2002 Golf - I'm back in a TDI!

[Zak99b5]

12.3v isn’t great for battery voltage. Should be more like 12.6v or higher.

Any MkIV-based car seats can be swapped in. I love the GLi Recaros I installed. But you can also easily swap the bottom cushions with upholstery left to right if the passenger one is better, as it usually is.

 

[spifflifkin]

12.3v isn’t great for battery voltage.

Is that bad after sitting for 3 weeks? When I'm driving it regularly it's about 12.6V.

love the GLi Recaros I installed

Thanks for the tip! I'll keep my eyes open for a set.

 

[Zak99b5]

I didn’t realize it was after sitting untouched for 3 weeks. That’s not too bad then.

 

[spifflifkin]

Got some time last week to do some work on the Golf.

On the blown engine the car came with, one of these was cracking. I used the ones that came with the donor engine. Just as a precaution I just replaced all these with new ones.

Outlet hose (right) 1J0 145 828 T
Intercooler short hose (upper and lower left) 1J0 145 834 A
Intake hose (left center) 1J0 129 627 A

Replaced all the bad body plugs.

Underbody Plug Round Grommet 30mm (left) N10138801
Underbody Plug Round Grommet 40mm (right) 1K0899185



Prior to replacing the rubber turbo tubes I checked out the turbo for leaks. A few weeks ago I popped that tube off and made sure the side with the indent in the inside was installed on the plastic pipe and the smooth side in the interior was on the turbo. So far, no more leaks.


When replacing the body plugs I see that this joint has a leak. It looks like it's blowing soot on the CAT.



@JonA motivated me to get back to working on the interior. I finished cleaning that nasty door card I got from the junk yard. It's still got some green on it. I sprayed mildew killer on it. If I have time, next week I will try to install the cover.


@burpod is helping me troubleshoot some stuff. We discovered that the plug for the MAP appeared to be flaky. I got a new one and installed that. It's soldered and covered with adhesive lined heat shrink. It's solid now.

 

[spifflifkin]

The wiper linkage was pretty sloppy. So I picked up a new Vaico one. Installed that tonight. Wipers are super smooth now ready for rain this week.


Wiper Linkage: 1J1955603B

 

[spifflifkin]

I did a compression test today with the engine cold. I cranked it and got about the same numbers as previous tests. Then I had my kid crank it while I watched the gauge. I had him crank it longer than I did and got higher numbers.

8/2024
#1 430 psi
#2 440 psi
#3 440 psi
#4 440 psi
#1 430 psi

2/2024
Engine warm (90°C)
#1 420 psi
#2 420 psi
#3 422 psi
#4 425 psi
#1 420 psi

11/2023
Engine cold (sitting on a pallet after picking it up from a junk yard).
#1 420 psi
#2 422 psi
#3 420 psi
#4 428 psi
#1 420 psi

 

[spifflifkin]

Got in the car to drive to OR last night after work and the sunroof tilt started opening and closing on it's own. This is the second time this has happened. After work today I did some Googling and it looks like it might be dirty contacts in the switch. When I get back I'll check that out.
Gonna hit some Pick-n-pulls on the way home tomorrow. Hopefully I can find some good interior parts.

 

[spifflifkin]

I didn't score any interior parts, but I found a windshield cowl with an intact VIN window.


Windshield Cowl w/ VIN window: 1J1819415BB41
Windshield Cowl w/o VIN window: 1J1819415EB41

And, I scored an 11mm IP out of a Beetle with 130,000 miles.. That makes me a bit suspicious. The engine I bought was out of a Beetle with 130,000 miles. Is that what they always say?

47mpg on the way OR. 60-75mph freeway only.
41mpg on the way back home. Some local driving, heavy traffic and 60-75mp freeway. A/C on the whole way.

 

[spifflifkin]

Busy day today!

I installed the new fuel pump. I ran it for a bit to see if there were any leaks.


