VW MK3 Golf 1.9TDI 66kw 1995

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
Hi, So after 4 years of not having a VW neither a TDI I've decided to get a cheap mk3 TDI. Was kind off impressed since I've never had a mk3 but had the mk2 and mk4 and this one is something in between. Loved the mk2 and the mk4 was also a good daily for about 3.5 years. So first off all yeah the car is in bad shape but I've just needed something to get to the hunting location, get to my land that has a bad road to access it and maybe when I have to drive something. So it is a 95' mk3 and I've got it for about 400€ here in Bosnia. Straight away when I bought it I drove it to the vehicle inspection and when it passed I got it registered so I can drive it on the road legally.



So this is it..











The first thing I've done is get the radio done. It had a cd player inside but there were 2x non working speakers on the backseats and in the trunk there were 2 pc speakers. I've took that out since I had 2 speakers from my old mk4 left in the garage and they were bigger. Only thing I was sad about is that the front doors do not have any cables or electricity in them and I've could not put the speakers in the front. Will try to get the ruber hoses latter and connect them in the front then but should work for now like this.







The radio was connected only from the battery and not a switch so I've could not do anything there but to buy a 0.5€ switch and connect it over it. I dont listen to music just to the news sometimes but still don't have an antena so this I will bother with latter.



Since the car will be mainly driven on bad roads my main project for now is to :

Get bigger tyres: 175/80/R14
Build in the struts and shocks from a b3 passat .

This is the setup now xD Will not hold out much longer





So my question about the shocks and struts are what are the cheapest and that will lift the car to the max ? Should I buy old original ones or new OEM that are about 20€ per piece ? Can the b3 passat shocks be mounted on golf mk3 struts ?

People here also install these to lift their mk3 up. What do you think ?




Other than that I've only saw till now when I floor it down at certain rpms the car like chokes and when you put down the pedal gets its power back. I did not put it on VCDS yet but I think its a MAF, or a solenoid problem. For the muf senson I've bought a z diode and will try driving it with that to see if thats the cause. Can I leave the z diode then in and drive it like that ? Will it cause problems or ruin the engine or not ?

I will post some pictures next week so be tuned. Will be fixing the manual shifter that I've ordered the bushings for. I could not put it in 5 gear and 1 and R were in the same level. Hope that will fix it.
 

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
That's pretty cool!! Not cluttered in the engine compartment!!
What's the Mk2 Golf sitting beside it?
Yeah I like to keep it tidy in the engine bay. Will swap all silicone hoses next when I finish the shifter.
That behind is an 90' 1.6TD 44kw. It is my friends lifted vw.



We still got allot of mk1 mk2 mk4s in Bosnia. The mk1, mk2 diesels are about 750€ - 1k and the mk4's are about 2.5k €. I got mine mk3 from my friend for cheep about 400€ and taught it would be a great project for me since I need a car for offroad and I could kill the time in the garage. We are lucky here because in Bosnia we can weld parts on the car and you can basically get anything over the inspection here. Mine went trough with a nail in the tyre with no profiles ( on the sides you can see the wires ) xD
 

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
New updates .. I got some spare time for working on the mk3.

changed out all the old vacuum lines that were all shot



they did not have the blue and red 3mm hoses so I ordered them online .



changed all the filters out. they were in bad shape. the cabin filter I did not get so ordered that as well









I cleaned the maf sensor since it was also clogged and had to high readings for it on the vcds. Idk could be bad or the wires are damaged since I saw its all taped out. Still did not get any other error codes on it.





Did also the shifter since I you could not get it in first gear and 1 and rv ..



did the cabin part but still could not get it in 5th but 1st and rv were doing good so I've changed out also the 2 parts in the engine bay.








I've broken half of the protection ring off since it was impossible to get the piece out .. Is that a problem ? Seems to be working fine without it.

I Still did not change the oil since I need a new stick and the lower part of it to measure it right so that will be my next thing to do.
 

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
So this week I did the following things...

1. Oil filter, oil change and a new stick





2. changed this guy out. I dont know why people dont change it. Its not expensive and bad for your health





3. Both front wheel bearings were shot







4. Got some cheap rear door shocks since the car did not have any ...



5. New front suspension arms and ball joints











6. Idk how you call them in English but changed both sides the heads and the socks .





I did a list of things that are coming up next ...

1. Change all the belts, colling fluid and pulleys
2. Trace the faulty cable thats causing fuel pump and generator error
3. Fix rust on front suspension towers
4. Front vw b4 passat coilovers / idk about the back yet
5. 175/80 r14 tyres
6. egr delete or block + clean egr and intake manifold
7. get a nice radio and wire the speakers in the front
8. get a new radio antena
9. new maf and n75
10. fully align the shifter (still off course)
11. car alignment
12. also found this fella all busted up. Already ordered both from Lemforder
13. fix front passenger side windshield wiper ( broken hand)
 
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mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
Should be good for a few thousand miles!! Nice work!
Thank you, I try to do as much as I can when I have spare time. Cant wait winter when I will have more time to clean the intake manifold and finally open the head to see inside since the car has 418k km / 260k miles

btw can you guys advice me what to do with the egr. I have several options in mind.

