rocketeer928 - My 2003 VW Jetta TDI

blacksheep

Veteran Member
Joined
Apr 14, 2005
Location
Phoenix, AZ
TDI
2000 JETTA TDI GLS
Hopefully you get that exhaust kink worked out! That has to irritate you more and more as time goes by.
 

shizzler

Veteran Member
Joined
Jun 25, 2005
Location
Ann Arbor MI
TDI
05 BEW Wagon
Yeah I hear you on the exhaust problems. When I added just a downpipe to my setup, it pushed the middle pipe into its hangar support. I lived with it by wedging a piece of rubber fuel hose in there to buffer it, but not for long. After a week it snapped the hangar welds off the factory pipe and everything went loose, sending various portions of the cat back pipe into heat shielding. That sucked. I had to slice and re-weld my downpipe to fix it.

But really, the heat shields are not necessary whatsoever. Diesel exhaust runs so cool most of the time. After the CAT especially. I say pull em out next time you have to mess with it. You could also add a couple more generic hangars in at strategic points to prevent the system from sliding around on you.
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
Shark Fin Stereo Antenna

Last Sunday it was a warm, sunny November afternoon, so I washed my Jetta TDI and installed a Visual Garage Shark Fin Stereo Antenna. I used their installation instructions, which were very good. Here’s recent pictures of my car with the shark fin antenna and the snow tires on the stock wheels installed.

My first assessment of the antenna is that it looks decent, the paint matches perfectly, and the FM stereo reception seems to be good so far. I think I may have lost AM radio reception. When I’m not using my iPod nano in the car, I listen to news and talk radio, so if the AM reception is indeed lost then that might become a problem. I kept my OEM antenna in case the shark fin antenna doesn’t work out.







Update: After trying out the shark fin antenna for a couple of days, I believe that I made an $80 mistake. The AM reception is definitely gone for stations I listen to from NYC and Hartford. The only AM station that sort of comes in is from my local area. The FM reception is dicey at best. The station from Fairfield, CT that I normally listen to comes in, but is a little choppy. Other stations I occasionally listen to from Bridgeport and Hartford don't come in well at all. So, I think this experiment will come to a fateful end, and I'll be pulling out the dental floss and Goo Gone, and going back to the OEM antenna.

I brought this up with Visual Garage and their response was: Yes, there is some reception loss possible when compared to the OEM stock antenna, however our shark fin is usually always better than the stubby antennas that are a popular option as well.

Yeah, well, that's not good enough. It's coming off this week!
 
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rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
brucebanes said:
Why is AM reception so crappy in the TDIs? Is their a work around for this?
I find that when living among hills, AM reception is bad in just about every car I've had. My concern is that the way the shark fin is designed, I may now have no AM reception. I need to check it out more today.
Jordan_Elias said:
that fin seems larger than some others ive seen. Or maybe im wrong, looks sharp with the color match tho
I agree. It does seem a little larger than usual. However, it has to fit around the base of the OEM antenna.
 
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rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
PD In-Tank Lift Fuel Pump

In anticipation of possibly adding an 11-mm injection pump, larger nozzles, and RC5 next year, I decided to add a PD In-Tank Lift Pump. I bought the pump and installation kit. I pretty much followed the installation guide provided by ID Parts. Except for a couple of ground wires and the power wire from the top of the battery where I used crimp connectors, I soldered all of the wires to avoid wires from coming apart and causing future problems. Also, the colors of the wires described in the installation guide weren’t the exact colors provided in the installation kit.

Removed the engine cover and upper stress bar.





Removed the MAF connector, vacuum connection, and airbox.





Removed the two windshield wipers.





The wipers were on tight and I had trouble removing them simply by wiggling them off, and I didn’t have a proper removal tool. I tried improvising with a to-be-unnamed tool, and I managed to crack the windshield, even though I was trying to be careful.



Actually, cracking the windshield was a blessing in disguise. When I bought the car I was very surprised at the amount of pitting on both the body and windshield. I am convinced that the lady who owned the Jetta before me drove behind a sanding truck every day on her way to work. So, thanks to full glass coverage on my insurance, I now have a new pit-free windshield. Now, I really want to have my car repainted.

Removed the windshield water deflector.



 
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rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
PD In-Tank Lift Fuel Pump Continued

Removed the covers to the wiring plenum and relay box, and pulled the relay tray out. I also removed relay 100 and 53, so that I could work in the box easier.





