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Go Back   TDIClub Forums > Picture Gallery/Specs of Members' TDIs > New Beetle TDI Picture Gallery

New Beetle TDI Picture Gallery Do you have a New Beetle TDI? If so write a message here describing it and insert a picture if you have one. If you don't have one on the computer, email me and I'll give you my address and I'll scan it for you. If you need web space for it, email me as well. Please make a short yet descriptive title for your vehicle.

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Old September 18th, 2015, 15:16   #1
Lightflyer1
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Default My 2003 New Beetle - BlueBoy

Here is my 2003 New Beetle GLS TDI as it sat for sale with a leaky IP and TB issue of tensioner installed incorrectly. Head/valve damage. Bought for $1200.











First bill for repairs on 9/2/2015:

Make/model 03 Beetle
mile 157,450

Labor:
Description: Charge:
Install injection pump seal kit $ 312.11
Install timing belt kit $ 385.00
R&I cylinderhead (6hrs@$90/hr) $ 540.00
Install lower radiator hose and repair expansion tank hose $ 45.00
Install inner drive axle boot, right and left (1.5hr/side) $ 270.00
Install fan set $ 90.00
Install glow plug harness $ 90.00
install oil pan $ 90.00

Total Labor: $ 1,822.11

Outside services:
Brooks Elliot Machine Shop head repair service exchange $ 280.00
Brooks Elliot Machine shop intake cleaning service exchange $ 50.00
Total: $ 330.00

Parts:
Description: Unit Price: Total Price:
1 Bosch IP seal kit $ 21.00 $ 21.00
1 fuel return line set $ 5.00 $ 5.00
1 dieselgeek.com ALH timing belt kit with $ 340.00 $ 340.00
timing belt, tensioner, water pump, 3 rollers
vacuum pump seal and serpentine belt
1 cylinder head gasket, 2 hole $ 23.40 $ 23.40
10 cylinder head bolt $ 1.26 $ 12.60
1 intake manifold gasket $ 2.00 $ 2.00
1 exhaust manifold gasket $ 9.95 $ 9.95
1 down pipe gasket $ 3.00 $ 3.00
1 EGR to intake o-ring, viton $ 5.00 $ 5.00
3 EGR pipe gasket, metal $ 3.95 $ 11.85
1 EGR pipe gasket, paper $ 3.80 $ 3.80
4 injector crush washer $ 0.90 $ 3.60
1 turbo oil return line gasket $ 4.00 $ 4.00
1 camshaft $ 100.05 $ 100.05
8 cam follower, INA $ 9.42 $ 75.36
1 camshaft oil seal, PTFE $ 10.00 $ 10.00
2 intake valve $ 13.00 $ 26.00
1 water outlet flange o-ring $ 5.00 $ 5.00
1 lower radiator hose $ 36.18 $ 36.18
1 hose repair union, repair hose and clamps $ 11.00 $ 11.00
2 drive axle boot, inner $ 20.00 $ 40.00
4.5 Fuchs Titan Supersyn 5w40 motor oil, liter $ 6.66 $ 29.97
1 oil filter $ 8.00 $ 8.00
1 glow plug harness $ 102.00 $ 102.00
1 cooling fan, left $ 66.37 $ 66.37
1 cooling fan, right $ 68.27 $ 68.27
1 oil pan $ 88.00 $ 88.00
5 G12 coolant, mixed 50:50 distilled H2O, liter $ 3.00 $ 15.00
1 coolant expansion tank $ 18.24 $ 18.24

subtotal $ 1,144.64
Tax: $ 94.43
Part Total: $ 1,239.07

Invoice Total: $ 3,391.18


Second bill for oil pan incidinet on 9/9/2015:

Make/model 03 Beetle
mile 157, 676

Labor:
Description: Charge:
Install oil pan $ 90.00
Install dieselgeek panzer plate w/ FMJ $ 60.00

Total Labor: $ 150.00

Parts:
Description: Unit Price: Total Price:
1 dieselgeek.com Panzer Plate kit $ 275.00 $ 275.00
1 side dkirt FMJ set $ 99.00 $ 99.00
1 oil pan $ 88.00 $ 88.00
4 Fuchs Titan Supersyn 5w40 motor oil, liter $ 6.66 $ 26.64

subtotal $ 488.64
Tax: $ 40.31
Part Total: $ 528.95

Invoice Total: $ 678.95

Car wasn't running so I bought a clutch set just in case:

$33.93 Volkswagen 02J 141 719 C, Clutch Release Arm
$34.33 Victor Reinz 67750 Rear Main Seal
$187.57 LuK 17-050 Clutch Set
$22.50 Axle Shaft Seals (2)
$12.00 CV Joint Bolt (12)
$1.75 Retaining Spring for Clutch Release Lever Pivot
$85.90 Clutch Slave Cylinder (A4)


$9.30 Audi Vw Mercedes Double Din Radio Removal Key Tool (2 Pair)
$72.97 New fog light set Amazon by AutoHalo.
$58 Dieselgeek Beetlebrace door handle reinforcement
$200 Maaco painting of front grill parts
$50 Bentley Beetle Manual

http://www.expressoemparts.com/

Part Number Part Name Price Quantity Total
1C0-805-903-G-GRU LOWER PANEL $105.21 1 $105.21
1C0-807-681-E-01C LOWER GRILLE $39.71 1 $39.71
1C0-807-341-A-GRU COUPLING $57.12 1 $57.12

Subtotal: $202.04
Shipping (UPS - Ground): $60.24
Handling: $2.75
Total: $265.03

Part Number Part Name Price Qty Total
1C0-868-107-B-FYZ DOOR TRIM PANEL, LEFT $350.03 1 $350.03
1C0-868-108-B-FYZ DOOR TRIM PANEL, RIGHT $350.03 1 $350.03
1C1-857-628-B-62J GRIP HANDLE CAP, RIGHT $4.55 1 $4.55
1C1-857-627-C-62J GRIP HANDLE CAP, LEFT $4.55 1 $4.55
1C0-858-069-AA-XNX CENTER BEZEL $165.12 1 $165.12
1C1-880-882-E-3SG GLOVE BOX DOOR $229.72 1 $229.72

Subtotal: $1,104.00
Shipping: $80.61
Handling: $2.75
Total: $1,187.36



Total so far: $7693.27

Starting to look like new!
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Last edited by Lightflyer1; September 18th, 2015 at 15:37.
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Old September 24th, 2015, 03:52   #2
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holy ****....... I don't know what to say, so I won't say anything.
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Old September 24th, 2015, 04:27   #3
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I could have reduced that to around $4500 total if I had not cracked the oil pan and just left it in the shape it was in. But I had just had a new car and I wanted this one to be like new, and it is now. A friend of mine just bought a new gas Beetle for $17k. Mine is as nice as his almost and much cheaper and more economical. My plan is to have it for a very long time. It isn't the thing most people do though. Here are my other cars, both with flathead V8's:







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Old September 24th, 2015, 05:16   #4
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Now, those are very impressive, and attractive. kudos !!
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Old September 26th, 2015, 18:19   #5
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I think you should chip it Dave!

The whole time your car was here Lance kept saying how much he liked it. And I agree it's a nicer car. Some cars just "have it"
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Old September 27th, 2015, 16:07   #6
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I have a used injector set on the way. DLC 520's by DBW I think. Then a tune. After I find out if I am getting laid off or not.
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Old September 29th, 2015, 18:31   #7
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Brand new OEM VW parts from Patrick VW came in today. The brand new door panels look beautiful and will be great when they get installed. I am glad I chose to go new now. It will really set off the interior. All the used ones I tried to get were expensive as well and old already. Brand new these should last me a long while. Maybe the old ones can be reworked and resold to offset the cost some.
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Old October 7th, 2015, 18:40   #8
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Working on the interior now. Rebuilding the door panels was more than I thought due to the plastic welds. The new injectors came in and will be sent off to DBW for rebuilding and DLC 520's soon. Sending for a new spring/suspension set from IDParts next week. I may raise it 2" as well while everything is out and being replaced.
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Old October 9th, 2015, 13:34   #9
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Ordered 4 DLC 520's stage 1, from DBW today. $449

http://www.dbwllc.net/product/dlc-52...-efficiency-2/

Also new suspension kit from IDParts.

http://www.idparts.com/

1 x Spring & Shock Complete Suspension Set (A4) (a4_tc_springs_set) = $515.60
Rear Bump Stops
Installation Bolt Kit
Front Bump Stops
Rear Shock Mounts
Model New Beetle
Shock Option Bilstein TC Sport
Front Strut Mounts FREE
2 x Front Spring Top Perch (A3)(B4)(A4) (springtopa4) = $23.98
1 x Rear Shock Boot / Dust Covers Pair (A4) (a4_rshock_cover_pair) = $9.95
2 x Strut Mount Top Nut (A4) (struttopnuta4) = $16.40
2 x Rear Lower Spring Seat (A4) (a4rearspringseat) = $16.40
1 x Front Strut Boot/Covers Pair (A3)(A4)(B4) (a4_strut_boot) = $18.95
2 x Audi TT Control Arm Rear Bushing (A4)(A3)(B4) (ttcabusha4.jpg) = $37.90
------------------------------------------------------
Sub-Total: $639.18
IDEAL IDeal Economy (5-7 Days) (54 lbs.): $4.95
Total: $644.13