There were no leaks so I finished wiring it. I ran 12AWG jacketed cable from the dash. I used a relay receptacle that I got at the junk yard yesterday.


No bubbles with lift pump running

This VDO fuel pump does not appear to be a flow through. I cut the power to it and bubbles appeared in the line then foam. I reconnected power and that all cleared up.

Bubbles with lift pump not running.





When in the car was wired, all I had to do was hook the signal wire to the IP. The nut was stuck to the stud. I spun it a bit before realizing it.


So, I decided to go ahead and install my newly acquired 11mm IP.



I borrowed a relay and a fuse from other circuits and tested it out before wrapping it up for the night.

I had all 4 windows down all day. Once I was done for the night, I rolled them up. The rear passenger made a crunch and the window stopped. I had to push it up by hand...

Tomorrow I will find my fuses and get a relay.

 

[spifflifkin]

Got a few more things done today.

I found a general purpose relay to power the fuel pump. It didn't work for the fuel pump, but it worked for the ignition. So I used the 53 relay for the fuel pump.

I removed the crimp connectors and soldered the fuel pump wires at the pump today then put the cover back on. I poured all the fuel I siphoned out back in the tank. While pouring that in, I noticed a clicking sound coming from the fuel pump. Not sure what that as about.

There has been a rattle that's been driving me crazy. I swear it was in the dash so I tore it apart and still heard it. So, I got my kid to ride with me. He gets in, listens for a second and points out that it's the center folding arm rest! The dash is back together now. I hope that really was the rattle.

I noticed that the rear driver window wasn't all the way up. I pushed the button, something in the door cracked and it was loose... Just like the passenger window. I'm tired of fixing these with junk yard parts so I ordered new regulators with panels for all 4 doors from Rock Auto and new window pins from ECS. Hopefully they will be better than junk yard parts.

 

[spifflifkin]

I noticed a little weeping around the injection line fittings. I cleaned the head thoroughly before driving around last night. It's not too bad but I'll keep my eye on it.

 

[spifflifkin]

Replaced the hood insulation pad with a new one today. $77.08 off Amazon.

I reused the stock clips in place of the ones that came with the new pad. The stock ones are a bit sturdier. I added the one missing in this pic after taking the pic.


Insulation: 1J0 863 835 F
Insulation clips: 1H5863849A01C

The old one was sagging a lot and was moldy.

 

[spifflifkin]

A few weeks ago there was a splattering of oil on the firewall, sub frame and other parts around there. I didn't find a smoking gun, but the only thing that's not new under there was the turbo oil return line. So I replaced that, the gasket and bolts today. Even before changing it today it was nice and clean down there. I have no idea where that oil came from...


Turbo return line: 028145736AJ

And, I installed a missing A/C line clamp.

 

[spifflifkin]

Replaced the driver rear door window regulator, panel, window pin and door latch tonight. One of the guides broke off. Then that window pin fell out.



This was a junk yard replacement after the original one broke where the window pin attaches.

Window guide: 1J5839461
Window Pin: 6N0 839 511
Door Latch: 3B4839016AM

 

[spifflifkin]

When I pulled out the fans that came with the car they had oil in them. Everything in the engine bay had oil on it!
Yesterday was the time to install new ones as a precaution.



Large Fan: 6X0959455F
Small Fan: 1C0959455C

 

[spifflifkin]

Rotated the tires tonight and installed a new vented fender liner.

Vented Fender Liner: 1JM809962A

Why are these so flimsy? I'd like to find some Long Beach wheels someday.


253297mi

 

[burpod]

long beach are heavy. i'm not a fan. look kinda cool but meh.

 

[J_dude]

I'd like to find some Long Beach wheels someday.

I have a set but shipping wouldn’t be cheap lol

 

[CanadianALH]

I have long beaches and I like how they look but they are heavy. I really like the 16” BBS’s that came on some golf’s but they are expensive and hard to find. Maybe one day.

