What did you do to your MKIV today?

gmenounos

Vendor
Joined
Jun 26, 2003
Location
Watertown, MA, USA
TDI
'99.5 Golf GLS, '01 Jetta GLX Wagon (TDI conversion)
Removed the Westfalia euro hitch from the wagon (which I'm getting rid of) so that I can install it in the Golf. While I had the tail lights off, I replaced them with some euro ocean lights that I had bought a while back but never installed.
 

SilverGhost

Veteran Member
Joined
Mar 25, 2005
Location
Back in So Flo - St Lucie
TDI
'05 Golf - totaled :(, wife's '13 Beetle - buy back, TDIless
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I also found this other part and I don't know if this came with the compressor as some sort of adapter or what, but I have no idea if this even goes to the Jettas. Anyone have an idea what this is? Tried to read and search the number on the molding but got nothing.

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VW changed the connector from early designs with the metal clip to later version all plastic, but the compressor is basically the same. So some after market places sell one version with an adaptor to fit older cars.

Jason
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
Not mine and not a diesel, but r&r’d the crank position sensor on his 03 2.0 Golf.

His engine just died while driving a couple days ago. He was able to restart it and get home. Yesterday same thing happened, and he came over with it to scan with VCDS. I was thinking ignition switch, but he had two codes for G28.

It was a grimy mess to pull the sensor out, but finally removed it and installed the new one I picked up at NAPA on my way home from work. Car started right up. All the wiring leading to the plug looked a-ok.

For shots & goggles i ohmed out the old sensor, which of course tested fine. But I expected that as the sensor hadn’t yet failed completely.
 

Powder Hound

Top Post Dawg
Joined
Oct 25, 1999
Location
Under a Bridge, Crestview, FL, USA
TDI
'00 Golf 4dr White 5sp, '02 Jettachero 5sp, Wife's '03 NB Platinum Gray auto(!)
Refreshed all the front end bushings on the Y2K Golf. Struts are Koni and doing fine. In trying to refurbish the roll bar link bushings, one broke (the link broke) so all is finished except installing the new links that are yet to come.

Tomorrow I get to start on the air conditioning. I will be replacing the compressor, condenser, receiver/dryer, and the valve. I won't replace the evaporator; I will just flush it and all the lines. The evaporator is much too big a PIA so I'll take my chances with a thorough flush. Wish me luck!

Cheers,

PH
 

dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
While back I did the diesel geek short throw shift kit, and ordered all the shifter bushings with it. Finally got sick of all the slop in the shifter so I tackled that. Only one I didn't replace was the front to back. I forgot the previous owner said there was a shift cable that went bad when his son was in school. His kid did the logical thing for an 18yo... Google vw dealers in Pittsburgh and had them come get it. I remembered Peter's was furious about it, but kinda had his hands tied. Wasn't a cheap bill. Lol. Anyway that bushing was nice and tight so I didn't bother messing with it. Loaded a new tune from burpod and went for a drive. We're getting closer to perfection I can feel it. Or we'll as perfect as it's gonna get with my combination of parts.
 

Diesel Fumes

Veteran Member
Joined
Dec 30, 2008
Location
Creston, bc
TDI
2003 alh tdi 5 speed
I tried recharging the air conditioning today. I had assumed the whole system was buggered now for like 3 years. Charged it and now it blows ice cold 😀
 

SilverGhost

Veteran Member
Joined
Mar 25, 2005
Location
Back in So Flo - St Lucie
TDI
'05 Golf - totaled :(, wife's '13 Beetle - buy back, TDIless
Not mine and not a diesel, but r&r’d the crank position sensor on his 03 2.0 Golf.

His engine just died while driving a couple days ago. He was able to restart it and get home. Yesterday same thing happened, and he came over with it to scan with VCDS. I was thinking ignition switch, but he had two codes for G28.

It was a grimy mess to pull the sensor out, but finally removed it and installed the new one I picked up at NAPA on my way home from work. Car started right up. All the wiring leading to the plug looked a-ok.

