Project Resurrection: Rebuilding a Junkyard Bound TDI

Ajlal24

Veteran Member
Joined
Oct 17, 2016
Location
California
TDI
98 Jetta TDI, 2012 Golf TDI
From Day 1 when I purchased the car, the previous owner said the car had an electrical issue that caused the car not to start with the key, hence why he installed a switch to the starter. We talked a bit about it and he was adamant it wasn't the ignition switch. I took his word for it as he was a diesel tech & instructor. He did a great job installing the bypass switch with a hefty relay and covered the wiring well. Though I came tired of driving the car with it, plus it was embarrassing to say the least when explaining how to start the car at Smog Inspections. So I inspected the wiring, took my multimeter to trace wiring and everything was great. Ignition switches are a common MK3 issue and I replaced the switch. Would you believe it if I told you it fixed the problem? It did. Should have done it sooner.

The factory shear bolts were on there tight, so I welded a couple nuts to them and replaced them on assembly with standard VW bolts I had removed from my MK5 when I did some upgrades.


While I was at it I installed a new switch and concealed it behind the dash. I liked how well the PO installed it, and the utility of it being there if the ignition switch went out again was worth it. And I had to take the steering column back out to reinstall this spring on the shaft. :cautious: PS: that bracket is from a MK4 1.8t intake.
 

Ajlal24

Veteran Member
Joined
Oct 17, 2016
Location
California
TDI
98 Jetta TDI, 2012 Golf TDI
With all the work in the interior, I found a knock off of DieselGeek's shifter bushing kit for the 02A transmission shifter linkage. I really want to do the 02J conversion, but don't have the time for it at the moment as I need to drop the exhaust. For $35, it was well worth it. It got rid of much of the slop that was there. Next will be the transmission and flush the fluid soon.


Flash forwarding to today a bit, I've been working on designing a Rallye Light bracket for the front. Did some CAD modeling and had this bracket cut for the lights. They are Hella 500 lights, and I plan on having two of them on the front. Just need to finish the bracket to mount to the chassis, I want it completely bolt in and reversible if need be. Also found this intake in my parts hoard, but I have no plan on installing it soon.
 
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