MattMan's 2003 Jetta Wagon 5 Speed

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
2003 Jetta Wagon 5 Speed

Purchased with a dead motor, with the help of TDIClub member Growler, replacement motor is coming from Franko6 and misc. parts from BoraParts.

Project details to come.

 

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Engine Hoist attached & Motor out

01/20/2012

Preparing to pull dead motor


Motor Out


Empty Motor Compartment
 

ymz

Top Post Dawg
Joined
May 12, 2003
Location
Between Toronto & Montreal
TDI
2003 Jetta TDI Wagon, 2003 Jetta TDI Wagon
So you guys took the engine out the top... I always thought it's less trouble out the bottom... but what do I know...

Yuri
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
just had to remove the hood, and it popped right out, notice the load leveler on the cherry picker, allows you to lower the trans/raise the engine as you pull it out to swing the pumpkin around the brake booster as you come out the top.

easy peasy :D
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
Yes, that is me on any given saturday,... I have gotten lots of good use out of my dickies :) and as you can see, I was wearing my TDIClub knit hat that morning before i got too warm.. hence the lovely hairdo. :D

Ant yes, the other picture is me when I am not getting durty working on cars..
 

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Week #2 - It's like Christmas !!!

Parts have arrived from BoraParts, The Panzer Deluxe Skid Plate has arrived from DieselGeek.

This week we plan on taking the transmission off and salvaging what is needed to install on the replacement long block engine coming from Franko6. (Frank's VW TDI's, LLC).

I hope to post Pictures of Christmas and tear down when time permits.
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
we got together last night and he took some photos of the parts we have received so far. we also stripped the old engine and removed the transmission.

upon pulling the injectors out, I noticed that I was not the first one to pull these injectors out of the car...

What is wrong with this picture..
 

greengeeker

Vendor
Joined
Feb 8, 2006
Location
Cambridge, MN
TDI
2002 Jetta GLS
With half of the injector holes shrouded like that I wonder what that would have done for smoke, FE, etc? Any cylinder damage?
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
don't know about cylinder damage. the engine is getting replaced with a whole new longblock, and with as bad as the #1 piston is beat up, the crank is essentially seized in the bore, I didnt even have to use the flywheel holding tool to break loose the flywheel bolts last night.. that should tell you how seized it is.
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
Silly boy... didn't you know that the first lesson in mekaniks skool is: "if one sealing washer is good, two are better" ??


Yuri
that must be why I don't do that.. I never went to mechanics school.
 

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Old Engine Prep & Parts Cleaning

Growler Disassembling old Engine


Bracket - Before Cleaning


Bracket - After Cleaning



Transmission Before Cleaning





Transmission After Cleaning


 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
Just got word that a rather large and heavy box/crate has shown up for us to go get...

hijinx will ensue tonight and continue on Wednesday!
 

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Day 4 - Engine Arrives

Engine in the box


Growler opening the box


Awww, what's in here ?


Rebuilt Engine from Frank's VW TDI's, LLC


Misc Parts




See, VW's are part of the NASCAR Family
 

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Day 5 - Engine Assembly

Engine on Stand


Accessory Bracket and Oil Cooler / Filter Housing


Turbo Installed


21# Single_Mass FlyWheel / Clutch / Pressure Plate







Transmission Installed



Finishing Touches on Day 5 Engine Assembly
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
I say it was a pretty productive evening.

Looking forward to friday and the reinstall into the chassis/First start :D
 

TonyJetta

Top Post Dawg
Joined
Sep 15, 2005
Location
Tucson, Az
TDI
'15 Jetta TDI SE / '06 Jetta TDI DSG Pkg0 / '96 Passat TDI
Nice progress! Glad to see a worthy car soon to be back on the road!

Tony
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
Aaaand after a 14 hour day yesterday... She runs :D and she runs nicely. Timing was EXACTLY in the middle the first time upon assembly and initial start.

HOWEVER.. today we need to do a few things.
1. Replace the alternator. It doesnt charge the battery. and we have a code for it as well.
2. Ziptie/solidly mount the side to side shift cable to the bracket on the transmission. its been broken and doesnt hold itself in place so we cannot find reverse. (Anyone have a shifter box and cables for sale?)
3. Reinstall the front bumper cover (had to remove it to get the hose clamp behind the headlight installed)
4. reinstall the hood.
5. Change the oil with the second round of Joe Gibbs BR after the initial 20 minute break in period from last night.

oh ya, one snafu we had.. make sure that BOTH of the two hoses that click into the firewall are actually clicked in place. those hoses will leak a LOT of coolant quickly and make it very difficult to bleed the coolant system. :D oopsie.

overall, it went very easily for my first complete engine replacement.
 

rackaracka

Veteran Member
Joined
Nov 15, 2001
Location
Monroe, NJ
Great work Aaron! That intercooler coupling behind the headlight can be a bear! Thank god for remote cable operated clamp pliers. No video?
 

TonyJetta

Top Post Dawg
Joined
Sep 15, 2005
Location
Tucson, Az
TDI
'15 Jetta TDI SE / '06 Jetta TDI DSG Pkg0 / '96 Passat TDI
Congratulations!

Glad to hear another TDI is back on the road! Well, very soon to be.

Tony
 

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Final Assembly





The Help (Oliver & Aaron Shaw)


Almost There





Engine Being Lifted


Wagon Awaiting
 
Last edited:

_MattMan

Veteran Member
Joined
Dec 29, 2011
Location
Lancaster, Ohio
TDI
03 Jetta GLS Wagon 5sp
Engine Install

Engine Going in



Some Disassembly Required


Ok, Let's try again - Tight Fit



It's In !! Lets start hooking things up !!




Growler Installing Fuel Injectors


Engine Almost ready to start
 
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