For shots & goggles i ohmed out the old sensor, which of course tested fine. But I expected that as the sensor hadn’t yet failed completely.
G28 usually fails hot - get it nice and toasty, then ohm it out.

jason
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
I tried recharging the air conditioning today. I had assumed the whole system was buggered now for like 3 years. Charged it and now it blows ice cold 😀
I'm facing a car with no A/C either (low/no pressure in the lines), so just curious how you did that? Did you do the whole vacuum of the system for an hour or whatever and then put in the refrigerant? Or just plugged in a can of R134a (or R12?) and dumped the contents?
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB
E-brake wasn’t holding , took a look and found rh lever wouldn’t move.
Tapped with hammer but barely moved. Got the cable off and still wouldn’t move.
Removed lever and destroyed the shaft seal trying to get it out , rubber came out but the steel in the rubber remained in the housing. Used a small flathead screwdriver and tapped side in till broke loose. It was filled with corrosion.
Used a pick to clean out corrosion and silicone spray and worked shaft back and forth to loosen it up.
I had a seized caliper that I pulled the seal out intact , greased up the inside along with the shaft , reinstalled seal , lever and spring and works beautifully….30 minutes of my time and not a dime spent…..priceless…..
 

benIV

Veteran Member
Joined
Oct 25, 2009
Location
Southeast NC
TDI
2003 PG 5m Jetta GL Sedan, 2003 RS 5m Jetta GLS Wagon (Golf Variant)
Replaced Wilbur's left knuckle and some other parts. put the pics in the pic thread in sig.
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
E-brake wasn’t holding , took a look and found rh lever wouldn’t move.
Tapped with hammer but barely moved. Got the cable off and still wouldn’t move.
Removed lever and destroyed the shaft seal trying to get it out , rubber came out but the steel in the rubber remained in the housing. Used a small flathead screwdriver and tapped side in till broke loose. It was filled with corrosion.
Used a pick to clean out corrosion and silicone spray and worked shaft back and forth to loosen it up.
I had a seized caliper that I pulled the seal out intact , greased up the inside along with the shaft , reinstalled seal , lever and spring and works beautifully….30 minutes of my time and not a dime spent…..priceless…..
When I cleaned up my parking brake to free it up, I couldn't see how to get the rubber boot off the shaft. So I just stuck a pick down between the boot and the shaft and scraped around a bit and sprayed Kroil in there to free it up.

I did order new calipers to swap in, but I'm planning on rebuilding the ones I take off so I have spares. Any tips on how to remove that rubber piece?
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB
When I cleaned up my parking brake to free it up, I couldn't see how to get the rubber boot off the shaft. So I just stuck a pick down between the boot and the shaft and scraped around a bit and sprayed Kroil in there to free it up.

I did order new calipers to swap in, but I'm planning on rebuilding the ones I take off so I have spares. Any tips on how to remove that rubber piece?
I had a spare caliper that was seized . I had shredded the one on the car.
I used needle nose pliers and grabbed as much of the seal as possible and kind of rolled it towards the shaft. I worked it around and it popped off…that was on the spare one I had…easier to look at. I thought it was all rubber but when I got it out I realized that it was a metal cup encased in rubber.
Once I got most of the rubber out with a pick and needle nose pliers, I scraped around the edge and found the metal cup .
I then used a small common screw driver and tapped the edge toward the shaft in two places next to each other and the seal popped out.
Cleaned the rest of the corrosion up and freed shaft up and used some wheel bearing grease.
The seal was packed with more grease and pushed in with a screw driver.
I believe that seal comes in a rebuilding kit.
I did one years ago .
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
I had a spare caliper that was seized . I had shredded the one on the car.
I used needle nose pliers and grabbed as much of the seal as possible and kind of rolled it towards the shaft. I worked it around and it popped off…that was on the spare one I had…easier to look at. I thought it was all rubber but when I got it out I realized that it was a metal cup encased in rubber.
Once I got most of the rubber out with a pick and needle nose pliers, I scraped around the edge and found the metal cup .
I then used a small common screw driver and tapped the edge toward the shaft in two places next to each other and the seal popped out.
Cleaned the rest of the corrosion up and freed shaft up and used some wheel bearing grease.
The seal was packed with more grease and pushed in with a screw driver.
I believe that seal comes in a rebuilding kit.
I did one years ago .
Great--thanks. I actually found a good video of how to rebuild the rear calipers on youtube.

Now if only I could find a rebuild kit. Only thing i've found so far is the seal & boot for the piston. I did see a kit on ebay from Great Britain, but my car wasn't listed in the compatibility list. Messaged the seller to see.
 

Diesel Fumes

Veteran Member
Joined
Dec 30, 2008
Location
Creston, bc
TDI
2003 alh tdi 5 speed
I'm facing a car with no A/C either (low/no pressure in the lines), so just curious how you did that? Did you do the whole vacuum of the system for an hour or whatever and then put in the refrigerant? Or just plugged in a can of R134a (or R12?) and dumped the contents?
Just dumped in a can. No idea how long it will last but for now it does.
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB
Zak check the number on the caliper…. There are 2 different size pistons……it’s on the round part of the casting where the piston is housed . I know one is 38…. Can’t remember if other is higher or lower.
They make two different kits.
 

Diesel Fumes

Veteran Member
Joined
Dec 30, 2008
Location
Creston, bc
TDI
2003 alh tdi 5 speed
10 psi before, 80 after. Turns out I filled it a bit much I think
Admittedly I didn't know what I was doing. Hooked a can up and it went to like 50psi. Took can off. Started car for 5 mins blowing full ac. Then shut down and check and it read 80. First time I ever recharged an ac system
 

dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
What pressure are you looking at? High side should be higher then that, and low side should be lower then 80. More like 35-45 ish. Really can't tell anything with out a manifold gauge set.
A rough idea of full charge will be sytem pressure after its been off for a while. It should be close to ambient temp. So 70psi if its around 70* out. The system needs to equalize first though, and it's just a general rule of thumb.
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
And the correct pressure only tells you there is SOME (and not way too much) in the system, so it should turn on.

I've heard it explained like this: think of a bottle filled a bit with liquid, under pressure. There's liquid at the bottom because of the pressure above it. That pressure doesn't tell you how much liquid there is, only that there's enough liquid for some of it to turn into a gas and keep the pressure (which keeps the bottom liquid).

Not sure if I'm explaining that very well, but that's why you need to know the mass of the R134.
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
Zak check the number on the caliper…. There are 2 different size pistons……it’s on the round part of the casting where the piston is housed . I know one is 38…. Can’t remember if other is higher or lower.
They make two different kits.
Cool I will check out the calipers for that after I remove them. New calipers should come today, so I'll do that tomorrow.

Shipping on the ebay rebuild kit from the UK doubles the price. Thinking maybe a group buy might be in order??
 

SilverGhost

Veteran Member
Joined
Mar 25, 2005
Location
Back in So Flo - St Lucie
TDI
'05 Golf - totaled :(, wife's '13 Beetle - buy back, TDIless
Ideal is around 30 PSI low side and depending on car and how hot it is outside between 150 and 250 high side (though 180 is a good number in 80*F weather out of direct sunlight).

Standing pressure (car/AC not running, will be close to ambient temperature. BUUUUUUUT, soon as you start the car to run the AC you add heat to system and the pressure will be higher. It will take hours to settle back to ambient temperature and pressure match again.

@Zak99b5 - good description on pressure vs total system charge volume. That's why I always recover system then charge with set amount. No way to tell how much is actually in the system until to take it out an weight it. And I have seen overcharged systems fail dramatically - fluid does not compress.

Jason
 

dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
Got my e brakes cables on. Found the left rear caliper pins were seized up. Got them out and cleaned up. Working well again. Also had to work to get the e brake lever freed up. Got rotors and pads ordered for it. On the bright side the brake pedel doesnt totally suck anymore.
 

romad

Top Post Dawg
Joined
May 27, 2011
Location
Prescott, AZ
TDI
2005 Jetta GLS Wagon "Cranberry"
Squeezed in a wash job between yesterday's & today's thundershowers. Next week I have to do the Miata.
 
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