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Go Back   TDIClub Forums > Picture Gallery/Specs of Members' TDIs > Jetta/Bora/Vento TDI Picture Gallery

Jetta/Bora/Vento TDI Picture Gallery Do you have a Jetta/Bora/or Vento 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 June 7th, 2017, 21:58   #1
benIV
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Default Knurren: The Final Chapter - 2003 Jetta Wagon 5spd

In an homage to the previous owner, Growler, and all that he did, I'm retaining the name Knurren.
Knurren is such a smooth, fun, responsive ride. I have not had this much fun driving a car in quite a while. Well done Aaron.
Click here to see Knurren's history as documented in Growler's thread.
Knurren as it still is.
Just some pics I borrowed from Aaron's listing. I will later replace them with my own pictures



This is how Knurren came to me:
The Basics:
  • 2003 Jetta Wagon
  • WVW Germany built VIN
  • Reflex SIlver
  • 5 Speed.
  • 230k miles
  • Black cloth interior, non heated seats.
Exterior:
  • GTI Nose Swap 10/23/11
  • Depo Smoked E-Code Headlights w/fogs, LED City Lights, Glass Lenses
  • Very Dark tinted rear doors, tailgate. (20% Llumar) will be getting measured soon for NC Inspection
  • Dark tint (35%) on front doors again, NC has to measure it for inspection
  • Factory VW Steel Skidplate
  • LED turn lights on front fenders
  • Rear fog light
  • Aspherical mirrors
  • Rubstrips are painted with black textured truck bed paint This needs a little touch up
  • Shark fin antenna needs fixing
  • Class 1 trailer hitch
Engine/Transmission:
  • Brand new complete T4 .216 Injectors - Installed @ 145K (so 85k miles on these)
  • Malone Stage 3 Custom tune(17.5 PSI with Dynamic idle control, and 1050 RPM permanent idle) (installed on 9/3/11)
  • Borg Warner VNT17 (Installed 178k miles 9/15/12)
  • South Bend Stage 3 Clutch with 17# Flywheel - Installed @ 145K
  • Wavetrac LSD - Installed @ 145K
  • 3.16 Final Drive - Installed @ 145K
  • Timing belt was changed @ 176k on 9/30/12 full Boraparts Kit (~45k left on this system)
  • No EGR Cooler
  • OMI
  • 2.5" Whitbread Catless Downpipe (2/26/11 153k miles) to 3" catback exhaust with resonator and mufflerectomy installed (5/18/11 158k miles)
  • Frostheater
  • 10mm rebuilt IP installed at 154k miles to solve hard starting issues.
  • 92*C MK2 hotter Thermostat (163,700 miles 11/24/11)
  • Has been run on B20 for the most of the whole time? Aaron has owned it
Interior:
  • 2004+ Cupholder center console
  • Audi Mk1 TT pedals w/Beetle S Dead Pedal
  • Aluminum trim set w/ in-dash cup holders
  • Original Double-din Monsoon receiver
  • Full sized and fully functioning glove box YAY
  • McNally A pillar pod w/ EGT/Boost gauge (0-30psi) - EGT probe located between the two RRs in Garrett to read properly (2/26/11 153K miles)
  • Euroswitch
  • Monster mats front and rear
  • Armrest with broken (soon to be fixed) lid hinge.
  • Sunglasses holder where driver OS handle goes
  • Rear parcel cover
Wheels and Suspension:
  • 16" NB alloy wheels - Fuzion 205 55 16 tires
  • Koni FSD shocks in Front
  • Sachs shocks in rear (5/16/2014 199K miles)
  • VR6 front springs
  • Wagon rear springs
  • Audi TT front CABs (to be installed)
  • New Calipers, Rotors and Pads (2014 at 200K miles)
Part of the deal was this wondrous bevy of parts:

Work to be done:
  1. CABs, ball joints, TRE's to be replaced shortly
  2. Struts/shocks, springs to be replaced soon
  3. The trunk floor mat has a decent new oil smell coming off of it and it sort of fills the car. This is the same thing that happened to my jetta too. I've had some interesting thoughts about how to fix it and will be trying a few ideas with the jetta
  4. Fix the arm rest
  5. vtex cover piece missing
  6. figure out how to fix this one headlight so it isn't allowing moisture in anymore. I wonder if it jarred lose on the drive home?
As far as maintenance items, Aaron just changed the oil and fuel filters so I should be good for a while. The timing belt kit that is on there now has about 40-45K miles remaining so I've got a bit.
I am trying to find a way to only fill up with B20, whether that means driving a bit further to find a retail location or hooking up a trailer and filling up some drums with B100 to mix or B20. As far as I know the closest biodiesel retail location to me is 130 or so miles inland around the Raleigh area. I'll make the drive, but I'm coming back like a tanker convoy in Mad Max, lol. Is Furiosa available?
I'm happy that I was able to keep Knurren in the tdiclub family and hope I can keep this beautiful and fun car up to snuff for a long time.
My 6 year old daughter saw it for the first time yesterday and told me right away "Daddy, when I'm a bigger girl and can drive, I want that car" - so I've got my orders.
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod

Last edited by benIV; June 13th, 2017 at 18:17.
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Old June 7th, 2017, 22:15   #2
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Default The Story of How I got Knurren

Just so I can keep a little reminder of the trip to get Knurren:

I had a wonderful opportunity to purchase the type of car I've been wanting ever since I joined the club here and began learning about TDI's; a 2003 5m Jetta Wagon.

It's been a struggle finding what I wanted, for the price I wanted and being sufficiently assured that what I was getting was a car with a trustworthy history.

Needless to say, Knurren answered all these concerns. I had no concerns about buying Knurren from Growler, other than was I going to be able to take care of Knurren at least as well as Aaron had.

So I booked a flight. I left with a ticket to Columbus and ended up in Dayton. Aaron was a fantastic help and went beyond what I expected to help me get to his place.

(I'm not lying or exaggerating when I say the last 4 times my wife or parents have flown from here to Columbus- every single time- there has been some cancellation or problem in Charlotte and they've ended up in Dayton. It's very odd)

We spent a short day getting things wrapped up, had an amazing lunch at the little place down the road in his town. I just felt so excited and thrilled to finally have that piece of the puzzle to my TDI dreams. :roll eyes:

All joking aside, I was very happy with the car and how everything went. Aaron, you've got a great setup there, a great little town and thanks again!!

The ride home lasted from 2pm - 1130pm. It was gorgeous all through Ohio, but as soon as I found my way into WV, it rained.... and rained, and rained..

I got to Raleigh after 470 miles and topped off with some B20. Though it was still a good 120-130 miles from home, this was the closest place I could find using the biodiesel locator maps online. The fuel economy for that part of the trip worked out to . (Aaron had graciously gifted me a full tank of B20 for my trip.)

The last bit of the trip was the worst. It was raining so hard and for some reason NC doesn't believe in lane reflectors on the interstates, so I could barely see the road. Thank goodness there was still some traffic that I could follow. We spent a good 30-45 minutes on I-40 going about 30mph.

I went right to bed.

Some of the pictures from the trip:

Flight of the Sardines: (These little regional jets are no friend to burly men)


I haven't flown commercially for more than 16 years and I had forgotten how much I missed flying. It's amazing up there.


At Dayton's airport, they not only have clean rooms, but a great place to dispose of needles... but how do you get needles through security ... diabetic stuff maybe? idk. I just have never seen this before.


Lunch before leaving for Knurren's new home. (Knurren in the background)





Knurren meets Orville


The first morning at the new home


Out front with Orville
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod

Last edited by benIV; June 7th, 2017 at 22:19.
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Old June 8th, 2017, 04:09   #3
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Quote:
Needs new front wheel bearing holder to replace the cross threaded/almost stripped carrier bolt. (have to check with Aaron about this)
Ben, one of the caliper slide pins in the drivers front is barely hanging in there, it was on the list of issues with the car in 2010 when I got the car, I never had trouble with it, I replaced the brakes some time ago, and still never had any problems with it.

It can be fixed with a Heli-Coil, I just never got around to it because it never caused me any concern. There is no need to replace the whole knuckle and wheel bearing for an almost stripped slider pin. Yes, if that wheel bearing also needs replaced and you can snag a new knuckle from a boneyard by all means go for it

Knurren looks right at home down there with his new buddy Orville.

Who is Wilbur? (from your car details below avatar..)
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Old June 8th, 2017, 07:39   #4
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Quote:
Originally Posted by Growler View Post
Ben, one of the caliper slide pins in the drivers front is barely hanging in there, it was on the list of issues with the car in 2010 when I got the car, I never had trouble with it, I replaced the brakes some time ago, and still never had any problems with it.
It can be fixed with a Heli-Coil, I just never got around to it because it never caused me any concern. There is no need to replace the whole knuckle and wheel bearing for an almost stripped slider pin. Yes, if that wheel bearing also needs replaced and you can snag a new knuckle from a boneyard by all means go for it
Knurren looks right at home down there with his new buddy Orville.
Who is Wilbur? (from your car details below avatar..)
You can also get a caliper pin from a GM that is a standard thread, not metric. It is *slightly* larger threads so it will cut some new threads on installation, that can buy you some time with that stripped hole.
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Old June 8th, 2017, 13:31   #5
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Quote:
Originally Posted by Growler View Post
Ben, one of the caliper slide pins in the drivers front is barely hanging in there, it was on the list of issues with the car in 2010 when I got the car, I never had trouble with it, I replaced the brakes some time ago, and still never had any problems with it.
It can be fixed with a Heli-Coil, I just never got around to it because it never caused me any concern. There is no need to replace the whole knuckle and wheel bearing for an almost stripped slider pin. Yes, if that wheel bearing also needs replaced and you can snag a new knuckle from a boneyard by all means go for it
Knurren looks right at home down there with his new buddy Orville.
Who is Wilbur? (from your car details below avatar..)
I saw that in your thread and had wondered but wasn't realy concerned because either you didn't mention it or I didn't remember you mentioning it. lol. either way i was sure if it was something that needed to be fixed immediately, you would've made a point to make sure i remembered, lol.

anyway, as long as it's not causing problems, i'm not gonna dive into replace the knuckle just for the pin.

Wilbur was the name I was going to use when I got a wagon (before you listed Knurren for sale and I was searching for one) So after I got Knurren I decided that if you were going to use Knurren for another car I was going to use Wilbur but I preferred Knurren.

I figured having an Orville and a Wilbur made sense for a pair of Carolina TDI's
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod

Last edited by benIV; June 8th, 2017 at 13:33.
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Old June 13th, 2017, 18:17   #6
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Well there's one thing I forgot about until today. The A/C. Last Tuesday I bought a can to refill the refrigerant, mainly to see how long it'd last. I was hoping a month, but I guess it's a week and a week only. I have driven Knurren probably 100 miles this week, mostly highway, and honestly I didn't use the A/C all that much, but apparently the leak is big.

So I'm gonna check a few things. Maybe the order is wrong, but it's the order I've deducted from reading through multiple threads.

1. Check twin fan operation. - that was easy. Driver side fan not running in slow mode

2. Check clutch engagement. - Clutch doesn't engage at all....
3. Check the fuses (4 in total i know of, battery: S180, cabin: 5,16,25) - All these fuses check fine
4. Check the pressures
5. Check VCDS (fant test) - not sure if there is a fan test for the a4
6. RCV (refridgerant control valve)
7. Foam on the mix doors

Right now I'm not sure after all that. I find it hard to believe that one of those things isn't the problem.

I also have been told that the drier is something that is supposed to be replaced every 3-5 years. I'm gonna have to search some threads.
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod

Last edited by benIV; June 15th, 2017 at 06:49.
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Old July 12th, 2017, 18:36   #7
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Had a bunch of white smoke and then a CEL pop today. Finally put VCDS to work. Tried to run it without the car on, vcds didn't like it. Ran it with engine on, seemed to run fine.

Knurren is sitting at 230,759 miles. Gonna drive down the road tomorrow I think and test drive a 6spd 2015 passat tdi sitting in the lot and then also fill up on B20 since the closest place i can get it is 30-45 min from my town.

