First VW, First Diesel...

[JettaTDlie]

Picked up a manual 99.5 MK4 Jetta TDI with 347,000km for $2500. Came safetied and e-tested with winters & summers, and the seller was an Audi dealership mechanic. Newer authentic turbo, timing belt done, new OEM battery, and some suspension parts inspected/replaced.

So far I have installed new fuel filter, intake filter, cabin filter, synthetic oil change, EGR delete, cleaned intake manifold, replaced ratty vacuum lines, along with miscellaneous china-special interior pieces (master window control, shift boot, arm rest etc).

Still to come is Stage 1 tune, 3" kermatdi exhaust, boost gauge, Koni STRT(with a POR15 special 'cause Ontario loves road salt)/HR kit, and 18" Rotiform BLQs. Pictures to follow...

Just wondering if there's anything you guys would recommend with respect to maintenance before putting it back on the road?


EDIT - Click link for photos... http://s1198.photobucket.com/user/tc09zc/slideshow/TDI%20PHOTOS
They are out of order and random, didn't plan on posting them! Will try to better document progress.

 

[JETaah]

You may or may not have problems with the clutch if it is original to the car. Once you start throwing power it can show up as the weak spot. The 99.5 had a better clutch than the later cars but, with that kind of kilometer-age on it....it will let you know, I am sure.
Go with the single mass flywheel set up when replacing it.

Check the vacuum pump nipple for looseness (if it can wiggle, it shouldn't), and brake booster vacuum tube for cracks at the barb fittings.

Any idea if the injector nozzles are original? If so, they will no doubt be less than perfect. Your are going to want to upgrade them anyway

 

[TDI smile]

You might have another 50,000 - 100,000 km, if you are a good shifter!
I just had my clutch done this week at 387,000. Got a OEM LUK kit.

 

[JETaah]

You might have another 50,000 - 100,000 km, if you are a good shifter!
I just had my clutch done this week at 387,000. Got a OEM LUK kit.

Are you chipped?

 

[JettaTDlie]

You may or may not have problems with the clutch if it is original to the car. Once you start throwing power it can show up as the weak spot. The 99.5 had a better clutch than the later cars but, with that kind of kilometer-age on it....it will let you know, I am sure.
Go with the single mass flywheel set up when replacing it.

Check the vacuum pump nipple for looseness (if it can wiggle, it shouldn't), and brake booster vacuum tube for cracks at the barb fittings.

Any idea if the injector nozzles are original? If so, they will no doubt be less than perfect. Your are going to want to upgrade them anyway

Thanks for the info. Will certainly check the vacuum pump and brake booster vacuum tube.

Previous owner installed a new OEM clutch, flywheel is original. The tune I'll be running is from a friend who has an '03 Golf TDI. It's an unlocked custom tune that he logged back and forth a few times with the tuner. Not for upgraded injectors. We will see how it likes my TDI, but it holds about 25psi on his with a newer OEM clutch as well.

Forgot to mention I'll be swapping the diff fluid to penzoil synchromesh as well.

 

[BobnOH]

Couple things-
1. The flywheel should have been replaced with the clutch.
2. The ECU on the 99.5 needs a chip soldered in before it will accept external programming.

 

[JettaTDlie]

Couple things-
1. The flywheel should have been replaced with the clutch.
2. The ECU on the 99.5 needs a chip soldered in before it will accept external programming.

Yeah I asked the previous owner about that, he simply stated it didn't seem like it needed changing. Seems to operate fine when I drove it, will cross that bridge if necessary.

With respect to the 99.5 needing a chip (I knew there'd be a catch...) - any more info on that? Applies to a post face-lift mk4?

EDIT: I see the process on Malone tuning... $99 charge isn't the worst.

 

[BobnOH]

Yeah I asked the previous owner about that, he simply stated it didn't seem like it needed changing. Seems to operate fine when I drove it, will cross that bridge if necessary.

With respect to the 99.5 needing a chip (I knew there'd be a catch...) - any more info on that? Applies to a post face-lift mk4?

Really nothing to do about the flywheel, it works.
The chip thing is info I sussed when I got my car ('99.5) chipped last year. There is info on the interweb, you can purchase one and do it yourself.
To check if you already have it, open up the ECU and look. But first get it hooked up to VCDS(vag-com) and look at the header data, many chip tuners will write data there (they all should).

