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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 December 8th, 2017, 21:56   #1
0leh
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Talking Jetta roll on bedliner paint and other repairs

Hello Folks,
I'm new to this forum and to diesel cars, but this summer i bought myself a little toy project - 2005 Jetta Wagon 1.9 TDI BEW. I went for summer vacation and just recently found some time to work on it.
I'm no mechanic or big DIYer, but beside breaking few stuff - so far so good. I would like to ask few advises on how to replace parts, so any suggestion or corrections will be greatly appreciated.
When I've got my new/old Jetta I decided to bedliner the whole car in color "read my lips" from "MonstaLiner", anybody did this kinda roll-on painting job before?
Secondly the car was in not to bad of the shape except grinding noise coming from driver side front suspension. This issue I solved - driver side CV axle joint failed (replaced)
Anyways, I needed to pass the safety inspection so I required to fix few things like replace E-brake cables, brakes, hazy headlights etc., but I went ahead and order buncha parts cause I want to keep the car for few more years and maybe give it to my daughter.
so here is the list~
Initial Cost - $500 (CAD)
Mileage - 321 076 km
MonstaLiner Paint - $700 (USD$582.08)
2 Gallon kit - Read my Lips color
1 Gallon kit - Black
1 Quart - Silver chassis saver
1 Quart - Black chassis saver
1 Quart - S8 Multi-Temperature Reducer
6 Extra rollers
Work Done:
  • Rear Bilstein Shock, strut top stop & dust boot, lower shock bolt & nut replaced (x2)
  • Rear E-Brake cable, e-brake clip (x2)
  • Rear Hub/Bearing assy, rear splash shield (new/painted chassis saver), rear brake disc & pads, ABS sensor and screw(x2)
  • Rear brake caliper cleaned and painted, rear caliper bleeder screw w/ dust cap, rear brake line aluminum washers/seals (x2)
  • Rear driver side rocker panel end rust repair/weld
  • Front Bilstein Shock and coil spring, strut mount w/ bearing & upper spring seat, dust boot & bump stop replaced (x2)
  • Front wheel steering knuckle & hub cleaned/painted (chassis saver), front wheel bearing replaced (kit) (x2)
  • Front splash shield (new/painted chassis saver), Brembo front brake disc & pads, front brake hose (x2)
  • Front brake caliper & caliper slider holder cleaned & painted (caliper paint / chassis saver), slider pins w/rubber boots (x2)
  • Front CV Driveshaft w/ joints, ball joint, inner & outer tie rod; control A-arm w/ bushings, sway bar link/bushing/clamp (x2)
  • Flushed w/ XADO - Total Flush & drained engine oil, changed oil filter and fuel filter, replaced oil cooler O-rings, cleaned oil cooler
  • Removed Intercooler for oil drainage and cleaning
  • Removed Roof rack & disassembled front grill for MonstaLiner paint
  • Replaced Stereo Head unit from stock to Sony WX-900BT
  • Cleaned rusted areas for chassis saver
  • Took off plastic from side mirrors, ready for paint
Work I want/needs to be done:
  • (Currently on this job, missing tool T#10050) Replace Timing Belt/Tensioner/Roller/Water Pump/Thermostat with O-ring & housing
  • Replace Serpentine Belt Tensioner/Serpentine Belt/
  • Flush/replace engine coolant (with G13), flush/bleed brake fluid (DOT 4)/Fill engine with oil (5W-30)
  • Replace headlight lens with glass, custom LED HALOs, upgrade 9007 bulb to GTR Lighting LED (3rd gen)
  • Replace lower front bumper grills with Fog lights, upgrade lighting control switch to automatic
  • Replace speakers, install amp and subwoofer, door logo lights
  • Replace interior and exterior light bulbs with LED
  • Remove wax/oil from whole car, rough up paint for MonstaLiner tape off non-painting area
  • Take off hood, front fenders, doors, front and rear bumpers, move them to paint area
  • Paint car body and taken parts, 2-3 coats
  • Install new mud flaps
  • Replace broken windshield spray nozzles
  • Remove door handles before painting (need help on that one)
  • Spray rubberized coating under wheel well fender liner
  • Clean EGR valve
I live up north in Canada (Manitoba) so the closest dealer or good shop is about 1000 km away so I have no choice but do it myself. I've got parts from germanparts.ca or germaneom.ca and ebay and shipping ain't cheap but I am already committed lol
I would appreciate any help/advice
Thanks
Oleh
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Old December 9th, 2017, 05:41   #2
maxmoo
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Welcome aboard!

wow....you're biting off a lot at once!

A little advice from someone that has made enough mistakes over the years to learn a thing or two....

- A quality timing belt kit is crucial if you don't know the history of previous maintenance.

- Using the correct oil is also critical in a BEW engine....full synthetic 5w40 505.01 spec or better....
http://forums.tdiclub.com/showpost.p...11&postcount=3

- Owning and learning to use a vcds diagnostic tool is mandatory to properly diagnosing and maintaining these cars.
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Old December 9th, 2017, 06:38   #3
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Quote:
Originally Posted by 0leh View Post
  • Remove door handles before painting (need help on that one)
  • Clean EGR valve
Find a thread on door latches for the handle removal, it's a real process. Not super difficult but there are few "gotchas" The threads with pics will explain.