Here is the black and white wire on the injection pump. I did not splice into the wire here, but rather within the wiring plenum. I wanted to make certain which wire I was looking for, so that I didn’t splice the wrong wire.



Fished through the middle wiring bundle and found the same black and white wire.



I sliced through the plastic insulation of the black and white wire in the wiring bundle. I soldered and taped up the pink signal wire from the installation kit to the black and white wire.







Fed the pink signal wire into the relay box, and soldered and wrapped the copper-ended repair wires to the pink signal wire. Inserted the signal wire through the purple lock and pin position 4 of the lift pump relay housing.



Wired the yellow power wire from the connections on top of the battery, through the wiring plenum, into the relay box. I also soldered in a 30-amp in-line fuse. Soldered and wrapped a repair wire to the power wire, and inserted it through the purple lock and pin position 8 of the lift pump relay housing.

 
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rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
PD In-Tank Lift Fuel Pump Continued

Wired the brown ground wire from GND 608, which is close to the ECU, down the wiring plenum, and into the relay box. I used vacuum tubing to cover the ground wire within the windshield cowl into the wiring plenum. Liquid detergent helped to feed the vacuum tubing onto the wire. Soldered and wrapped a copper-ended repair wire to the power wire, and inserted it through the purple lock and pin position 6 of the lift pump relay housing. Page 97-6 in the Bentley manual shows where GND 608 is located.







Wired the yellow 16-foot pump wire across the windshield cowl, through the wiring plenum, and into the relay box. I used four sections of vacuum tubing to cover the pump wire within the windshield cowl into the wiring plenum, wrapping each section connection with electrical tape. Liquid detergent helped to feed the vacuum tubing onto the wire. Soldered and wrapped a repair wire to the pump wire, and inserted it through the purple lock and pin position 2 of the lift pump relay housing. Tied down the vacuum hose covered pump wire along the front of the windshield cowl with cable ties to the passenger side.





Clipped the purple lock into the relay housing, connected all the relays, replaced the wiring plenum cover, replaced relay box, and replaced the airbox. So that the relay box cover would fit, I had to stuff the fuel pump relay into the relay box.





The installation guide indicates that there is a rubber grommet within the windshield cowl on the passenger side. In my car, I could see where the grommet was supposed to be located, but it was just metal. First, I removed the cabin filter and its holder with a 10‑mm socket. Then, I carefully drilled a hole, removed the interior door sill and footwell trim, and fed the pump wire into the cabin. After inserting the pump wire, I spread some silicone sealant around the wire and hole.



 
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rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
PD In-Tank Lift Fuel Pump Continued

Fed the pump wire underneath the front and rear door sill trim to the fuel level sender unit under the rear seat. Along the way, I tied the pump wire to the other wires under the sill.



I removed the cover to the fuel level sender unit, and found a surprise. There was bird seed and shells on top of the unit. I do remember last winter finding a mouse nest on top of the cabin filter full of my firewall insulation, and also evicting the mouse one cold morning. I saw the mouse drop from underneath the car and scampering away. This must have been its food stash.



Removed the connector on top of the fuel level sender unit and the brown/white and black/purple wire clips from the connector using my extractor tool.



Inserted the black/purple wire into pin 2 and the brown/white wire into pin 3 of the new 4-pin connector.



Soldered a repair wire to the pump wire and inserted into pin 1 on the 4-pin connector. I took another repair wire and installed a crimp ring-terminal to it and inserted into pin 4 on the 4-pin connector for the ground. Drilled a small hole into the metal near the wiring and attached the ground wire with a sheet metal screw.



Disconnected the blue and black fuel lines from the top of the fuel level sender unit. This was rather difficult to do as they were on rather tight, requiring long pliers, a lot of straining, and a good deal of muscle. Not fun!!

Edit from tstdimk4 Dec 2013: At the base of each 90 there are 2 tabs 180 degrees apart. You simply push those in and pull up and the lines come off very easily.



What’s the deal with the little filter on the black fuel line? Assuming it is a filter, it seems like it could easily become clogged and cause a problem.

Using a large file and a mallet, unscrewed the black retaining ring on the fuel level sending unit. This also was difficult to do because it was on very tightly. For a while, I thought that I was not going to be able to get this retaining ring off, but after a lot of whacks it finally started to unscrew.



Pulled out the fuel level sending unit and the grey, rubber O-ring.



