Project Resurrection: Rebuilding a Junkyard Bound TDI

[Ajlal24]

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.

 

[Ajlal24]

A little update while I have the motivation to post here. A big change was the transmission fluid service, I think this was the OEM fluid from factory judging by color. Everyone raves over GM Sychromesh, which is basically Pennzoil rebottled...some bottles call it GL3, others don't even mention. I referenced 02A/02J oil capacity as 2.1L, measured the drained oil and it was 1.6L, and basically that much went back in. If you're going to be doing this service, just buy 2 liters of oil. Shoutout to HarborFreight for this hand pump, worked awesome.

 

[Ajlal24]

Now I kept wanting a better radio, I needed Carplay. Went through a couple Chinese(AliExpress) radios and they're garbage. The sound quality is terrible, no pre-amp connections, the button layouts are terrible, BUT THEY HAD CARPLAY...and I bought three. Then I found this Walmart Power Acoustik BIG*** LCD/LED/HDTV/VIP headunit. And I wish I would have found this thing years ago. It was about $140.

In the stock dash, it fits pretty bad. It stuck out 1/4" all the way around, so I took out the factory surround out and cut the bezel enough to make it flush and glued in the aftermarket radio basket. I also bought a newtome boost gauge from ebay for $28, repainted the black bezel, and now its like new.

 

[garciapiano]

Carplay single DIN is super cool.

As for the trans fluid fill, I find it marginally easier to pour fluid into a long skinny funnel into the top of the trans through the VSS port rather than monkey around with a transfer pump.

 

[Ajlal24]

Carplay single DIN is super cool.

As for the trans fluid fill, I find it marginally easier to pour fluid into a long skinny funnel into the top of the trans through the VSS port rather than monkey around with a transfer pump.

Radio works perfect and has simple controls, and that was my biggest gripe with the chinese units. I think I'll get some matte or semi-gloss black vinyl to cover the glossy sides as it looks a little off as is. My other option was to buy a bluetooth amp and put a factory radio delete panel in place, but bluetooth amps are still pricy.

And the fluid pump worked surprisingly well, it's a 30 min job under the car once you have everything out. I wouldnt think to screw around with the VSS hole unless I wanted to get exactly 2.1L in there.

This car was supposed to be a quick clean up and sell...doesnt look that way anymore.

 

[garciapiano]

I think you may be stuck with keeping it after all this. No buyer will compensate the love you've put into it.

prices on the mk3s are starting to rise… I think the market may be finally waking up to the fact that these were some of the best cars VW made! Hindsight is always 20/20…

 

[Ajlal24]

I don't mind keeping it, however I have a MK3 GTI project that has been on the back burner for a while and I'll start working on that soon.

I did make some headway on completing the hydraulic overhaul. Since I replaced the Clutch Master & Slave, I was thinking on going with SS clutch line, but I didn't want to spend $60-80 on one...so I installed the factory rubber hose back in and the clutch worked great, but the feel was still spongey. So I reached out to a local guy that makes Industrial & DOT hoses and he was hesitant at first but after some explanation he helped me out - I promised him I would would offer of these out as he made 10 kits while he did mine. In the end I got the correct fittings to adapt an AN hose. It fixed the lazy brake pedal and made a BIG difference in clutch feel.

California cars don't rust.

 

[garciapiano]

Hook me with one ‘o those!

 

[Ajlal24]

Hook me with one ‘o those!

Shoot me a message. I know you’re fairly local.

 

[Ajlal24]

Does it have AM/FM, or FM only?

I think you may be stuck with keeping it after all this. No buyer will compensate the love you've put into it.

It has AM/FM too, I just checked today. Since I have euro VR6 fenders on the car, I had to buy an aftermarket antenna. I hid the antenna in the dash behind the radio compartment and surprisingly I receive great reception from all local channels.

 

[Ajlal24]

No big updates on the TDI this week, I feel the transmission has gotten a bit louder with the Pennzoil fluid, and it's either because of the fluid itself or because only 1.6L of fluid went back into the transmission instead of the required 2.1L. Thankfully I've only driven the car under 20 miles since the service. I'll either fill the addl .5L through the VSS or replace the fluid with another brand.

On another note, I looked at a Vanagon as a potential buy, but I backed out due to condition. I think you all will agree with me.

 

[jhax]

Out of curiosity, how much did the seller want for that? That thing is a mess.

 

[Ajlal24]

Out of curiosity, how much did the seller want for that? That thing is a mess.

I didnt get that far in conversation. Its a Syncro Westy. I knew driving there that it wasnt going to be cheap, but the more I looked at it, the more I realized it needed basically every panel touched, not looking at the suspension and motor.