and yank it. Do be careful cleaning it, just the stuff in the air path, and I would try to not use any harsh chemicals or at least use them very carefully.
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Welcome aboard!
wow....you're biting off a lot at once!
A little advice from someone that has made enough mistakes over the years to learn a thing or two....
- A quality timing belt kit is crucial
- Using the correct oil is also critical in a BEW engine....full synthetic 5w40 505.01 spec or better.
- Owning and learning to use a vcds diagnostic tool is mandatory
Thanks maxmoo!
well I figure I do what I can and replace most major parts to prolong life this Jetta, I own 3 vehicles so this one can have down time.
- as for timing belt kit - I've got HEPU Timing Belt/Tensioner/Roller/Pump Kit PART #: 1K7421 | OEM #: 038198119A
- for the engine oil I will be using "TOTAL QUARTZ INEO MC3 5W30" - FULLY SYNTHETIC Low SAPS; approved for VW 502 00/505 00/505 01. It gets really cold up here, could be -45 or -55 (deg C)with windchill in winter and +25 in summertime, so i don't know if using 5w-40 would help in colder condition (winter here lasts up to 8 month)
- as for vcds tool I just received "OBDeleven + PRO" Audi/VW Diagnostic Tool, is it good enough or I need something better?
Oleh
 

Jetta_Pilot

Top Post Dawg
Joined
Apr 14, 2005
Location
West Hill, Ont.
TDI
2015 Passat Highline TDI Candy White (SEL Premium) long gone 2002 Jetta TDI
There are also some specialized tools required to do a timing belt change. I.e for one the tool to hold the camshaft in position. But I may be wrong here maybe the 2005 is different from a 2002.
I'm sure someone else will correct me if I'm wrong.
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Find a thread on door latches for the handle removal, it's a real process. Not super difficult but there are few "gotchas" The threads with pics will explain.
EGR is simple, pull electrical connector, remove 3 bolts and yank it. Do be careful cleaning it, just the stuff in the air path, and I would try to not use any harsh chemicals or at least use them very carefully.
Thanks, will do. I suspected it's not gonna be super easy.
EGR valve is in not to bad of the shape and thanks for suggestion
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
There are also some specialized tools required to do a timing belt change. I.e for one the tool to hold the camshaft in position. But I may be wrong here maybe the 2005 is different from a 2002.
I'm sure someone else will correct me if I'm wrong.
It's the same tools as 2002, T#3359 for TDC on camshaft and T#10050 for TDC on crankshaft I believe.
 

aja8888

Top Post Dawg
Joined
Dec 25, 2007
Location
Texas..RETIRED 12/31/17
TDI
Out of TDI's
Damn its gets cold up there! :eek:I spent a week in Norman Wells in the winter one time. Good luck with your project and please do post photos. Also after it's painted. :cool:
 

mjydrafter

Veteran Member
Joined
Jul 12, 2015
Location
dsm, ia
TDI
2004 Jetta Wagon
Thanks, will do. I suspected it's not gonna be super easy.
EGR valve is in not to bad of the shape and thanks for suggestion
That's your ASV, it's a shutdown valve that closes when you shut of the car. The EGR valve is up above the valve cover just past that valve.

Careful cleaning on the ASV as well.
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Just few before and after pics on done job

Front driver side brakes before


and after


 
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wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagon,2003 Jetta 261K Sold but not forgotten
Front suspension & brakes look nice when their new.
If you haven't ordered the parking brake cables ID-Parts has updated cable that are heavier then the original ones.
Not sure if they have it for the 2005.
Easiest upgrade I did in a long time, nice to have it dependable. :)
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Front suspension & brakes look nice when their new.
If you haven't ordered the parking brake cables ID-Parts has updated cable that are heavier then the original ones.
Not sure if they have it for the 2005.
Easiest upgrade I did in a long time, nice to have it dependable. :)
Yeah, I've ordered one of the heavier ones too after I replaced the originals. Well, I will replace it in the future. Is ID-parts Canadian based or from the US?
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Allright, just wanted to post an update. Mechanically all work is done as far as I could and now I'm in stage of sanding/prep for paint. Also wanted to get your opinion guys on headlights retrofit that is currently in progress. Here's picture

 
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Cuchulainn

Active member
Joined
Feb 13, 2017
Location
Winnipeg
TDI
05GolfGLS/ 06 Jetta wagon 5spd.
Looking really good so far, your definitely jumping in with both feet! I live just slightly north of Winnipeg these days, have ordered parts thru I.d. Parts-good people there and shipping wasn't too bad. 1000km's from nearest VW dealer, you must be north of Thompson? Beautiful country side, go hunting and fishing a couple times a year at my buddies lodge.Welcome to the forum
 

0leh

Member
Joined
Dec 8, 2017
Location
Northern Canada
TDI
2005 Jetta Wagon 1.9 TDI (BEW)
Yup 300 km from Thompson, way up in Gillam. Definetely good hunting and awesome fishing! Shipping up here would definitely hurt, close to Peg city not as much. Today will figure out wire connection for switchback drivers and how I'm gonna deal with heat sinks on 9007 Putco silver lux led bulbs
 
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