Never having seen the inside of a fuel tank, I was pleasantly surprised how clean it was inside the tank. There were a few particles and I pulled out a small piece of silver foil usually found on fuel additive bottles, but overall it was really clean. I guess I was expecting to see some sort of sludge on the bottom of the tank. Glad there wasn’t any.

Inserted the new in-tank lift pump into the fuel tank. I found it easier if I first slipped the large, gray O-ring onto the lift pump and then made sure everything seated correctly. Reinstalled the black retaining ring and the fuel lines, and then attached the 4-pin connector.



Reinstalled the cover, replaced the carpet, and put the seats back into their upright position. Turned the ignition key to the “on” position and the fuel pump started working. The car fired up without a problem.
 
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n8ronJ

Veteran Member
Joined
Oct 11, 2007
Location
Niagara Frontier - Somerset, NY
TDI
2014 BMW 328d XDrive, 2003 Jetta GLS TDI 5speed Platinum Grey (sold), 2010 Jetta 6speed (bought back)
Rocketeer928, I love following your thread. I'm just hoping that I'll be able to go mod-happy within a couple years. The children are still young and time/money is short.

You had pitting on the windshield too? I've been hoping that the two tiny cracks in my windshield will finally grow big enough for a replacement. That shiny speckling in the sun is annoying to look through. It's possible that I'll need to help the cracks along....

I hope that replacement antenna works well for you. But losing AM radio just stinks. I'm quite an AM junkie myself. I wouldn't want to go without it.
 

mech644

Veteran Member
Joined
Feb 7, 2007
Location
Blue Hill, Maine
TDI
'00 Golf, '14 Touareg
1st of all- you are your own warranty, if you put the hammer, your hand and arm thru your windshield don't blame me.

wishing your windshield cracks would get bigger? take a piece of 2x4 about 6" long and lay it on the windshield over the crack and hit the block with a hand sledge or small mall. start with an easy tap and then look at the crack, keep increasing force until crack starts to get longer.
 

n8ronJ

Veteran Member
Joined
Oct 11, 2007
Location
Niagara Frontier - Somerset, NY
TDI
2014 BMW 328d XDrive, 2003 Jetta GLS TDI 5speed Platinum Grey (sold), 2010 Jetta 6speed (bought back)
I haven't been in a big hurry. I figured I would let it crack on it's own. I need to time it for when I get vanity plates for my car so that the new registration sticker goes on a new windshield rather than transferring from one to another and having the sticker fall off (or have to use tape - yuck!)

Back on topic: Nice car.... :)
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
I had to re-apply my CT registration sticker, and it's frayed and barely hanging on. Doesn't expire for almost two years from now. I could get a new one from the DMV for 20 bucks, but the various governments get enough of my hard earned $$$ in the form of taxes and I'm not willing to give anything extra. Might have to use some tape.

I have to say, not much beats a clear view through the new windshield.
 
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n8ronJ

Veteran Member
Joined
Oct 11, 2007
Location
Niagara Frontier - Somerset, NY
TDI
2014 BMW 328d XDrive, 2003 Jetta GLS TDI 5speed Platinum Grey (sold), 2010 Jetta 6speed (bought back)
I just got my new sticker 2 months ago and it's dangling off already. These NY stickers are getting worse and worse I think. It must be "environmentally friendly" stickum. And we are on that 2 year deal too.

I just noticed in your pictures that you have a spoiler on the back. Is it just for looks? does it affect the ride at all?
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
n8ronJ said:
I just noticed in your pictures that you have a spoiler on the back. Is it just for looks? does it affect the ride at all?
The spoiler came stock with the car when I bought it, so I wouldn't know the difference in drivability.

Sometime next spring, summer, or fall we plan to come to Middleport to visit my folks and sister's family. We should get together then and chat. No decision yet on dates. Perhaps by then I'll be ready to sell you those PP520 nozzles you are craving from me.
 
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n8ronJ

Veteran Member
Joined
Oct 11, 2007
Location
Niagara Frontier - Somerset, NY
TDI
2014 BMW 328d XDrive, 2003 Jetta GLS TDI 5speed Platinum Grey (sold), 2010 Jetta 6speed (bought back)
Oh you tease me....

And on the otherhand, when Ho5G is scheduled again I'm going to try and make the trek east again.
 

shizzler

Veteran Member
Joined
Jun 25, 2005
Location
Ann Arbor MI
TDI
05 BEW Wagon
So any noticeable gains from the lift pump?

