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I was really optimistic after finding your post. My daughter has the exact same symptoms you described, so I went ahead and order the part on ebay. They sent me the wrong part. The part they sent is relay 449. It's the exact same part number without the "A" at the end. Since we had it apart I...

close up of the screen showing dirty screen before cleaning

lift pump screen was dirty [/IMG]Today I checked the lift pump and the screen was nasty. I ran one of the test that Dang144 recommends and monitored output to the canister with each key turn. Dan says I should get 50-100 CC of diesel per key cycle, but I am only getting half of that. I cleaned...

The zip tie trick didn't work. Any other ideas?

My daughters 2005.5 jetta TDI is having acceleration issues. The car starts to surge/sputter at about 2500 RPMs when accelerating. I thought it might be a fuel starvation issue, so I replaced the fuel filter today. The fuel filter was super dirty. There was caked on black soot on the filter, and...

OK I read about the zip tie mod. If I am still able to adjust my stop screw (not totally rusted out), would it be better to try that first? For my under boost condition, I will want to limit the travel of the rod, so from under the car I would thread the screw in one full turn....corect?

What is Zip tie mod Can you elaborate on what Zip Tie mod to proof the Turbo? Is there a post you can refer me to?

I know there are probably a lot of posts on this, but I was hoping someone could save me some time. I have owned this car since 2008. I was driving on the free way recently and when I go to accelerate at below 2000 RPM, the car will sometimes go into Limp mode. The only other telling thing...

Not that anyone cares, but the Melett Turbo is working like a charm. It says made in the UK right on the box. It also came with an inspection sheet signed by the guy who built it and ran it up on the VSR at 150K RPMs. Yes, it was a little extra work cleaning the turbo vanes and assembling the...

I wasn't getting a lot of input from the forum, so I decided to purchase a Melett aftermarket cartridge for about $320.00. My intake housing is fine and my exhaust manifold/turbo housing is fine. There appears to be no carbon build up or problem with the vane assembly. From what I...

I have the turbo out and the CHRA is seperated from the exhaust manifold. I spent the better part of the day doing research and basically the only option available from Borg Warner is to buy a new turbo. The Cartridge part number from Borg Warner is 5439-710-8004, however this is not available...

OK, I pulled off the intake on the compressor side. I was able to send my phone down into the tight space and took a photo. There is a little play in shaft, but it's hard to say if it's excessive. It looks like the blades are scuffing the aluminum housing...right?

Yes, I am sure the noise is comming from the Turbo. I also have the noise comming from the flywheel and that is on the list of things to repair soon. The noise definetly is associated with the turbo. It would be if I could see a youtube video showing what excessive play looks like. Assuming that...

I can probably handle that. I did after all replace my cylider head about 80K miles ago. How much play is there suppose to be?

I have a 2005.5 manual PD TDI with 185K miles. Recently I have noticed a slight rattling sound from the turbo. The noise is more obvious just after the car has been started. At idle the noise is non existent, it is only when I rev the engine over 2K RPMs that I notice. On the de-acceleration I...

I have changed the entire cylinder head a year ago due to a Chinese timing belt failure. I went with a new AMC head made in Spain. The ironic thing was that my BRM cam looked beautiful. I always used the mobile one turbo synthetic oil. Initially people cautioned me about not using the 505.5 oil...

I bought my 2005.5 Jetta TDI as the second owner back in 2009. The car had 90K thousand miles, but looked and drove like a new car. Almost 4 years latter the car has 180K and the usually signs of cosmetic wear and tear. Mechanically the car needs the Flywheel/cluth kit ($350.00), EGR bypass...

I now have a small coolant leak from somewhere. I only loose a small amount (about about 2 cups) a day. I can't tell where it is leaking from. The hoses look fine. Where the coolant drips from the body of the car to the ground. I have not been successful and tracking the leak back to it's orgin...

Thanks. People were probably tired of all my threads on here, but I was seriously just trying to get help. The car is still running smooth, so the improperly seated injector must have been the problem. Take Care

Update. After replacing the Tandem pump, the problem continued. The tandem pump still lost it's prime. I inserted a check valve on the supply side of the fuel line and the pump still lost it's prime. The only way the pump would not loose its prime was if I clamped both the supply and return line...