EGR is simple, pull electrical connector, remove 3 bolts and yank it. Do be careful cleaning it, just the stuff in the air path, and I would try to not use any harsh chemicals or at least use them very carefully.
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Old December 9th, 2017, 15:13   #4
0leh
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Quote:
Originally Posted by maxmoo View Post
Welcome aboard!
wow....you're biting off a lot at once!
A little advice from someone that has made enough mistakes over the years to learn a thing or two....
- A quality timing belt kit is crucial
- Using the correct oil is also critical in a BEW engine....full synthetic 5w40 505.01 spec or better.
- Owning and learning to use a vcds diagnostic tool is mandatory
Thanks maxmoo!
well I figure I do what I can and replace most major parts to prolong life this Jetta, I own 3 vehicles so this one can have down time.
- as for timing belt kit - I've got HEPU Timing Belt/Tensioner/Roller/Pump Kit PART #: 1K7421 | OEM #: 038198119A
- for the engine oil I will be using "TOTAL QUARTZ INEO MC3 5W30" - FULLY SYNTHETIC Low SAPS; approved for VW 502 00/505 00/505 01. It gets really cold up here, could be -45 or -55 (deg C)with windchill in winter and +25 in summertime, so i don't know if using 5w-40 would help in colder condition (winter here lasts up to 8 month)
- as for vcds tool I just received "OBDeleven + PRO" Audi/VW Diagnostic Tool, is it good enough or I need something better?
Oleh
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Old December 9th, 2017, 15:42   #5
Jetta_Pilot
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There are also some specialized tools required to do a timing belt change. I.e for one the tool to hold the camshaft in position. But I may be wrong here maybe the 2005 is different from a 2002.
I'm sure someone else will correct me if I'm wrong.
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All interior bulbs to LED. Several VCDS modifications. Darker window tint. EVO skid-plate. Malone Stage 2, Winpower Projector headlights. Angel eyes.LED DRL's.24mm H&R rear sway bar.
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Old December 9th, 2017, 15:44   #6
0leh
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Quote:
Originally Posted by mjydrafter View Post
Find a thread on door latches for the handle removal, it's a real process. Not super difficult but there are few "gotchas" The threads with pics will explain.
EGR is simple, pull electrical connector, remove 3 bolts and yank it. Do be careful cleaning it, just the stuff in the air path, and I would try to not use any harsh chemicals or at least use them very carefully.
Thanks, will do. I suspected it's not gonna be super easy.
EGR valve is in not to bad of the shape and thanks for suggestion
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Old December 9th, 2017, 15:49   #7
0leh
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Quote:
Originally Posted by Jetta_Pilot View Post
There are also some specialized tools required to do a timing belt change. I.e for one the tool to hold the camshaft in position. But I may be wrong here maybe the 2005 is different from a 2002.
I'm sure someone else will correct me if I'm wrong.
It's the same tools as 2002, T#3359 for TDC on camshaft and T#10050 for TDC on crankshaft I believe.
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Old December 9th, 2017, 15:52   #8
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Damn its gets cold up there! I spent a week in Norman Wells in the winter one time. Good luck with your project and please do post photos. Also after it's painted.
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Old December 9th, 2017, 16:07   #9
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Quote:
Originally Posted by 0leh View Post
Thanks, will do. I suspected it's not gonna be super easy.
EGR valve is in not to bad of the shape and thanks for suggestion
That's your ASV, it's a shutdown valve that closes when you shut of the car. The EGR valve is up above the valve cover just past that valve.

Careful cleaning on the ASV as well.
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Old December 9th, 2017, 16:40   #10
0leh
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Just few before and after pics on done job

Front driver side brakes before


and after



Last edited by 0leh; December 9th, 2017 at 17:34. Reason: Images too large
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Old December 9th, 2017, 19:03   #11
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Front suspension & brakes look nice when their new.
If you haven't ordered the parking brake cables ID-Parts has updated cable that are heavier then the original ones.
Not sure if they have it for the 2005.
Easiest upgrade I did in a long time, nice to have it dependable.
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Old December 9th, 2017, 21:17   #12
0leh
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Front suspension & brakes look nice when their new.
If you haven't ordered the parking brake cables ID-Parts has updated cable that are heavier then the original ones.
Not sure if they have it for the 2005.
Easiest upgrade I did in a long time, nice to have it dependable.
Yeah, I've ordered one of the heavier ones too after I replaced the originals. Well, I will replace it in the future. Is ID-parts Canadian based or from the US?
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Old December 10th, 2017, 15:06   #13
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IDParts is in Boston, Mass area. They are a vendor here.
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Old March 7th, 2018, 20:33   #14
0leh
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Allright, just wanted to post an update. Mechanically all work is done as far as I could and now I'm in stage of sanding/prep for paint. Also wanted to get your opinion guys on headlights retrofit that is currently in progress. Here's picture


Last edited by 0leh; March 7th, 2018 at 21:33. Reason: Image too large
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Old March 8th, 2018, 08:52   #15
Cuchulainn
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Looking really good so far, your definitely jumping in with both feet! I live just slightly north of Winnipeg these days, have ordered parts thru I.d. Parts-good people there and shipping wasn't too bad. 1000km's from nearest VW dealer, you must be north of Thompson? Beautiful country side, go hunting and fishing a couple times a year at my buddies lodge.Welcome to the forum
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