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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old September 24th, 2015, 02:19   #1
cbman18j
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So I purchased an my first TDI about a month ago an 03 Jetta with 190K miles questionable last timing belt change. Previous owner said with in past 20K miles but I went ahead and did the following as a little insurance since I will putting 1000 mile on a week over three days. I changed the timing belt water pump, rollers, new fans (previous no low speed operation possibly rebuild old), serpentine belt tensioner, main radiator hoses, fuel filter, oil filter and oil (Shell Rotella T 5W40). I also cleaned the front two sunroof drain plugs. I put in a new alternator from NAPA because I couldn't get a voltage regulator in time to rebuild the old one. I now a voltage regulator hopefully I can get it fixed and have a spare. Now my A/C doesn't work. It did before all the work. Here is what it look like at its worst.
[IMG][/IMG]
[IMG][/IMG]
Now I need fix the A/C, glow plugs, and figure out this random leak on the front passenger side but at least I am now driving. Additional I need to get new battery tray and a panzer plate.
Thanks everyone I not could have done that timing belt without the forum articles

Last edited by cbman18j; October 3rd, 2015 at 10:55. Reason: Add Pictures
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Old September 24th, 2015, 02:47   #2
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Nicely done. That's a lot of work. I bet it feels good to have it all done.

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Old September 24th, 2015, 05:43   #3
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Yeah it does feel pretty good. I also swapped my seats to leather ones. Now I can start enjoying it with some confidence that the vehicle will not leave me stranded. That timing belt really had me worried prior to changing it. Does anyone know if VW is using plastic impeller water pumps because the one removed was plastic while new one was metal?

Last edited by cbman18j; September 24th, 2015 at 05:44. Reason: Added info
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Old September 24th, 2015, 10:28   #4
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My replacement water pump also has the metal impeller. I think that is what is available now.
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Old September 27th, 2015, 19:02   #5
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Turns out my acc wasn't working due to a wire being corroded. My leak was from the oil pan drain plug.
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Old September 27th, 2015, 23:06   #6
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as far as metal vs plastic: depends on the vendor. there are 2 thoughts; plastic is OEM, less power used to turn. metal; last longer.
you will have to do the research to determine what you want. on my next, i will go plastic. been told that is best.
i have metal now, close to 100K, been no faults. but, i believe the TDI guru: plastic is what VW designed it for.
want to swap to leather too. it has better padding. it doesn't last long in our environment: humidity and heat. but i still want it.
glad you got it on the road.
there are a few good threads on GP problems. main one is the harness, simple DIY fixes can remedy that.
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Last edited by deejaaa; September 27th, 2015 at 23:13.
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Old September 29th, 2015, 07:43   #7
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Quote:
Originally Posted by deejaaa View Post
as far as metal vs plastic: depends on the vendor. there are 2 thoughts; plastic is OEM, less power used to turn. metal; last longer.
you will have to do the research to determine what you want. on my next, i will go plastic. been told that is best.
i have metal now, close to 100K, been no faults. but, i believe the TDI guru: plastic is what VW designed it for.
want to swap to leather too. it has better padding. it doesn't last long in our environment: humidity and heat. but i still want it.
glad you got it on the road.
there are a few good threads on GP problems. main one is the harness, simple DIY fixes can remedy that.
I have a new glow plug harness and glow plugs because my current one is cracked in multiple places. I just haven't install them yet because I am waiting on my replacement battery box to come in.

The jetta ran pretty good this weekend on my 1100 my trip from Friday to Monday, but I got an overboost condition then limp mode. It appears that my actual boost would not regulate to 1.9 bar at full throttle but would stay at 2.2 bar or higher. I have new vacuum lines that I had planned to replace later but it appears this will be moving up the priority list.

Updated:
Following the troubleshooting guide for overboost/limp mode.
I unplugged the MAF and no over boost. Vehicle would regulate to the correct boost level at full throttle with MAF disconnected. I cleaned the MAF last night and will check today if it fixed the problem. The one thing I didn't do was very it would still overboost prior to disconnecting the MAF last evening.

Another update:
Hooked up MAF this afternoon and it went into limp mode again. Just for my sanity a unplugged it again and no limp mode or overboost no matter how long I held full throttle in 4th or 5th so I guess this means my MAF is bad???

