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.


Replaced all the bad body plugs.




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.

 

[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.


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.



The old one was sagging a lot and was moldy.