YUP! My BEW intercooler met the same fate! You didn't hear it "chuffing" at idle? I heard the "chuffing" for awhile before I was finally able to finally pressure test my system.Today I found the reason for my recent frustrating bout with limp mode.
And a little closer view:
It would appear that the shroud that hangs in front of the intercooler and is intended to direct air into the intercooler has, in my case, worn a stripe through the bottom outside of the aluminum tubes. This is what caused my limp mode (charge pressure negative deviation, or words to that effect).
I found this and was lucky enough to find a local guy who is parting out several VWs and had an intercooler. I installed it and the limp mode is gone.
Unfortunately, the performance is still rather anemic. I am thinking at this point that the large nozzles I was trying out (Bosch 1019s, 216 um) combined with the lack of boost clogged the aftermarket catalytic converter (another ugly story - I HATE inspections). How best to clean that out, if it is indeed the problem I think it is, is the next chapter in lost performance. I've changed back to stock nozzles, not that it helps the anemic performance. Sigh...
Cheers,
PH
Did the 1.8T gasser and the 1.9 TDI use the same Intercooler?https://www.ebay.com/itm/Side-Mount...=1617987839106ec38640f6804118aaec309ff52a6cd8
Powder Hound,
Get one of these, and leave the big nozzles in.
Found a screw in my tire. Tire was at 10psi, bumped it up to around 35psi, I'll check it tomorrow to see how bad the leak is. Tire has warranty, so I'll be taking it in first thing Monday.
Did an oil change.
Replaced my large fan, it works now.
And also drained and replaced my trans fluid; around 2.1 quarts of Pennzoil synchromesh. Although, I'm concerned now, i notice this Synchromesh has "API GL-3 level performance." And i have read here something of us needing GL4 for our mk4s. What say you smart folks?
Is it the right or wrong stuff?
(Pennzoil synchromesh for GM 12345349 and 12345577 meets 9985648 and Chrysler 4874464 meets MS-9224)
Sent from my VS987 using Tapatalk
Did the 1.8T gasser and the 1.9 TDI use the same Intercooler?
Old ears - and no, I didn't. I did a little driving yesterday before digging into the system (pulling enough stuff off to see the extra oil on the outside of the intercooler) and thought I could hear a boost leak somewhere.YUP! My BEW intercooler met the same fate! You didn't hear it "chuffing" at idle? I heard the "chuffing" for awhile before I was finally able to finally pressure test my system.
SentOld ears - and no, I didn't. I did a little driving yesterday before digging into the system (pulling enough stuff off to see the extra oil on the outside of the intercooler) and thought I could hear a boost leak somewhere.
I just don't drive it much right now.
csstevej: I did that a while ago, but did it by cutting and then re-welding the 'can'. An overzealous inspector* accused me of cutting out the cat's gut and forced me to replace it with an aftermarket unit. Performance has been on a downhill slide ever since, so I'll have to figure out how to do it without external evidence. Note to self and any interested parties: don't try and weld stainless, particularly thin, rusty 409 crap that barely qualifies as stainless, with a flux core mig welder with no gas. Welds horribly, looks like crap, and has a few other onerous ugly qualities I would just as soon forget.
Anyway, it'll probably take me a while to finish this cure out as I have some other very pressing projects to occupy me right now. The CEL is out, the error isn't returning, so I'll ignore it for the moment.
Cheers,
PH
* - I don't hold it against the guy. He was under severe pressure from a state eunuch who thinks it is his calling in life to make things difficult for people who actually work for a living. I figure the state twit is a disappointed bureaucrat who thinks he ought to get statues built in his image for his tree hugging attitude while seeking breathable exhaust from the rest of us.
Every single thread about this is just like your reply. DO NOT USE GL5, USE GL4.You would be better off running a GL-4. The lubrication additives help with synchronizers and smoother shifting. Don’t use GL5 because it may say meets GL4, which is true, but is actually too slick and causes grinding between gears. Fried had that issue and we switched to a high quality GL4 and smooth as new.
I used Amsoil GL-4 gear oil which meets VW specs and shifting smoother out a lot.
06 Golf 5MT, BEW, Kerma tune, Catectomy, Bypass oil filter system
I'd read alot of the threads about it.A lot of people (including me) use Synchromesh (Pennzoil number 3501) in 02J transmissions. I find it's better than the OE gear oil, particularly in older transmissions, as it smooths shifting and helps minimize issues with worn synchros. I have it in 4 TDIs right now, including my son's 400K transmission that was grinding on the 3/4 shift before the synchromesh went in. Problem solved. Lots of people here have had similar results.
The technical data sheet I found https://www.evolubesupply.com/content/docs/dfec1cc5-4f28-4910-b894-a22d2dbaa35e/pds.pdf makes no mention or GL4 or GL5. Does say "excellent yellow metal compatibility."
If I had a nickel for everything different on the '99.5...It was challenging on the Golf because the '99.5 has different plumbing to the vents than later cars.
I have stretch bolts on my car. I've loosened and reused them three times. For a stock car I'd say it's a safe gamble, especially if fuel economy has taken a hit.Among other things, I checked my fuel injection timing.
It was retarded.
But, it was within spec with stretch bolts, so I'm going to save it for my next TB job.
It's amazing how much extra wind noise there is when those seals are missing, and they nearly always are after a visit to the body shopWind noise is significanlty less. I'm surprised at how quiet this car is overall.
With these seals missing, did you have a problem with water entering the cabin? I might be missing one of these on one of my Golfs.Discovered that my '99.5 Golf is missing a seal on each front door. The body shop probably removed these when painting the car and I didn't realize it.
They're so bloody expensive that I took to Kraftwerke to have Chris put them on. Didn't want to make a mistake.
Wind noise is significantly less. I'm surprised at how quiet this car is overall.