Then 2" lift kit from Metalnerd. $300 (Includes a $100 refundable deposit)

http://www.metalnerd.com/cat09.htm

I will send off the used injectors I bought this weekend. I am also trying to finish redoing my door panels. I got the top panel cut away from the old door panel and will try glueing it this weekend with Locktite Epoxy. Harbor Freight had a Dremel type tool for $24 that worked fine for cutting all the plastic welds. Left some nice stubs for gluing but not enough for plastic welding (my other choice).
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Old October 9th, 2015, 19:24   #10
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Well I worked on the door cards today. Replacing the top portion. Mine are painted to match the car so I didn't want to buy new and have to repaint if I didn't have to. I went to Harbor freight and bought a Dremel like tool ($24). I cut the existing welds down parallel to the stubs sticking up leaving the stubs as long as I could. I used a thin cutting disc for this. It pays to use a slow speed as the plastic gets hot and melts fast. Take your time too. There is a huge block of foam that needs to be broke free as well. I used a pry bar to get it to break free in one mostly large piece. It blocks some of the plastic welds. I cleaned everything up with alcohol. Then test fit the top piece to the bottom door card. The stubs were long enough to fit back in place and pretty much hold it together for gluing. I also bought some Loctite Heavy Duty Epoxy High strength Builders Formula. I used this to epoxy the pieces togeter with great results. IIRC the plastic was marked ABS on the inside of the door panels.


Here you can see the block of foam that had to come out to get to the tabs underneath, and all the finished epoxied tabs.



You can see how I just put the epoxy into the spaces where the tab were here.



Finished panel now looks like brand new (it is).


I will install this panel tomorrow and remove and do the other side. I broke the surround around the drivers window switches as it was brittle. Dealer had one for $28.
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Old October 9th, 2015, 19:24   #11
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Well I worked on the door cards today. Replacing the top portion. Mine are painted to match the car so I didn't want to buy new and have to repaint if I didn't have to. I went to Harbor freight and bought a Dremel like tool ($24). I cut the existing welds down parallel to the stubs sticking up leaving the stubs as long as I could. I used a thin cutting disc for this. It pays to use a slow speed as the plastic gets hot and melts fast. Take your time too. There is a huge block of foam that needs to be broke free as well. I used a pry bar to get it to break free in one mostly large piece. It blocks some of the plastic welds. I cleaned everything up with alcohol. Then test fit the top piece to the bottom door card. The stubs were long enough to fit back in place and pretty much hold it together for gluing. I also bought some Loctite Heavy Duty Epoxy High Strength Builders Formula. I used this to epoxy the pieces together with great results. IIRC the plastic was marked ABS on the inside of the door panels.


Here you can see the block of foam that had to come out to get to the tabs underneath, and all the finished epoxied tabs.



You can see how I just put the epoxy into the spaces where the tab were here.



Finished panel now looks like brand new (it is).


I will install this panel tomorrow and remove and do the other side. I broke the surround around the drivers window switches as it was brittle. Dealer had one for $28.
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Old October 10th, 2015, 10:55   #12
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Doin' it right.
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Old October 11th, 2015, 19:20   #13
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I am IN LOVE. That color is spectacular. I'm assuming it's not factory.

You've put a TON of love into that car. I hope she returns it!
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Old October 11th, 2015, 20:17   #14
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It is factory. Blue Lagoon Metallic says the Monroney label. LA5W LK

https://www.google.com/search?hl=en&...etallic+beetle

I like it better than cosmo green my last one was!
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Old October 13th, 2015, 22:49   #15
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IDParts suspension arrived today. Quick as usual. 57 lbs in 3 boxes for $4.95 shipping! No tax. I love ordering over the internet!

New OEM Beetle carpeted floor mats $88

New Shift boot $27
http://www.fixmyvw.com/new-beetle-shift-boots/

Spare Key and remote cut via picture w/VW emblem $68
http://www.fixmyvw.com/replacement-v...beetle-immo-3/

Flashzilla for Malone tune $180
http://www.malonetuning.com/flashzilla/

Once the DLC 520's come back a Malone stage 2 tune. $299
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