Little Yellow Projects

Joined
Mar 16, 2024
Location
Oklahoma city
TDI
2004 Beetle TDI
So I have a 2004 Beetle tdi, std transmission, 168k miles, so far I have replaced the starter, battery, tires, MAF, oil, and air filters. Checked the intake, it was clear. It did run a little better after I changed out the MAF, but not by much.

The projects I need to still do and may need some expert advice on..meaning I'm in deep and need someone to throw me a line here...

Vacuum lines. I have crap power and can't keep speed going uphill, so my next logical (in my head) step is to replace those. I have looked at the diagrams, they look like a foreign language to me. I want to replace with silicone tubing, I'm assuming I need the 3.5mm id hose? I want the yellow, that way i have a damn map for in the future. Whether or not that is the actual problem is TBD. However, I'm pretty sure the lines in there are all original and changing them won't hurt anything. Am I going to need new connectors or if I'm really careful can I reuse any that are already there?

Headlights and wiring harness. I currently (I bought it this way) have an autobot switch on the hood of the car that turns the headlights on. Apparently there was a problem with the headlights so the best solution for the previous owner was to cut the headlights off of the wiring harness and directly connect to the battery with a switch. How much of a pain is it going to be to put a new wiring harness in? The headlights I'm going to get the whole new shebang, because I'm sure those were cut into to "rewire" them, and the cans arent sitting right in the headlight slots. I can't drive the car at night at all, the lights don't shine on the road correctly, I made that mistake one time, never again. Has anyone else ever had a problem with their lights like that and what was the actual problem? Is this more of a wiring harness problem or the inside switch problem?

Door panels, because....well if you know, you know.

Glove box door. Dude must have been a genius, it's ziptied shut right now. I have no idea what might even be hidden within the confines of that magical area. I'm thinking salvage yard to find a new one?

Emergency brake. Because why would you need one of those in a standard? Do I really have to take the center console out to fix it or could it be fixed from underneath?

Shifter boot is really worn and the top piece has come off of the knob, so that will be replaced too. I'm thinking about getting one of the acrylic clear knobs that have flowers in them and a black leather boot.

Upholstery seriously needs to be cleaned. I don't know what type of livestock were hauled around in there, but the smell has to go. Yet the trunk looks like it has never had anything placed inside it. Seatcovers will be gotten after the smell has gone, not before.

The front grill has the lower rail that has been busted off, it is currently in the back seat. Easier to have it welded back on, or should I look for a replacement from the salvage yard? Doesn't matter to me if the front is a completely different color because she's getting a new paint job after all the other projects get done.

Anyone know how to change out the light bulbs in the front dome thing, the one by the clock? I replaced all the others and the tail lights with the really bright leds.

Can I glue the hood thing over the speedometer back on to the dash so it quits coming out? Any guesses as to why one would be loose to begin with?

Front end suspension. I did get an alignment and they found a few problems, so that's a project that I think I'm going to farm out to a shop. I don't feel confident enough in my or my standby mechanics abilities to do this on my own, unless I'm overcomplicating the process? Anybody done this as a diy before?

I'm wanting to do a blackout of the interior, so seatcovers and doorpanels will be bought in black, the only thing I would need to paint would be the console, everything else is already black.

My previous bug did not have these problems. Besides the door panels. It was a 2000 tdi, automatic. It only gave me a problem with the cat clogging up. I wish I still had that car.

Any advice is greatly appreciated. Any suggestions are welcome too. My "mechanic" is my 16yo nephew and he's going to be too busy to help with these projects, hay season is right around the corner. So I'm going to be getting very familiar with this car very soon.
 

Tdijarhead

Top Post Dawg
Joined
Nov 10, 2013
Location
Lawrenceville PA
TDI
2003 TDI Jetta Daughters Car, 2001 TDI Beetle, Wife’s car, 2005 Golf TDI Mine, all 5 spds
acuum lines. I have crap power and can't keep speed going uphill, so my next logical (in my head) step is to replace those. I have looked at the diagrams, they look like a foreign language to me. I want to replace with silicone tubing, I'm assuming I need the 3.5mm id hose? I want the yellow, that way i have a damn map for in the future. Whether or not that is the actual problem is TBD. However, I'm pretty sure the lines in there are all original and changing them won't hurt anything. Am I going to need new connectors or if I'm really careful can I reuse any that are already there

You not only should replace the vacuum lines but make sure the turbo actuator is holding vacuum and adjusted correctly there is a how to in the 101 section.