Last edited by cbman18j; October 7th, 2015 at 05:24. Reason: Update info
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Old October 7th, 2015, 05:38   #8
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Update
Based on another members tip I did some additional troubleshooting on my overboost problem prior to replacing my MAF with my mityvac. When I remove my the hose from the vac on the N75 valve I get the appropriate amount of vacuum. I then connect to hose going to the n75 actuator it starts to move at 3-5 inHg but it doesn't hold vacuum and I have to continue to pump it. It appears that either I have a leak in the hose or will need a new N75 actuator. Hopefully this evening I can get my mityvac on the actuator to rule out the hose.
As a side note does anyone near 31404 have a known good MAF I can use as a second check prior to purchasing a new one.
Update 10/8
Well I replaced the vacuum line fron the N75 to the actuator. While I had the vacuum line of I checked the actuator and it would not hold a vacuum. Additionally after I attached the new vacuum line, I executed the N75 test with my VAGCOM and I could see the level move from one direction to another. It looks like I need a new VNT actuator which I will be ordering. I am a little skeptical if that will solve my issue. Fingers crossed.
Update 10/12
I fixed my broke glow plug harness and replaced the glow plugs, so far no more glow plug faults. I am making some progress.


Last edited by cbman18j; October 12th, 2015 at 17:22. Reason: Update
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Old October 16th, 2015, 12:39   #9
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I got my new VNT actuator from idparts installed last night, the lever on the turbo moves fine, vanes don't appear to be sticking. I adjusted everything per the TSB. :-) So here is were the fun starts I got up early this morning, 0500 in order to test out my new VNT to see if it solved my overboost problem prior to going to work. I get the vehicle off jack stands. Crank the vehicle it starts as I am bagging down the driveway, it dies notstrange noises of anything almost like someone cut off the fuel or ignition. I try to start it a few times I get RPM movement on the tach but no joy. I push it back up the driveway which is a slight incline. The first think I think is did my timing belt break or jump a tooth. I know over dramatic. I pulled the timing cover and but the transmission in N so that I can turn the engine by hand to check the belt and timing. The IP and crank were both still aligned. I even used a mirror to verify IP alignment whole, but I didn't check the camshaft yet. My last fill up was 494 miles ago. My timing belt and fuel filter change was completed ~3000 miles ago and I was on the green line on the VAGCOM. I hooked up the VAGCOM and the only thing there was something pending about injection window I will update with the actual code when I get home. Hopefully it is something simple and cheap. As a side note I did remove the battery cable this morning and reinstall it. So I need to check for fuel going into and out of the IP at the injectors. I am not sure which no start section to use. Should I use the one about driving then dies or just crank but no run.

Last edited by cbman18j; October 16th, 2015 at 12:42. Reason: Add info
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Old October 20th, 2015, 16:56   #10
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I did some troubleshooting on my no start using the information provided and it looks like my IP died. :-) I found one reasonably local that is being shipped to me hopefully by Friday I will be up and running. After I finished troubleshooting I decided to clean my intake and EGR. It wasn't as clogged as some of the ones I have seen on here but it definitely needed.



I also started install my panzer plate. To be continued.

Last edited by cbman18j; October 20th, 2015 at 17:07. Reason: Add pictures
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Old October 21st, 2015, 21:11   #11
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I am not looking forward to cleaning my intake and EGR... Bigger jobs to tackle at this time lol

I look forward to seeing some install info for your panzer plate. I'm thinking about getting one for my Jetta soon!
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Old October 28th, 2015, 08:07   #12
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I got the replacement IP installed last night after verify all timing in good order. While i was there I also replaced the thermostat and its housing and a couple of vacuum hoses that looked rough. Everything fired up after priming the new fuel filter, IP, and bleeding the injectors. I also noticed my driver's CV axle boot is torn and I need another passenger rear caliper. Hopefully get the front end back together this evening because I also replaced my AC receiver dryer and get my cv axles pulled or should I wait until I have more time.
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Old October 29th, 2015, 06:10   #13
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This morning I was able to drive the Jetta, finally. I checked my timing and it seems to be advanced quite a bit but still inside the normal range. I also checked my boost cmd vs actual and it seems that the cmd vs actual is out of wack at full throttle. I don't let it go into limp mode this time since I was on my way to work, more to come. I did some logging today and it looks like the actuator resolved my overboost/limp mode issue. The cmd vs actual that I thought was out of wack was me not giving the computer time to work. Since I purchased the vehicle this has been the first time I can use all of my go pedal. Thanks everyone for the information on the forum. More to come. I forgot to add that I recharged my AC after changing my high pressure valve and my receiver dryer so I now also have AC just in time for winter.