 

[JettaTDlie]

Really nothing to do about the flywheel, it works.
The chip thing is info I sussed when I got my car ('99.5) chipped last year. There is info on the interweb, you can purchase one and do it yourself.
To check if you already have it, open up the ECU and look. But first get it hooked up to VCDS(vag-com) and look at the header data, many chip tuners will write data there (they all should).

Understood. I will have to look into that, buddy has a vag-com cable so I'll have to borrow it. Can't say I'm familiar with what I'd be looking at but he should be...I may have to borrow his knowledge as well!

 

[Schoust]

I was in the very same position as you last fall. After spending 1500.00 for my 00 Jetta I proceeded to go through the car myself. I bought a manual and the tools that are nessesary to get the jobs done on the mk4 ALH. And another 1500.00 in parts I'm happy!
The car has Great Tq and delivers on the Mpg's! I like it so much I am in the process of replacing the front fender and then I'm going to paint it... These cars are Iconic and if you have the ability and love diesel Tq it will be hard to go back to a gasser..

 

[BobnOH]

Here's how mine is tagged, note the component data, it's a RC-2, Rocketchip Stage 2.

Address 01: Engine Labels: 038-906-018-AGR.lbl
Part No: 038 906 018 EB
Component: RC s02g EDC G420SG 2143
Coding: 00002
Shop #: WSC 00066
VCID: 5AB565F4C60623EE73-4AB4

This is what a factory tune looks like-

Address 01: Engine Labels: 038-906-018-AGR.lbl
Part No: 038 906 018 EB
Component: 1,9l R4 EDC G400SG 2143
Coding: 00002
Shop #: WSC 00066
VCID: 5AB565F4C604583

 

[JettaTDlie]

Here's how mine is tagged, note the component data, it's a RC-2, Rocketchip Stage 2.

Address 01: Engine Labels: 038-906-018-AGR.lbl
Part No: 038 906 018 EB
Component: RC s02g EDC G420SG 2143
Coding: 00002
Shop #: WSC 00066
VCID: 5AB565F4C60623EE73-4AB4

This is what a factory tune looks like-

Address 01: Engine Labels: 038-906-018-AGR.lbl
Part No: 038 906 018 EB
Component: 1,9l R4 EDC G400SG 2143
Coding: 00002
Shop #: WSC 00066
VCID: 5AB565F4C604583

Thanks for the heads up. In theory, if my ECU is already socketed or once that's done, would I be able to run the same tune as his '03? He has the file on his laptop, just wondering if there's a difference in the programming since I had to add new chips...

 

[UhOh]

Malone Stage 1 and 3" exhaust are going to do little for you power-wise. The stage 1 tune won't cause any issues with a stock clutch: stage 2 and above will require a new clutch (well, that's been the case for one out of two of my cars). Exhaust is pretty much one of the last things that one would look to do if trying to garner more power: better to toss money at up-sized nozzles (along with having the injectors calibrated etc.).

 

[JettaTDlie]

Exactly why I'm staying at Stage 1 for now. Not to mention it's only costing me $150 at most (not a Malone tune, file itself will be free). Reason for the exhaust is really more for volume and the fact that I picked it up off a totalled TDI for $200. Bigger injectors and a re-tune may be down the road.

 

[[486]]

We will see how it likes my TDI, but it holds about 25psi on his with a newer OEM clutch as well.

relined clutch disc on the stock flywheel and pp on mine, running 35+ PSI and all the fuel that a 10mm pump will push through pp764s
doesn't slip now that it's broken in, when I just put the relined disc in it would slip a bit, but it just had to wear in
Not a recommendation, just a suggestion to worry about it when it becomes a problem and not before.

 

[SaxmanKana]

I was in the very same position as you last fall. After spending 1500.00 for my 00 Jetta I proceeded to go through the car myself. I bought a manual and the tools that are nessesary to get the jobs done on the mk4 ALH. And another 1500.00 in parts I'm happy!
The car has Great Tq and delivers on the Mpg's! I like it so much I am in the process of replacing the front fender and then I'm going to paint it... These cars are Iconic and if you have the ability and love diesel Tq it will be hard to go back to a gasser..

Great post, that's what I figure as well, Thanks, Dave!

 

[JettaTDlie]

Small update...picked up a 6000K HID Kit, and after a struggle I've decided to order a set of retrofit headlights from Midwest Light Creations.

I swear I'll have pics once the TDI is up and running.

 

[Dodoma]

Because the car is now over 16 years old, I am sure the paint must be dull or fading. Take it to Maaco for paint job.