The headlights are notorious on beetles for having problems, if the old ones are clouded and bad get new ones I think idparts has pig tails to replace what has been cut away in the harness or hit your local junkyard up.

Door panels, glove box...eBay or local junkyard , again common problems but fixable, dieselgeek has a door handle fix if you need it.

Worn shifter boot is common...eBay, fcpeuro, etc.

Just tackle one thing at a time you have an awesome little car if you address all the neglect from the previous owner.

When was the timing belt last done, what parts were used and what exactly was replaced?

What codes are currently present?
 
Last edited:

Jr mason

Veteran Member
Joined
Oct 20, 2013
Location
Ohio
TDI
01 Beetle, 2012 Jetta
Vac lines are surely due for replacement if they are original. Turbo actuator is a known problem as these cars age. I live in the rust belt.....mine literally rusted through. Can't hold vacuum when it's so well ventilated.

Any active codes? That would be a good starting point, but the lines should be addressed and actuator tested, regardless.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Sounds like the house I’m working on.
Can’t help you with too much of it, but you can get a cheap 5 ball shifter knob down at the local pool hall and leaving the windows down will help with the smell
 
Joined
Mar 16, 2024
Location
Oklahoma city
TDI
2004 Beetle TDI
Thank you so much for the links, I will use those to check the things you mentioned.

The headlights are clouded up, bad. I'll go look for the pigtails I didn't know they even made those. That is excellent to know.

The passenger door panel just needs the new insert, but the driver panel is broken. Cracked from the top about halfway down, goes through the handle, I'm worried every time I go to close the door that it's going to keep cracking. Even the screws that someone put in it aren't holding it together any more.

I haven't touched the timing belt. So apparently that's another project to tackle?

I know the brake light pops on about 2 seconds after it starts. The long beep and the orange circle light. It's been a while since I messed around with it. There is a CEL on, but I'll have to have the codes read again. Iirc, it might have been an overboost code?
 
Joined
Mar 16, 2024
Location
Oklahoma city
TDI
2004 Beetle TDI
I will have to check the actuator. Not that I expected much, but there isn't much showing on the car fax history. Maybe a few oil changes and that's it. Lol

I want to say it was an overboost code, but it has been a while since I've done anything to the car. And the brake light, the orange circle pops up about 2 seconds after starting the car.

I wanted a project car, I certainly got one.

The ac won't work unless the car is moving, is it more common to be a bad relay or actual fan motor?
 

Tdijarhead

Top Post Dawg
Joined
Nov 10, 2013
Location
Lawrenceville PA
TDI
2003 TDI Jetta Daughters Car, 2001 TDI Beetle, Wife’s car, 2005 Golf TDI Mine, all 5 spds


If the ac works only while the car is moving, it’s likely the fans are not working. Here is the AC troubleshooting thread.

 

JETaah

Vendor , w/Business number
Joined
Jan 18, 2001
Location
mi 48836
TDI
96 B4V, 2005 BEW Beetle, 2005 Jetta Wagon
I'd really look over the vacuum lines. The BEWs and later engines seldom need replacement in my experience. They are almost all formed to some shape and hold up exceptionally well over time.
They could be worn in spots from abrasion if they were not properly restrained in their supports during operation.
But the rubber well outlasts what the ALH and earlier cars had on them.
 
Joined
Mar 16, 2024
Location
Oklahoma city
TDI
2004 Beetle TDI
Update on projects! I sourced a great deal on the glove box, leather seats front and back, and door panels locally. Got them out of an 08, same yellow color only black on the bottom instead of gray. So far I have installed the glove box, still need to tear down my car and while I have everything out I'm going to clean the carpet. I did clean the new door panels and seats, it appears to have been a teenager's car, lots of soda spills and candy residue down the sides of the seats.