Last edited by cbman18j; October 29th, 2015 at 18:48. Reason: Update info about overboost
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Old November 3rd, 2015, 07:52   #14
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Quote:
Originally Posted by Drunken_Unicorn View Post
I am not looking forward to cleaning my intake and EGR... Bigger jobs to tackle at this time lol

I look forward to seeing some install info for your panzer plate. I'm thinking about getting one for my Jetta soon!
The panzer plate was a fairly easy install except the passenger side front mount due to my inter cooler bracket being in the way which I had to bend in order to get my wobble extension on the bolt. I didn't take pictures during the install because i always forget unless someone reminds me, but I will get a couple in order to show you later.

I did some logging of my cmd vs actuall boost. I thought it would trip overboost but didn't, maybe the actuator fixed this issue hopefully I can get the data posted this week. I also got my first official 700+ mile tank with pic. :-)

The road was wet for portions of the trip and I used AC which I haven't been able to do because it didn't work. Jetta seems to be running good even with the new to me 11mm pump. I can't really tell if there is any power difference because I was fighting the overboost prior to needing to replace the IP.

Last edited by cbman18j; November 3rd, 2015 at 08:02. Reason: Add pic and info
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Old November 5th, 2015, 07:21   #15
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So I got around to logging some data, I am not sure if everything is operating per spec. I will try to add a chart but for some reason I can't post picture right now here is the data. Everything was going well then I got another random limp mode. Should I adjust my actuator more but I did the adjustment based on the TSB. :-(

Group A: '011
Engine Speed Boost Boost Charge Pressure
TIME (G28) Specified Actual (N75) Solenoid
STAMP /min mbar mbar %
0.38 1470 999.6 989.4 37.5
1.48 1491 1142.4 1009.8 29.9
2.6 1596 1764.6 1264.8 30.3
3.71 1743 1846.2 1662.6 40.2
4.82 1911 1938 2009.4 53
5.92 2058 1948.2 2244 68.1
7.01 2226 1948.2 2335.8 78.9
8.09 2373 1948.2 2346 89.3
9.17 2499 1948.2 2274.6 94
10.25 2625 1948.2 2172.6 93.6
11.33 2751 1948.2 2009.4 91.6
12.41 2856 1948.2 1683 77.3
13.49 2940 1948.2 1479 66.5
14.57 3024 1948.2 1570.8 66.5
15.65 3108 1948.2 1652.4 66.5
16.73 3213 1948.2 1713.6 67.3
17.81 3318 1948.2 1774.8 66.9
18.89 3423 1948.2 1846.2 64.9
19.97 3528 1948.2 1887 64.5
21.05 3612 1948.2 1907.4 64.9
22.13 3717 1948.2 1927.8 64.5
23.21 3801 1948.2 1927.8 64.5
24.29 3885 1948.2 1927.8 65.7
25.37 3969 1948.2 1938 65.7
26.45 4053 1938 1938 66.5
27.53 4116 1917.6 1927.8 67.3
28.61 2814 1030.2 1122 60.6
29.69 3003 1040.4 1020 53.4
94.11 1911 1009.8 999.6 40.2
95.22 1911 1081.2 999.6 44.6
96.34 1953 1448.4 1193.4 33.9
97.43 2079 1897.2 1693.2 37.5
98.51 2226 1948.2 2131.8 59
99.59 2373 1948.2 2315.4 74.5
100.67 2499 1948.2 2335.8 84.5
101.75 2625 1948.2 2274.6 90.4
102.83 2730 1948.2 1989 86.5
103.91 2835 1948.2 1642.2 70.5
104.99 2898 1948.2 1560.6 65.3
106.07 2982 1948.2 1672.8 66.5
107.15 3066 1948.2 1734 66.5
108.23 3150 1948.2 1785 64.9
109.31 3234 1948.2 1856.4 64.1
110.39 3318 1948.2 1907.4 64.1
111.47 3381 1948.2 1907.4 63.4
112.55 3465 1948.2 1927.8 63.8
113.63 3528 1948.2 1938 63.8
114.71 3591 1948.2 1938 63.8
115.79 3654 1948.2 1938 64.5
116.89 3717 1948.2 1938 64.9
117.97 3759 1948.2 1938 64.9
119.06 3822 1948.2 1938 64.9
120.13 3885 1948.2 1948.2 65.7
121.21 3927 1948.2 1938 66.1
122.3 3969 1948.2 1938 66.5
123.37 4011 1948.2 1948.2 66.5
124.47 4011 1091.4 1744.2 94.4
125.56 2583 1020 1071 57.4
126.64 2961 1040.4 1040.4 51

Last edited by cbman18j; November 5th, 2015 at 07:31. Reason: Add data
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