My 2003 New Beetle - BlueBoy

[Lightflyer1]

Here is my 2003 New Beetle GLS TDI as it sat for sale with a leaky IP and TB issue of tensioner installed incorrectly. Head/valve damage. Bought for $1200.











First bill for repairs on 9/2/2015:

Make/model 03 Beetle
mile 157,450

Labor:
Description: Charge:
Install injection pump seal kit $ 312.11
Install timing belt kit $ 385.00
R&I cylinderhead (6hrs@$90/hr) $ 540.00
Install lower radiator hose and repair expansion tank hose $ 45.00
Install inner drive axle boot, right and left (1.5hr/side) $ 270.00
Install fan set $ 90.00
Install glow plug harness $ 90.00
install oil pan $ 90.00

Total Labor: $ 1,822.11

Outside services:
Brooks Elliot Machine Shop head repair service exchange $ 280.00
Brooks Elliot Machine shop intake cleaning service exchange $ 50.00
Total: $ 330.00

Parts:
Description: Unit Price: Total Price:
1 Bosch IP seal kit $ 21.00 $ 21.00
1 fuel return line set $ 5.00 $ 5.00
1 dieselgeek.com ALH timing belt kit with $ 340.00 $ 340.00
timing belt, tensioner, water pump, 3 rollers
vacuum pump seal and serpentine belt
1 cylinder head gasket, 2 hole $ 23.40 $ 23.40
10 cylinder head bolt $ 1.26 $ 12.60
1 intake manifold gasket $ 2.00 $ 2.00
1 exhaust manifold gasket $ 9.95 $ 9.95
1 down pipe gasket $ 3.00 $ 3.00
1 EGR to intake o-ring, viton $ 5.00 $ 5.00
3 EGR pipe gasket, metal $ 3.95 $ 11.85
1 EGR pipe gasket, paper $ 3.80 $ 3.80
4 injector crush washer $ 0.90 $ 3.60
1 turbo oil return line gasket $ 4.00 $ 4.00
1 camshaft $ 100.05 $ 100.05
8 cam follower, INA $ 9.42 $ 75.36
1 camshaft oil seal, PTFE $ 10.00 $ 10.00
2 intake valve $ 13.00 $ 26.00
1 water outlet flange o-ring $ 5.00 $ 5.00
1 lower radiator hose $ 36.18 $ 36.18
1 hose repair union, repair hose and clamps $ 11.00 $ 11.00
2 drive axle boot, inner $ 20.00 $ 40.00
4.5 Fuchs Titan Supersyn 5w40 motor oil, liter $ 6.66 $ 29.97
1 oil filter $ 8.00 $ 8.00
1 glow plug harness $ 102.00 $ 102.00
1 cooling fan, left $ 66.37 $ 66.37
1 cooling fan, right $ 68.27 $ 68.27
1 oil pan $ 88.00 $ 88.00
5 G12 coolant, mixed 50:50 distilled H2O, liter $ 3.00 $ 15.00
1 coolant expansion tank $ 18.24 $ 18.24

subtotal $ 1,144.64
Tax: $ 94.43
Part Total: $ 1,239.07

Invoice Total: $ 3,391.18


Second bill for oil pan incidinet on 9/9/2015:

Make/model 03 Beetle
mile 157, 676

Labor:
Description: Charge:
Install oil pan $ 90.00
Install dieselgeek panzer plate w/ FMJ $ 60.00

Total Labor: $ 150.00

Parts:
Description: Unit Price: Total Price:
1 dieselgeek.com Panzer Plate kit $ 275.00 $ 275.00
1 side dkirt FMJ set $ 99.00 $ 99.00
1 oil pan $ 88.00 $ 88.00
4 Fuchs Titan Supersyn 5w40 motor oil, liter $ 6.66 $ 26.64

subtotal $ 488.64
Tax: $ 40.31
Part Total: $ 528.95

Invoice Total: $ 678.95

Car wasn't running so I bought a clutch set just in case:

$33.93 Volkswagen 02J 141 719 C, Clutch Release Arm
$34.33 Victor Reinz 67750 Rear Main Seal
$187.57 LuK 17-050 Clutch Set
$22.50 Axle Shaft Seals (2)
$12.00 CV Joint Bolt (12)
$1.75 Retaining Spring for Clutch Release Lever Pivot
$85.90 Clutch Slave Cylinder (A4)


$9.30 Audi Vw Mercedes Double Din Radio Removal Key Tool (2 Pair)
$72.97 New fog light set Amazon by AutoHalo.
$58 Dieselgeek Beetlebrace door handle reinforcement
$200 Maaco painting of front grill parts
$50 Bentley Beetle Manual

http://www.expressoemparts.com/

Part Number Part Name Price Quantity Total
1C0-805-903-G-GRU LOWER PANEL $105.21 1 $105.21
1C0-807-681-E-01C LOWER GRILLE $39.71 1 $39.71
1C0-807-341-A-GRU COUPLING $57.12 1 $57.12

Subtotal: $202.04
Shipping (UPS - Ground): $60.24
Handling: $2.75
Total: $265.03

Part Number Part Name Price Qty Total
1C0-868-107-B-FYZ DOOR TRIM PANEL, LEFT $350.03 1 $350.03
1C0-868-108-B-FYZ DOOR TRIM PANEL, RIGHT $350.03 1 $350.03
1C1-857-628-B-62J GRIP HANDLE CAP, RIGHT $4.55 1 $4.55
1C1-857-627-C-62J GRIP HANDLE CAP, LEFT $4.55 1 $4.55
1C0-858-069-AA-XNX CENTER BEZEL $165.12 1 $165.12
1C1-880-882-E-3SG GLOVE BOX DOOR $229.72 1 $229.72

Subtotal: $1,104.00
Shipping: $80.61
Handling: $2.75
Total: $1,187.36



Total so far: $7693.27

Starting to look like new!

 

[hughc]

holy ****....... I don't know what to say, so I won't say anything.

 

[Lightflyer1]

I could have reduced that to around $4500 total if I had not cracked the oil pan and just left it in the shape it was in. But I had just had a new car and I wanted this one to be like new, and it is now. A friend of mine just bought a new gas Beetle for $17k. Mine is as nice as his almost and much cheaper and more economical. My plan is to have it for a very long time. It isn't the thing most people do though. Here are my other cars, both with flathead V8's:

 

[hughc]

Now, those are very impressive, and attractive. kudos !!

 

[runonbeer]

I think you should chip it Dave!

The whole time your car was here Lance kept saying how much he liked it. And I agree it's a nicer car. Some cars just "have it"

 

[Lightflyer1]

I have a used injector set on the way. DLC 520's by DBW I think. Then a tune. After I find out if I am getting laid off or not.

 

[Lightflyer1]

Brand new OEM VW parts from Patrick VW came in today. The brand new door panels look beautiful and will be great when they get installed. I am glad I chose to go new now. It will really set off the interior. All the used ones I tried to get were expensive as well and old already. Brand new these should last me a long while. Maybe the old ones can be reworked and resold to offset the cost some.

 

[Lightflyer1]

Working on the interior now. Rebuilding the door panels was more than I thought due to the plastic welds. The new injectors came in and will be sent off to DBW for rebuilding and DLC 520's soon. Sending for a new spring/suspension set from IDParts next week. I may raise it 2" as well while everything is out and being replaced.

 

[Lightflyer1]

Ordered 4 DLC 520's stage 1, from DBW today. $449

http://www.dbwllc.net/product/dlc-520-239-best-for-stockfuel-efficiency-2/

Also new suspension kit from IDParts.

http://www.idparts.com/

1 x Spring & Shock Complete Suspension Set (A4) (a4_tc_springs_set) = $515.60
Rear Bump Stops
Installation Bolt Kit
Front Bump Stops
Rear Shock Mounts
Model New Beetle
Shock Option Bilstein TC Sport
Front Strut Mounts FREE
2 x Front Spring Top Perch (A3)(B4)(A4) (springtopa4) = $23.98
1 x Rear Shock Boot / Dust Covers Pair (A4) (a4_rshock_cover_pair) = $9.95
2 x Strut Mount Top Nut (A4) (struttopnuta4) = $16.40
2 x Rear Lower Spring Seat (A4) (a4rearspringseat) = $16.40
1 x Front Strut Boot/Covers Pair (A3)(A4)(B4) (a4_strut_boot) = $18.95
2 x Audi TT Control Arm Rear Bushing (A4)(A3)(B4) (ttcabusha4.jpg) = $37.90
------------------------------------------------------
Sub-Total: $639.18
IDEAL IDeal Economy (5-7 Days) (54 lbs.): $4.95
Total: $644.13

Then 2" lift kit from Metalnerd. $300 (Includes a $100 refundable deposit)

http://www.metalnerd.com/cat09.htm

I will send off the used injectors I bought this weekend. I am also trying to finish redoing my door panels. I got the top panel cut away from the old door panel and will try glueing it this weekend with Locktite Epoxy. Harbor Freight had a Dremel type tool for $24 that worked fine for cutting all the plastic welds. Left some nice stubs for gluing but not enough for plastic welding (my other choice).

 

[Lightflyer1]

Well I worked on the door cards today. Replacing the top portion. Mine are painted to match the car so I didn't want to buy new and have to repaint if I didn't have to. I went to Harbor freight and bought a Dremel like tool ($24). I cut the existing welds down parallel to the stubs sticking up leaving the stubs as long as I could. I used a thin cutting disc for this. It pays to use a slow speed as the plastic gets hot and melts fast. Take your time too. There is a huge block of foam that needs to be broke free as well. I used a pry bar to get it to break free in one mostly large piece. It blocks some of the plastic welds. I cleaned everything up with alcohol. Then test fit the top piece to the bottom door card. The stubs were long enough to fit back in place and pretty much hold it together for gluing. I also bought some Loctite Heavy Duty Epoxy High strength Builders Formula. I used this to epoxy the pieces togeter with great results. IIRC the plastic was marked ABS on the inside of the door panels.


Here you can see the block of foam that had to come out to get to the tabs underneath, and all the finished epoxied tabs.



You can see how I just put the epoxy into the spaces where the tab were here.



Finished panel now looks like brand new (it is).


I will install this panel tomorrow and remove and do the other side. I broke the surround around the drivers window switches as it was brittle. Dealer had one for $28.

 

[Lightflyer1]

Well I worked on the door cards today. Replacing the top portion. Mine are painted to match the car so I didn't want to buy new and have to repaint if I didn't have to. I went to Harbor freight and bought a Dremel like tool ($24). I cut the existing welds down parallel to the stubs sticking up leaving the stubs as long as I could. I used a thin cutting disc for this. It pays to use a slow speed as the plastic gets hot and melts fast. Take your time too. There is a huge block of foam that needs to be broke free as well. I used a pry bar to get it to break free in one mostly large piece. It blocks some of the plastic welds. I cleaned everything up with alcohol. Then test fit the top piece to the bottom door card. The stubs were long enough to fit back in place and pretty much hold it together for gluing. I also bought some Loctite Heavy Duty Epoxy High Strength Builders Formula. I used this to epoxy the pieces together with great results. IIRC the plastic was marked ABS on the inside of the door panels.


Here you can see the block of foam that had to come out to get to the tabs underneath, and all the finished epoxied tabs.



You can see how I just put the epoxy into the spaces where the tab were here.



Finished panel now looks like brand new (it is).


I will install this panel tomorrow and remove and do the other side. I broke the surround around the drivers window switches as it was brittle. Dealer had one for $28.

 

[runonbeer]

Doin' it right.

 

[deegingerkid]

I am IN LOVE. That color is spectacular. I'm assuming it's not factory.

You've put a TON of love into that car. I hope she returns it!

 

[Lightflyer1]

It is factory. Blue Lagoon Metallic says the Monroney label. LA5W LK

https://www.google.com/search?hl=en...#hl=en&tbm=isch&q=blue+lagoon+metallic+beetle

I like it better than cosmo green my last one was!

 

[Lightflyer1]

IDParts suspension arrived today. Quick as usual. 57 lbs in 3 boxes for $4.95 shipping! No tax. I love ordering over the internet!

New OEM Beetle carpeted floor mats $88

New Shift boot $27
http://www.fixmyvw.com/new-beetle-shift-boots/

Spare Key and remote cut via picture w/VW emblem $68
http://www.fixmyvw.com/replacement-vw-key-fob-for-late-mk4-golf-jetta-passat-and-new-beetle-immo-3/

Flashzilla for Malone tune $180
http://www.malonetuning.com/flashzilla/

Once the DLC 520's come back a Malone stage 2 tune. $299

 

[Lightflyer1]

Completed and reinstalled door panels. The passenger side had to have some cutting done to the foam (interior to the panel) on the new door panels. It was too big and wouldn't let the panel fit up against the door. Broke the lock grommet at the top of the door ($7) and the puddle light lens (module and lens come together $35) very brittle (passenger side).

 

[Lightflyer1]

A few new shots I took today!












Replacing this center bezel with new soon, to fix AC vent and crappy appearance.


Replacing the glove box door and the grab bar end pieces when the center bezel is done.

 

[Lightflyer1]

and these:











Runonbeer and Lance's handiwork.

 

[Lightflyer1]

Got to clean the drivers side sunroof drain and clean the stain in the headliner it made. Need to polish headlights clear. Hard to wait for the injectors, Malone stage 2 tune and suspension refresh. This thing is getting to be nice! I need a BT radio though so my phone can work through it hands free. The one thing I miss most from the Passat.

 

[runonbeer]

Looks like we missed a little bit of crud on the back of the oil filter housing. And what's going on with #4 injector? Is that oil?

 

[Lightflyer1]

I installed the rebuilt and painted front grill last night and ordered a Kenwood KDC-BT762HD head unit from Crutchfield. I plan on waiting to hear what it sounds like with the stock speakers. If I don't like it I am ordering some (4) Polk Audio DB651 6.5"/6.75" 2-Way Marine Certified db Series Car Speakers with Liquid Cooled Silk Tweeters. They got good reviews and seem to fit properly. The 2" lift kit should be delivered today as well as the shift boot and spare key.

I don't know what is up with the injector, I will look at it this afternoon after my new job interview. I am going to try and install the center dash bezel, glove box door, grab bar trim pieces and shift boot if I can. You will be seeing the car soon for suspension refresh and lift and injector install as soon as DBW sends them back to me. If Lance liked my car before he is going to "LOVE IT" next time!

 

[runonbeer]

Yeah he's gonna be pissed if I schedule you for next Friday because he's going to E Tx to help his buddy set up his new powder coating shop.

 

[Tdijarhead]

Very nice looking Beetle.

 

[Lightflyer1]

I won't schedule till the injectors come back. Installed shifter boot, new floor mats and programmed remote of the new key tonight. Job interview ran 4 1/2 hours so botched my timing for the center console and glove box. I did manage to get the glove box open and the owners manual and all the paperwork since new was in there. Including the Monroney label!

Thanks Tdijarhead!

 

[Lightflyer1]

Pics of some of the completions to date.

New center dash bezel installed with working AC vents and non-scarred up rubber coating.



New glove box door and new grab bar end pieces.



New shifter boot and knob.



New Beetle carpeted floor mats.

 

[runonbeer]

Looks great but it's hard to tell with all the grease smudges on my computer screen

 

[Lightflyer1]

Better get your GoJo out before I get there. Don't want that getting around.
.
Installing Malone Stage 2 tomorrow if they send it in time.

 

[minilooker]

I could have reduced that to around $4500 total if I had not cracked the oil pan and just left it in the shape it was in. But I had just had a new car and I wanted this one to be like new, and it is now. A friend of mine just bought a new gas Beetle for $17k. Mine is as nice as his almost and much cheaper and more economical. My plan is to have it for a very long time. It isn't the thing most people do though. Here are my other cars, both with flathead V8's:

OT that is one neat classic ride you have there....

 

[Lightflyer1]

Well actually 2. A 1935 Ford sedan and a 1936 Ford coupe. Thanks!

 

[Lightflyer1]

Added Malone Stage 2 (EGR off) today.

Stage 2
122whp/228wtq (137bhp/257lb-ft)

Ordered new clear headlights from user Strykeviper.

http://forums.tdiclub.com/showthread.php?t=450097