Battery is dead so I haven't read any codes yet. Got a suspension guy though. He's going to take a look at it next week to see exactly what it needs. (It's everything, I promise. The front end is about 2 inches lower than the back)

Next up checking the vac lines and bowl thing.

I did make some phone calls to find the fans, does the tdi engine really have 2 different fan assemblys? One with a 3 wire and one with a 4 wire? Why would they do that?

Electrical will be up after that. You know, when it's fun to drive again. I'll take it over to my dad's house and he said he would help me with the headlights, so here's to hoping!
 

JETaah

Vendor , w/Business number
Joined
Jan 18, 2001
Location
mi 48836
TDI
96 B4V, 2005 BEW Beetle, 2005 Jetta Wagon
Both real fans each have only three wires.
One large fan with a short motor. Jetta fan won’t fit.
One small fan.
Chain auto part stores are not the place to buy parts for these cars.
 
Joined
Mar 16, 2024
Location
Oklahoma city
TDI
2004 Beetle TDI
So I went out and actually looked under the hood today. I took some pictures, please ignore the dust, it's been sitting for a while, however it's making all the oil easier to see. I'm going to assume that the weird looking thing that doesn't look anything like any other egr's I've seen for a 1.9tdi is actually my egr?
Egr?
Also is the black puck underneath the ccv? I'm trying to identify one of those on this car as well. I'm trying to check everything I can think of, and that means identification as I go.

the intercooler pipe (i hope thats the correct name for it, its the really expensive plastic pipe that comes off the intake manifold) isnt really secure against either end, it just slides all over the place, so no seal. Im assuming that could cause a vacuum leak, right? And loss of power under load? I just know that when it comes to a big hill you can start at the bottom at 75mph and you might still be at 50mph by the time you make it to the top, it isn't as zippy as my 01 was. Both were/are diesels but the yellow is a standard, my other one was an automatic. The rpms kind of flatten out by the time you get to 4th and 5th gears, there is no kick it in the ass and move.

The big plastic pipe

the oil dipstick is catching on the fabric on the inside of the hood, because i havent started the car and when i popped the hood again today the dipstick was up again, so it has to be catching on the loose crap hanging down, thank god for small favors on that i suppose.

Thank you so much to everyone. I really appreciate how patient and knowledgeable you all are. The only other car I've ever really worked on was my first and it was an ancient car when I got it at 16, a 66 mustang that had no where near the same parts as my bug. (Besides the standard transmission)
 

BobnOH

not-a-mechanic
Joined
May 29, 2004
Location
central Ohio
TDI
New Beetle 2003 manual
Secure that pipe, it could be the source of your power issue. If the hood fabric is catching the dipstick, remove it.
Do the vacuum tubes one at a time, can't go wrong. mcmaster.com carries some colors.
 

NavyTDI2000

Well-known member
Joined
Mar 8, 2024
Location
Orlando, Florida
TDI
2000 New Beetle 1.9L
I'm intrigued by this, as my Beetle has been a great source of discovery. I had a similar power issue, but replacement of all vacuum lines really fixed THAT issue. I just redid my entire suspension (or almost all of it)- and I REALLY love wrenching on this bug- it is fun. Keep us posted about your progress.
 

Prairieview

Veteran Member
Joined
Jul 9, 2017
Location
Too close to Sturgis 'ithole
TDI
Two 2000 Beetles, 2002 Jetta, 2002 gas avh Jetta, fleet of older 1.6 turbo and non's
I suspect there will be resentment toward me if I inquire whether or not someone near you has a crusher.
I own three beetles and they are NEVER......"fun."
Keep your wits about you because they will be tested very thoroughly.

Hint: Jetta's are MUCH easier to work on....I got three of those as well.
 

John Wesley Hardin

Veteran Member
Joined
Aug 28, 2022
Location
Rockport Texas
TDI
2003 VW Jetta 1.9 Diesel GLS , Five Speed Standard Shift
Sounds like the house I’m working on.
Can’t help you with too much of it, but you can get a cheap 5 ball shifter knob down at the local pool hall and leaving the windows down will help with the smell
Sell it to some other sucker
 
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