I started a thread about the smoke/cel/autoscan here

Autsocan Results:

Wednesday,12,July,2017,21:29:30:00816
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 17.1.3.0 HEX-V2 CB: 0.4336.4
Data version: 20170320 DS267.7
www.Ross-Tech.com


VIN: WVWSP61J83W580243 License Plate:
Mileage: 371370km-230758mi Repair Order:


Chassis Type: 1J (9M - VW Jetta IV (1998 > 2014))
Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
75 76

VIN: WVWSP61J83W580243 Mileage: 371370km-230758miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-012-AGR.lbl
Part No: 038 906 012 GN
Component: 1,9l R4 EDC G440SG 4308
Coding: 00002
Shop #: WSC 01266
VCID: 629EA334CD5F82175BD-4B3C
WVWSP61J83W580243 VWZ7Z0C7298552

1 Fault Found:
17056 - Cylinder 2 Glow Plug Circuit (Q11)
P0672 - 35-10 - Electrical Fault - Intermittent
Readiness: 1 1 0 0 1

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ABS.lbl
Part No: 1C0 907 379 L
Component: ABS FRONT MK60 0101
Coding: 0004097
Shop #: WSC 01266 785 00200
VCID: 3330167027255B9FE0B-5184

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 F
Component: 03 AIRBAG VW61 0202 0003
Coding: 12339
Shop #: WSC 01266
VCID: 2708F220E6FD273F4C3-5160

1 Fault Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 906 L
Component: KOMBI+WEGFAHRSP VDO V11
Coding: 04432
Shop #: WSC 00000
VCID: 313C1C78D839698F927-5160
WVWSP61J83W580243 VWZ7Z0C7298552

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 01266
VCID: 70BAD97C13B32087DD9-5160

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 8A Komfortgerát HLO 0003
Coding: 00259
Shop #: WSC 01266
VCID: 37282260365DB7BFDC3-4B1E

Subsystem 1 - Part No: 1C1959801A
Component: 8A Tőrsteuer.FS KLO 0009

Subsystem 2 - Part No: 1C1959802A
Component: 8A Tőrsteuer.BF KLO 0009

Subsystem 3 - Part No: 1C0959811A
Component: 8A Tőrsteuer.HL KLO 0009

Subsystem 4 - Part No: 1C0959812A
Component: 8A Tőrsteuer.HR KLO 0009

1 Fault Found:
01299 - Diagnostic Interface for Data Bus (J533)
49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio Labels: 3B7-035-1xx-56.lbl
Part No: 3B7 035 180 E
Component: Radio NP2 0008
Coding: 00031
Shop #: WSC 01266
VCID: 221EE3348DDFC2171BD-5160

No fault code found.

End----------(Elapsed Time: 07:54, VBatt start/end: 14.1V/14.3V)-----------
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod

Last edited by benIV; July 12th, 2017 at 19:08.
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Old July 13th, 2017, 03:43   #8
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I do believe I sent a 4 wire glow plug harness along with the car. If not, I would start there.

I tested those glow plugs and did change one of them before you came and got the car. I think it was either cyl1 or cyl 4.. they are easy to check with a simple ohm meter reading.

I do know that the GP harness was looking kinda crunchy in its old age.. the 2003s with the 4 wire system are easy to replace by just overlaying the entire harnsss up into the wire chase behind the battery.

with the white (whitish blue to me) smoke, I am thining that 230k miles and at least 100k of those being tuned might have caused some wear on the valve guides allowing some oil to drip past the seals when the car sits. the longer the car site, the more can build up, the bigger the plume. if it sat for a week it would put out an impressive plume when first started.. but it always went away after driving. if it is still smoking at idle after moving down the road a bit then that is new and likely should be investigated further.
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Last edited by Growler; July 13th, 2017 at 03:53.
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Old July 16th, 2017, 18:22   #9
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hey. yeah i found the harness. I'm gonna check all the plugs to start and replace the harness at the same time. I was reading through some of the posts about valve guide wear, so I"ll keep reading and see what I can do. I need to drive it more and as soon as I get this AC fixed it won't be as bad to drive it around lol. I did drive it again the other day and although a lot of smoke came out it did stop while driving.

Thanks for your help, again!
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod
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Old April 15th, 2018, 19:23   #11
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Sorry kooya, guess I never saw your post. The house was built in the early 50's, around the time this town/city was founded around the marine corps base here. It's right off of downtown, and was the place where all the doctor's et. al were building and moving into. 1-2 acre lots on a small creek off the river. There's maybe 10-20 homes in this neighborhood and almost all of them are either lived in by the original owner or a child and family of the original owner. This house was completely gutted for several years and a couple years ago was finally fixed up and added onto. It was a clean slate to work with since the only thing inside was the original oak floors and the studs. No plaster/drywall, never had been hvac... just some baseboard oil heat units and a double fireplace. Everything was in such great condition that it didn't need any repair work than some minor window issues. The roof needed new shingles but the roof structure and underlayment were unscathed.

Anyway, I got on to add this to the database of Wilbur (formerly Knurren).

I had been planning to do some work but several months ago hurt my back. Mild herniation has sidelined my ability to do a lot of the work I wanted to do with Wilbur and Orville, but found a good set of guys down near me to do the work that I can't wait on anymore.

I don't have any pictures yet of the completed work, but I'm going tomorrow or Tuesday to pick Wilbur up.

In the shop (East Coast Eurowerks in Wilmington NC)


I lost power steering right before I injured my back, so that was my main concern at the time. While I had them fixing that issue we saw that both front springs had fractured and several other components were very worn (which Growler had told me that they needed to be replaced, so I wasn't surprised by any means). I had them go ahead and replace the front suspension components Growler had as part of the purchase deal.





I want to do the back myself, and since the back wasn't as bad, I decided on waiting til I could do that in a month or two.

They also replaced the valve cover and vacuum pump seal to stop the leaks. The leaks weren't horrible, but the price wasn't bad and it was something I wanted done before they noted. The guys were very thorough and aren't pushy by any means. I am glad it's getting done, Wilbur deserves it. lol

Valve cover leak

Vacuum pump leak



Will have some more pictures after heading down to get Wilbur tomorrow. Finished work and what they took off. I've been told the struts looked like they were on the bottom of a boat .. lol. Guess Ohio DOT likes to use a lot of salt.
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
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1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod
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Old April 16th, 2018, 10:41   #12
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Yes, I would say that Ohio LOVES the new Brine solution.. however, I also got those struts USED from a guy in Michigan in 2010 they werent in that great of shape to begin with... KONI FSDs are nice dampeners, but can only do so much with the road salt.

Sure glad I sent all of those suspension bits along with you.

Glad to see the old wagon is getting taken care of.

sorry to hear about your injury. I hope you continue to mend up. I bet it feels like a whole new car after all the new suspension bits.
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Old April 16th, 2018, 18:51   #13
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Thanks Aaron.

I drove it home today... I can’t explain how much smoother everything felt, especially in the turns.

When I pulled into the parking lot, the front end didn’t look like it was dragging on the ground. (I thought back to my driving it home from Columbus to NC and wondered if I had damaged the suspension on the way through WV.)


Some of the old



The new stuff on


Some other pics while it’s up on a lift
I was a little more concerned about the rusty components, but the mechanic said it’s replaceable parts, that the wagon itself is in great condition, and nothing is so bad it needs replacing right now. So I’ll just add it to the list in case I have the time/money to do those bits.


I’m saving the back for my own job.


The mechanics asked if they could drive it to the alignment shop to test it out. I gave the go ahead, and they said they were surprised how quick it was. They were quite enamored with it. lol.

I wish I could’ve done the work, but I’m glad I was able to have a reason to connect with these guys. They’re helpful and the seem very honest, and they love talking tdi, almost to the point where my wife had to come in and tell me “let’s go”. lol

I think the work they did was great. They kept me informed and weren’t pushy, and they were more than happy to spend time explaining things. They put it back on the lift, walked me around, showed me what they did, answered random questions I had, etc. Hopefully these guys will be around for a while, especially since the only other shop down here I have seen recommended on the forums is closed for good.
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Orville, 2003 Jetta 5m Sedan, Platinum Gray
Wilbur (Knurren), 2003 Jetta 5m Wagon (Golf Variant), Reflex Silver

1974 Super Beetle Conv
1986 Mercedes 560 SL
1956 Chevy Truck - Hot Rod

Last edited by benIV; April 16th, 2018 at 18:55.
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Old April 17th, 2018, 03:45   #14
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Yeah, I do miss how fun that wagon was to drive. you stomp on it, it hesitates for 1/2 second or so and it just takes off and pulls and pulls.. that Wavetrac LSD is sooo nice.
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