 

[spifflifkin]

Thanks for the tips on the wheels! I'll keep the ones I have. They are fine.

I missed the 1 year anniversary of getting the Golf! It was 9/10. A lot has happened since then!
This is the first time I saw it. I had a pic of it on the trailer, but I can't find it...

 

[spifflifkin]

Replaced the rear passenger door window regulator and door lock module. Whatever those black plastic things are that have the 3 sockets that protrude through the door panel are called, I hate them! They are a pain!

 

[J_dude]

Replaced the rear passenger door window regulator and door lock module. Whatever those black plastic things are that have the 3 sockets that protrude through the door panel are called, I hate them! They are a pain!

And they’re almost always broken too

 

[spifflifkin]

Got some work done today.

New down pipe and mid-pipe.


Everything looks good under here. No more oil on the turbo actuator.


New pipes installed


Here's the door card ready for adhesive. I used 3M Super 77 Multipurpose Permanent Spray Adhesive Glue. I lined up the cover the best I could then used a couple of binder clips on the top to hold it while I sprayed on the glue.


The area around the hole in the middle had a wrinkle. I may not have stretched it correctly. I cut out the extra. It came out OK.


I'll use the zip tie and the hose clamp methods to attach the door card.


Lastly, I put in a new dip stick tube. Just as a preventative measure.


253514 mi

 

[Bradm]

Got some work done today.

New down pipe and mid-pipe.


Everything looks good under here. No more oil on the turbo actuator.


New pipes installed


Here's the door card ready for adhesive. I used 3M Super 77 Multipurpose Permanent Spray Adhesive Glue. I lined up the cover the best I could then used a couple of binder clips on the top to hold it while I sprayed on the glue.


The area around the hole in the middle had a wrinkle. I may not have stretched it correctly. I cut out the extra. It came out OK.


I'll use the zip tie and the hose clamp methods to attach the door card.


Lastly, I put in a new dip stick tube. Just as a preventative measure.

What down pipe did you go with? Looks good

 

[spifflifkin]

What down pipe did you go with? Looks good

Thanks!
I got this from IDParts: https://www.idparts.com/downpipe-catalytic-converter-1j0253058g-711933-p-14842.html

 

[spifflifkin]

When I was loading some stuff into the car tonight I noticed a fair amount of water on the sills of both back doors. This is the first significant rain that the VW has been in since all the work I've done on it.

It doesn't look like ay water got pas the door seal and into the carpet.

Driver side

There's a fair amount in the bottom of the door too.

Passenger side

On both sides it's wet inside above the seals.

Passenger side

I popped off the door panel on the drivers side and found water on the door under the panel. There didn't appear to be any on the inside of the door panel.

Driver side

Both front doors were bone dry.

Seems like this isn't a rare problem.

I'll try this out to see if I can track it down this weekend.

 

[P2B]

Water on the sills after heavy rain is normal, water inside the door usually means the door drains are blocked. I clean them out with a hacksaw blade.

 

[spifflifkin]

Water on the sills after heavy rain is normal, water inside the door usually means the door drains are blocked. I clean them out with a hacksaw blade.

Thanks for the info! I'll keep an eye on that to make sure the carpet isn't getting wet.

 

[P2B]

Thanks for the info! I'll keep an eye on that to make sure the carpet isn't getting wet.

In theory the inner door panel is sealed so water in the door can't leak onto the carpet, but in practice the seal is often compromised if the inner panel has been removed (e.g. to fix the door open switch).

 

[spifflifkin]

In theory the inner door panel is sealed so water in the door can't leak onto the carpet, but in practice the seal is often compromised if the inner panel has been removed (e.g. to fix the door open switch).

Thank you for pointing that out!
I just replaced both rear door panels with new ones from Rock Auto. Maybe those are leaking. I'll see if I have time to do a water test tonight after work. I'll report back with the results.