2003 VW Jetta diesel wagon auto, 165,000 miles

[sgtpopeye43]

Hi folks,
Been a while since I posted here. A quick update; engine coolant temp sensor, turbo waste gate and exhaust recirculation valve all had codes and the car went into the limp in mode. I replaced all the vacuum hoses, the waste gate actuator and its solenoid N75, inspected the turbo, cleaned the EGR valve and intake manifold, replaced the coolant temp sensor, removed the EGR cooler and installed a cooler bypass tube which I had purchased a long time ago. Put it all together and a week later got code P0401, insufficient EGR flow. Vacuum tested the EGR valve and it had failed, replaced it and no codes!!!! I had scraped about 2 cups of carbon from the EGR valve and intake manifold, the is the 3rd intake cleaning that I have done. Meanwhile 2 wheels were leaking air at the bead area from corrosion of the aluminum wheels. I had cleaned the beads on one of the wheels awhile back, but the leakage returned. Bought two reconditioned wheels, had new tires installed. So I have been busy with this relative low mileage car. With an emissions test coming up soon I didn't want any hangups with the state of CT! At 92,000 miles the transmission and torque converter had to be replaced$$$$$$!!! 3rd timing belt and water pump, 2nd water pump leaked. Fortunately I have a pit in my garage so I am able to get under vehicles easily.
Have a great day all!

 

[MATPOC]

I paid a professional to install 4 tires and clean rims, specifically asked to use brush and knock off loose paint...
ended up having to do it again because that prick just put goop on it instead of grinding the paint off, also did not replace stems or balance the wheels... Had it done right the 2nd time and no more flat tires.

 

[sgtpopeye43]

Local "town scare tire" won't clean the wheels and just puts goop on the beads telling me that the dust from cleaning the aluminum rims is a health hazard which it probably is! Not sure if they are aware of dust masks, I wear one when I am doing a dust producing project.
My wheels are badly corroded but I may clean up the two that I replaced and keep them as spares for when the other two start leaking!
The corrosion buildup gets bad enough that it affects the tire sealing bead area. Car sits on a crushed stone driveway which is not good and doesn't get used very often. This is my wife's car now, but I bought it new as my job at the time required me to drive 200 or more miles a day.

 

[MATPOC]

Brake dust is probably more of a health risk and so is being stupid and lazy...
I ended up cleaning rims myself with wire brush, does not require much effort because air escapes between the paint then the rim, so goop does not work since it seals tire to the lifting paint. When I dismounted the leaking tire most of the paint was stuck to the tire anyway and it was easy to clean the rim.

 

[sgtpopeye43]

Followup on my 2003 TDI Jetta Wagen,
Engine is running fine! Quicker cranking and starting. No smoke on cold starts. Reduced oil consumption. MPG is back above 40. I did install an EGR cooler bypass pipe and hoses, this has decreased the engine warmup time considerably. So I am a happy camper!