 

[JettaTDlie]

I'd love to paint the car, but it is not in the budget. I am in the process of doing some rust repair/re-painting the sill plates and around the rear license plate. Rest of the car will get a good 3 stage wax.

 

[IndigoBlueWagon]

Some misinformation in this thread. First, as JETaah noted, the '99.5s have a different clutch than later cars, and it's significantly more robust. I ran 145/270 at the wheels in a '99.5 Golf on the stock clutch (with fewer total miles) and it worked fine.

However, I've never seen a clutch kit only (no flywheel) available for that LUK clutch. If the original owner replaced it years ago perhaps he found one. But I've never been able to. Second, the LUK kit that's available in the aftermarket is not the same as the OE clutch on the OP's car. It's a great clutch, but it doesn't have the holding power that the OE clutch did. And the parts aren't interchangeable.

I bet the car has a SMF kit in it.

 

[JettaTDlie]

Thanks for the info, still learning lots - and it seems the 99.5 comes with some curve balls. Unfortunately I only have the seller's word with respect to the clutch replacement. He is a technician at Audi/VW dealer and ordered the part through his work. He only owned the car for 2 years so it wouldn't of been years ago. I did ask why he didn't do the flywheel as well, and he said when he has it apart it was still fine.

Whatever the case may be, the clutch works well and I have no chatter at idle associated to a SMF. Hopefully that holds true with the stage 1 file.

 

[JettaTDlie]

Question as I've been looking into wheel fitment...

I am hoping that Rotiform BLQ's 18x8.5 et35 will fit all the way around? I have 225/40/18 tires already. I've read some people having issues rubbing on the front struts without spacers (see link: http://forums.vwvortex.com/showthre...Offsets-amp-Tire-Sizes-Request-Thread/page134)

And other people running those specs with no issues (3DSM wheel but same specs - http://forums.vwvortex.com/showthread.php?5646298-MK4Forum-Offsets-amp-Tire-Sizes-Request-Thread/page109&p=85304810#post85304810).

For the rears should I run 9.5 wide? Looking to fit relatively flush. Will consider spacers if needed. Will be lowered on 1.5" on H&R Sports.


EDIT: Did some more research... will have to run 10mm spacers up front to clear the struts. Will also install 15mm spacers in the back to bring the 8.5s flush. Don't think I'll have any issues rubbing on the fender since I'm only down 1.5".

 

[UhOh]

Whatever the case may be, the clutch works well and I have no chatter at idle associated to a SMF. Hopefully that holds true with the stage 1 file.

Good SMF clutch setups won't chatter.

 

[JettaTDlie]

Update... Koni STRT struts have 2 coats of POR15 on them. Still doing some bodywork on passenger sill plate. Ordered some retrofit headlights from Midwest lighting... should be installed shortly!

Along with the Koni kit, ordered new:
- Strut Mounts
- Strut Bearings
- End links
- Sway bar bushings
- Ball joints

 

[JETaah]

Audi TT solid control arm bushings?

 

[JettaTDlie]

Ordered...

http://m.ebay.com/itm/Energy-Suspen...-Arm-Bushing-Set-Red-/301904814013?nav=SEARCH

 

[JETaah]

Ordered...

http://m.ebay.com/itm/Energy-Suspen...-Arm-Bushing-Set-Red-/301904814013?nav=SEARCH

Ouch! That looks like a harsh ride.
Here is what I was referring to:
http://www.idparts.com/audi-tt-control-arm-rear-bushing-a4a3b4-p-700.html

 

[JettaTDlie]

Yeah I know those are the TT bushings. For $30 though I couldn't say no to all poly. I don't mind a firm ride, just hoping the rears last.

 

[UhOh]

Yeah I know those are the TT bushings. For $30 though I couldn't say no to all poly. I don't mind a firm ride, just hoping the rears last.

Well, I suppose we'll hear back from you on this (MANY people end up pulling the polys back out- for me I don't like to re-do work, so I went with the TTs- these are highly regarded [I have found that the TDIClub consensus is almost always the way to steer]).

 

[JettaTDlie]

Well, I suppose we'll hear back from you on this (MANY people end up pulling the polys back out- for me I don't like to re-do work, so I went with the TTs- these are highly regarded [I have found that the TDIClub consensus is almost always the way to steer]).

Alright the tribe has spoken. Poly bushings cancelled, and these have been ordered:

http://www.ebay.ca/itm/161522733075?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT