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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

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 April 19th, 2017, 18:37   #1
jrsride2002
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Location: Houston, TX
Fuel Economy: 48.07 <> 47.03 @ 70mph ~2400RPM's
Talking My project: DußCity 2.X - '02 Jetta Wago M/T

It's a serious project. Promise.

Back story about me:
I used to own a '03 Jetta wagon GL with the manual transmission(DußCity 2.0). Used it for work, drove around the U.S. After 130K miles, while going through Oklahoma. A snow patch, swallowed me whole. Pulling me into, the roadside drainage ditch. I slide right through a road sign, doing major damage to the front passenger door AND roof. Damage was severe, body shop estimate was more than I thought worth the effort. I was wrong.
I quickly sold the car, cheap, to a guy from Florida. After about a year, I missed my Jetta. So I started to hunt down another. One that I would cherish, fix, and keep long term. So I searched Craigslist, long, far, and hard. Until I found her. She will be my next DußCity....



DußCity 2.X (2.1):
There was a posting for a sister Jetta, to the one I used to own. Forest green in color. Black interior. Heated seats, that was a perk. Even had a sunroof!!! I’m sold, just on the photos. She was in Sibley Mississippi, along the Louisiana border.
Even as had I found her dead, laying in the backyard of a General Contractor. Next to a well used excavator, a small tractor, another MK4 Jetta Sedan TDI in dire need of attention, and the remains of a vehicle long lost to time. All I could do, was smirk. Challenge accepted. The owner knew nothing of the current condition, other than the driver's door opens. His story was, “Daughter was rear ended, wrecked the hatch. Parked it until he found a hatch.” That was 3 years before my acquisition. Flimsy story, AT BEST. Open the door, and was broadsided by the wave of mildew. Shifter would only move from 3rd to 4th. Any other gear, was extremely difficult and not worth snapping the shifter or anything frozen/not frozen. He had one key, lost the other. Owner did not have any battery to try and crank off of. So who knows. Other than leaves, rust, and calcium deposits(rust for aluminium parts). It was a clean engine compartment. Nothing living, nor took residents there. After an hour of loading her onto the tow dolly. The exchange was made. Title for cash. We were on our way.
Tires held air, but have plenty of rot on them. They would hold, for the journey back to Spring Texas. After spending a few minutes at Das European Autohaus, I got the initial report:
She had a seized motor. Front quarter panels, front bumper, rear hatch totaled, rear bumper, heavy mildew under the carpet and in the seats, frozen shift linkages, no brakes pressure, no clutch fluid, a ungodly presence of rust, and other smaller issues. Yup, that was within minutes of getting to the shop.
So then I was on the hunt for a running 1.9L motor. Found one, bought it. Had it installed. Now I have updated to DußCity 2.2. Still didn’t run. Christian noticed that the windows were working, and then stopped working. Popped open the fused panel, completely corroded out. He looks at me, “You have to replace the fuse panel.”.... Damn… (DußCity 2.3??)


Mostly swapped over to a new junkyard replacement.

After getting that done. We TRY to bleed the fuel system. Not working so well. Christian said to replace the Injection Pump. Bought a used one(I know, I know. That’s also coming up in the story), swapped it in. This time, we did not waste so much time, with bleeding the fuel lines with the air compressor. We broke out a can of either. After TWO YEARS of sitting, the engine comes to life!!!! After a couple of minutes of either down the intake, we get diesel in the IP and she was running under her own power!!

Now you’re up to speed with my current situation. I will give a little more details.
Now we have a little bit of an issue, not major. But a fly buzzing around your head, kind of issue. While the car does run, and starts. It take about 10 seconds of cranking, to get ignition. My thought, is that my used 11mm IP might have a leak, or looses pressure. I don’t know for sure. My thought is to replace the clear lines going to and from the IP, run the car for a minute or two, then let it sit. To see if there may or may not be some kind of loss from there. I have replaced the, in tank sending unit already.


But to be honest, I am not going to worry about it now. All I want to do, is bold the intercooler up, reattach the power steering lines, radiator support, condenser, and radiator. Whatever is going on with the fuel system, is small details. And I am not ready to deal with small details. I am trying to get the big picture stuff done, first.

Should I be considered to be at version 2.2, or 2.3(for the fuse panel)??

Now that we’re all on the same page, I thank you for staying and reading about my excitement for getting this machine running again. I will certainly update, with more info, when it happens.
~Junior
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'03 Jetta Wagon GL TDI M/T - RIP
'02 Jetta Wagon GLS TDI M/T - She's ALIVE!!!!
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Old April 19th, 2017, 18:49   #2
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Forgot to mention about the new car.
Due to the weak story from the PO, I have a theory about the car. MY THEORY:
The car was parked. When the last hurricane went through that area, the was flooded out, and stuck/bumped into by other floating debris. This would explain all the mold, corrosion to everything, and could explain the damaged front clip.

I told this to Christian, he thinks it is the likely story also. But would not say, "THAT IS EXACTLY WHAT HAPPENED." So, that is my theory as to the real history of the car. Which storm? I wouldn't know. I was never living out here during those times. Nor have I lived in or through such troubles. I was born and raised in California. We panic with three inches of rain, in a week.

That's my story, and i'm sticking to it,
~Junior
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'03 Jetta Wagon GL TDI M/T - RIP
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Old April 22nd, 2017, 20:16   #3
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Well, I hooked the intercooler back up, and the power steering. The stupid coupler on the lower IC(intake side), was a pain in the Kraken. But it was over came, with some lube and a new clamp.



I was in a rush to get to work. So I just put the two upper bolts in, on the radiator support.



I have to find time, to hit the junkyards!!

Baby steps,
~Junior
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'03 Jetta Wagon GL TDI M/T - RIP
'02 Jetta Wagon GLS TDI M/T - She's ALIVE!!!!
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Old April 30th, 2017, 07:11   #4
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Not much this week.
Bought, ordered, and installed new upper and lower radiator hoses.
Also was replaced the o-rings for the AC lines. Back of compressor, to the drier, to and from condenser.

Had to remove the front clip to get those plastic pieces off the radiator(between the radiator and the hose. What is the point of that piece?) and used a little bit of lube to install the new hose. Also, I did not get a new hose clamp with the lower radiator hose(to the block) and the old one. Well, it was old... So I replaced it with a regular hose. I'll probably swap out to regular clamps anyways. I just don't like/trust those pressure clamps.

Had to make a couple of trips to NAPA, to get the right o-rings. The line to the rear of the AC, as different from the rest. So that took a little more time out of the day.



Next I have to hit the junkyard, to pick up some radiator fan BRACKETS. Those plastic spider pieces, that hold the actual fan into the shroud. The old fans were seized. I was so long ago, that I totally forgot that those pieces were cut off! No worries. Next i'll be ordering the new fans. It's coming to that time, for her to idle for minutes and not just seconds.

I may not be there yet, but I'm closer than I was yesterday.
Slow progress, is still progress.
~Junior

P.S.
Yes, that is a new AC drier. And yes, it is still plugged from the bottom. I'm not hook that line up, until im ready to run the engine. I don't want any moisture getting in there.
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'03 Jetta Wagon GL TDI M/T - RIP
'02 Jetta Wagon GLS TDI M/T - She's ALIVE!!!!

Last edited by jrsride2002; April 30th, 2017 at 18:32. Reason: Said mounts, not brackets. 'Doh' moment
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Old May 7th, 2017, 14:12   #5
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Well, I ordered on sunday, they shipped on Monday. Here they are, ready for install, yesterday.



So I assembled the new fans, new brackets, onto the old shroud. Reconnected the front clip(found it easier to mount the fans with it off). It was only held in by the two upper bolts. All I had to do was unhook the upper rad hose, install the fans, and reconnect.



Then I install my. $3 junkyard battery tray. That task was a hell of a lot harder to do. I had figure out how to route the wires, and that took me for ever to figure out!



But I am now ready to bleed the clutch, the brakes, and coolant system. Once that is done, I will be able to run the engine. Do some more diagnostics, and prep for state inspection.

Also, I tossed the old headlights. Since I have new once in the front seat, I wouldn't need those hunks of weight.
I had to cut my time short, my cousin needed some help with his truck. His alternator died on him. Towed the truck to his place, spent 3 hours replacing it. But it seemed to work well, even with the chinese parts.

Now it's time for finals..... Joy??
~Junior
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'03 Jetta Wagon GL TDI M/T - RIP
'02 Jetta Wagon GLS TDI M/T - She's ALIVE!!!!
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Old May 14th, 2017, 06:40   #6
jrsride2002
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Well. Couldn't Bleed the system(s).
Turns out that my clutch line, is ruptured and requires replacement. The actual hard line, where it is clamped to a plastic connector, is ruptured. Well, with this much work ahead of me. Set backs are bound to happen. Not going to bother with the boneyards, yet. I want to ask Christian, about using a steel braided line. Found one on eBay, for less than factory replacement on ECS. I will take the advisement of a Guru, any day.

Side note:
With as much rust that this machine has. I might just replace the whole engine cradle. That is not needed to be worried about now. But down the line.... This thing just might need it.

Until next time,
~Junior
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'02 Jetta Wagon GLS TDI M/T - She's ALIVE!!!!
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