How long did the install take? The TDIparts directions and your posts make it seem like a hell of a job, considering its really just adding a relay and a power wire back to the new pump plus a ground....


Did you do the LCR mod to the lift pump first? (vacuum t-fitting to allow fuel to be pulled around pump, should it fail). If not, I would look into it. If that pump dies you will be stranded.
 

AThreeTdi

Veteran Member
Joined
Oct 10, 2005
Location
NJ
TDI
06 jetta Tdi , 03 jetta Tdi
shizzler said:
So any noticeable gains from the lift pump?

How long did the install take?
Interested to know about these 2 questions also, about to do this mods also. Nice write up!
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
I haven't really pushed the car since I installed the lift pump, so I'm not yet sure about noticeable gains. Frankly, I did this now for future benefits, such as when and if I add an 11-mm IP and larger nozzles.

I would say the install took me about 6 hours total. I was on vacation and I have a pickup, so I split the work over several days. I took my time, and I'm sure soldering rather than using crimp connections extended the time. I didn't want inaccessible crimp connections giving out.

Didn't know about the LCR mod, so I'll have to look into that. I had a '89 Ford Escort as my first new car, and its fuel pump failed while on the road, so I know what it's like to be stranded.
 
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n8ronJ

Veteran Member
Joined
Oct 11, 2007
Location
Niagara Frontier - Somerset, NY
TDI
2014 BMW 328d XDrive, 2003 Jetta GLS TDI 5speed Platinum Grey (sold), 2010 Jetta 6speed (bought back)
I had a '86 Dodge Daytona with a finicky fuel pump. Sometimes whacking the gas tank with a stick or rock would wake it up.
 

Concat

Veteran Member
Joined
Oct 6, 2009
Location
Edmonton, AB
TDI
2005 Jetta GLS TDi
Hey dude, thanks for the info on that shark fin. I was gonna get one myself. I think the stock antenna looks so... well lame.

Perhaps I will have to go with an alternative... a shorter chrome one or something.
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
Dumped the Shark Fin Antenna

I took the shark fin antenna off. No more messing around with the antenna. I'll just be content with what I have.

Here's some pictures of my Jetta TDI in winter mode and the day before New England Dyno Day 2009.







I bought the "turbo diesel inside" decal off of eBay. The blue matches my brake calipers and the boring CT rear license plate.



 
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rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
Dyno at Dent Sport Garage in Norwood, MA on 5 Dec 2009

Modifications at the time include:
  • Rocketchip RC4/EGR Delete Chip Tune Software
  • DC Stage III+ Clutch and 17.5 lb Flywheel
  • PP520 Nozzles
  • 17/22 Hybrid Turbo
  • 3-Bar MAP
  • EuroJet SMIC with MAF voltage switched pulling fan
  • 0.658 Fifth Gear
  • PD Lift Pump
  • 2.5-inch Downpipe & CAT-back Stainless Steel Exhaust
  • OMI Turbo Intake with DEI Titanium Exhaust Wrap
  • Upgraded Intercooler Pipes
  • Dieselgeek By-pass Oil Filter, DG Short Shifter, DG Panzer Skid Plate, DG Race Pipe and DG EGR Delete
  • TDI FrostHeater
  • CAT Fuel Filter
  • McNally Boost/EGT Gauge
  • Enkei 17-inch Silver Wheels with Yokohama 235/45R17 Tires
  • Drilled and Slotted Rotors
  • Rear Fog Lamps
  • Headlights with Fogs and LEDs
  • LED Taillights and Signal Lights
  • LED-strip Trunk Lights
  • G2 Blue & Black Painted Calipers
  • Koni FSD Struts/Shocks
  • Ventectomy
  • Rear & Upper Front Stabilizer Bars
The stock engine is rated at 90 hp / 155 ft-lbs torque. At 137 hp / 245 ft-lbs torque, this translates to an increase of 52% hp / 58% ft-lbs torque.


 
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IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
I know you wanted the numbers to be higher, but those are great curves, especially the nice flat HP curve. Looking good. More fuel and a bit more air and you'll see better, I'm sure.
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
Thanks for the encouragement. I know you are right, and yes, I was happy about the flat HP curve.