1.) Clean EGR and Intake manifold and put it back on.
2.) Clean InMa, EGR and disconnect the vacuum pipe on it and delete egr cooler ( Is this possible like on ALH engines? )
3.) Clean InMa and delete Egr and cooler

I would rather go with option 1 and 2 since isn't the egr good for when you have a runnaway? Whats the best option ?
 
Last edited:

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
New update

The stereo the car came with was beat up. You could not even change the volume and it hat no USB/AUX. Found this Pioneer DEH-1800UBB for 10 bucks.



I also got the gaskets for the EGR, intake manifold, engine head and fuel injection pump.



Some parts to make the car even better. Front blends, front vipers, Glove box system and the suspension thingy that I saw was worn.



all parts were about 66$ and stereo 10.

I've also ordered some aditional shifter parts that were worn or displaced. Stay tuned.
 

Windex

Top Post Dawg
Joined
Apr 1, 2006
Location
Cambridge
TDI
05 B5V 01E FRF
You may want to consider changing to the shifter me hanism from the later. Mk4 (2000 and up).

Requires the in-car shifter, cables, transmission bracket and pivots and (the hardest part) selector shaft and bottom bushing from the transmission.

However, the install is not hard, and the precision of the later shifter is so much better than the factory mk3 shifter.
I retrofitted my B4 Passat (same shifter as the mk3) after a year of ownership and kicked myself for not doing it sooner.
 

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
You may want to consider changing to the shifter me hanism from the later. Mk4 (2000 and up).

Requires the in-car shifter, cables, transmission bracket and pivots and (the hardest part) selector shaft and bottom bushing from the transmission.

However, the install is not hard, and the precision of the later shifter is so much better than the factory mk3 shifter.
I retrofitted my B4 Passat (same shifter as the mk3) after a year of ownership and kicked myself for not doing it sooner.
I considered that before I got the other bushings. I over a mk4 before and loved its shifter stock but decided not to since they wanted 60$ for a used one + for me to change all the bushings it would be around 90-100$. Since I use this car for hunting, woods and driving stuff around I felled like thrown away money. In the woods I don't shift allot and its mainly 1,2,3 and since I've changed the bushings it shifts good now just have to fix that its not aligned atm ( when in neutral its in the far left - first more than in the middle (3rd 4th). My main plan for this car war lift it as high as it goes to still be comfortable to drive and not brake the axles, learn to weld ( I will be fixing the underneath and body latter ) and just have fun with it.

I also own a BMW X3 2014 with 4wheeldrive which is amazing for going to the wood cabin and other but I got so many scratches from the branches and similar and costed me 3k to repair the paint and polish it and decided to buy this one. With the car price and parts I am about at 850$ with this golf and it drives great. I dont even lock it and the keys stay inside over night and I dont even care :LOL:

Here is a pic of it when I had a side job and had to transfer all the material and tools to the jobsite. Before that I had to rent a flatbed that I had to pay 40$ a day and now I do 2-3 drives.

 
Last edited:

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
New updates on the car ~

Got these installed and throwed away the one painted and other one missing.







I am missing one bumper grille so ordered it.. Also will need to screw the under lip with longer screws since the ones now are to short.





got these old yellowish front bulbs changed for a bright truck halogen ones ( also saw then my passanger light was not working and spend 1 hour going through all wires, connections cleaning with contact cleaner and did not found the issue. I think cleaning the ground wires where they connect to the chassis fixed it.





Did all the 3 belts, tensioners and the suspension pulley or what you call it. The pulley was the most expensive part but was needed since I had a loud knocking sound when I turned the steering. The main belt was also in bad condition and I was sure lucky it dident slip or snap off since I was driving it like that since I got it.







also found this one in bad shape so ordered new one from SASIC that allot of people mention is a good alternative if you dont want to pay 70$ for a LEMFORDER.

 

mahir

Active member
Joined
Dec 19, 2017
Location
Sana, BIH
TDI
1.9TDI ALH
Examined the rust spots on the front strut towers. Driver side is the worst and the other one will need some patches.

driver side ~









passanger side ~













So its not really that bad since I drived offroad and the thing is still holding but sure it needs maintenance. What do you guys suggest should i buttweld it with 14 or 16 gauge ? also are the lower parts that are under the strut mounts also that thick or is it 1mm sheet ?

List of things that I will focus on now are...

1.) Repair the Strut towers
2.) Mount Front passat suspension and back just the 35i springs with mk3 suspension.

I've also got new pair of tyres today. Only driven 2 months so great catch for 40$. They are 175/80 R14...





 
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