On my way to the elusive 150 hp. Bought a PD 150 intake manifold, EGR, and elbow pipe from RyanP in the UK today. I didn't realize until I talked to Mr. Chill that the PD 150 made that much of a difference. TDI Club is so informative!

Next month, I'll look into getting bigger nozzles and a PD 150 race pipe. Then RC5??? We'll see.

On advice from you IBW, I might stay away from the 11-mm IP to maintain my mileage. I'm not trying for Jason, JoeTDI, or Delvi type of numbers for my daily driver. Their cars rock!!!
 
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tothemax

Top Post Dawg
Joined
Aug 7, 2006
Location
Nevada
TDI
TDIs: 2003 Jetta, 2016 Q5 3.0
Great numbers and curve. I love how flat is. The lift pump helped you flatten your curve.

The PD150 intake manifold will be a huge help to you. Glad you got it.

Here's what your car will do w/ RC5 , PP502, a PD150 intake manifold and an 11mm Pump (all other mods being equal):










http://www.youtube.com/watch?v=EbeRj...e=channel_page

On the subject of the 11 pump, Robert gets over 50 mpg with his car and he has RC6

Here's his dyno. The only difference between him and mine is that he has RC6 and DO water meth injection.









rocketeer928 said:
Mods at the time include: Rocketchip RC4/EGR Delete Chip Tune Software; DC Stage III+ Clutch and 17.5 lb Flywheel; PP520 Nozzles; 17/22 Hybrid Turbo; 3-Bar MAP; EuroJet SMIC with MAF voltage switched pulling fan; 0.658 Fifth Gear; PD Lift Pump; 2.5-inch Downpipe & CAT-back Stainless Steel Exhaust; OMI Turbo Intake with DEI Titanium Exhaust Wrap; Upgraded Intercooler Pipes; DG By-pass Oil Filter, DG Short Shifter, DG Panzer Skid Plate, DG Race Pipe and DG EGR Delete; TDI FrostHeater; McNally Boost/EGT Gauge; Enkei 17-inch Silver Wheels with Yokohama 235/45R17 Tires; Drilled and Slotted Rotors; Rear Fog Lamps; Headlights with Fogs and LEDs; LED Taillights and Signal Lights; LED-strip Trunk Lights; G2 Blue & Black Painted Calipers; Koni FSD Struts/Shocks; Ventectomy; Rear & Upper Front Stabilizer Bars.

The stock engine is rated at 90 hp / 155 ft-lbs torque. At 137 hp / 245 ft-lbs torque, this translates to an increase of 52% hp / 58% ft-lbs torque.





 
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n8ronJ

Veteran Member
Joined
Oct 11, 2007
Location
Niagara Frontier - Somerset, NY
TDI
2014 BMW 328d XDrive, 2003 Jetta GLS TDI 5speed Platinum Grey (sold), 2010 Jetta 6speed (bought back)
So can I get dibs on those nozzles that you're pulling out? :)

Nice numbers you put up. I'm still learning thru tdiclub about HP/torque curves and all that. Being a math junkie I like graphs.
 

rocketeer928

Veteran Member
Joined
Jan 24, 2008
Location
Enfield, Connecticut
TDI
2003 Jetta GLS TDI 5-speed
tothemax said:
Great numbers and curve. I love how flat is. The lift pump helped you flatten your curve.

The PD150 intake manifold will be a huge help to you. Glad you got it.
Shortly after I install the PD150 intake manifold, race pipe, and bigger nozzles, I'm tempted to take a drive to Jeff's to get RC5 and then Dent Sport Garage to see what my numbers are before deciding on getting an 11-mm IP.

The video of your dyno runs is great! Love that plume of soot, though I imagine that it wasn't very healthy to breath all those fumes in while filming.

Bet you're excited that TDI Fest 2010 is in Portland. I won't be there; too far away for me.

n8ronJ said:
So can I get dibs on those nozzles that you're pulling out? :)

Nice numbers you put up. I'm still learning thru tdiclub about HP/torque curves and all that. Being a math junkie I like graphs.
C'mon, you gotta know you're the first person I'll contact about my PP520s if I indeed do the upgrade.

Via education and my job, I'm an analytical chemist, with the emphasis on "analytical". So, I'm big into data, numbers, math, etc. That's why I installed that Scan Gauge II in my Jetta to keep an eye on the car's data, especially the IATs. My wife just rolls her eyes at my data obsession.:rolleyes:
 
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