What did you do to your MKIV today?

[Powder Hound]

Maybe part of the way. Maybe. The macpherson strut front suspension does not allow for much adjustment other than the usual toe in, and subframe adjustment by the diligent mechanic with all too rare integrity. Or maybe they find too much rust in the nuts and bolts and don't want to break stuff trying to get it apart.

My Y2K Golf has had a CEL staring at me for quite a while, and I diagnosed it via VCDS a couple of months ago to be something easily fixable (coolant temp sensor*) and glowplugs. I figured this last one was coming, although needing to worry about that in a very hot and humid summer here in FL is not on my to-do list. So, a couple of days ago I finally did it.

In wanting to clean around the glowplugs before pulling them I used some water and noticed #2 and #3 were bubbling while warming the car since I wanted to do a compression check as long as I was there. And the ohm test showed #4 at 1.9 ohms and open for the other 3.

Good compression test. 460, 455, 450, 435. I suspect that last one was due to the cooling engine and (most likely) a test device that was not holding the pressure as well, so I am not alarmed in the least and the number is within 5-6% anyway. 307k miles on the engine with little more than required maintenance.

After fitting 4 new glowplugs, it starts with barely any cranking and I will start a full tank of fuel for a new mileage check as it has been low for quite a while.

Cheers,

PH

* Well, maybe not so easily fixable. I ended up having to remove the end of block coolant casting because the plastic clip that holds the sensor in place was deformed and I had to cut things apart to get it out in pieces. The new sensor had been kicking around for a while and then it turned out that I had used it (the clip) on a different car (a whole 'nuther story about that POS) because those clips are too delicate to be reuseable. Nobody in town (i.e. the FLAPS) had one, so I finally ordered a bunch online and fabricated my own spring clip from some safety wire. A long hot day on what should have been a relatively quick job. I wish Murphy would go hara kiri himself and get out of my house.

 

[J_dude]

My old eyes missed that part. Wonder if some finageling with the ball joint would get it the rest of the way?

I wouldn’t know which way to move it...

Or maybe they find too much rust in the nuts and bolts and don't want to break stuff trying to get it apart.

Well everything but the subframe is new, and it’s not really rusty, this was an Alberta car and they don’t salt there, just sand. So I dunno.

 

[J_dude]

Just got the printout for my wheel alignment. A little hard to see the numbers in the pic, but why would he not be able to get RF caster and camber within spec? Anything else that looks wrong?

3B9D05E1-2D2C-417C-9D20-41E8978F86B9.jpeg

• J_dude
• Sep 8, 2023

147AA5BE-B367-43C3-AB81-5FCA86C7561A.jpeg

• J_dude
• Sep 8, 2023

Oh crap, right front! That’s the one!
I wasn’t sure if the strut was fully seated in the knuckle on that one, seemed like there was a bit of a bump of weld on the bottom of the strut that was keeping it from seating all the way. Mind you it wasn’t off by much, and I smacked it with a hammer and it looked like it was okay but that may be the issue here.
Now I’m going to have to pull it apart and grind that bump off I guess...

 

[Zak99b5]

I had to really hammer and pound my front right strut into the knuckle. So much so I will probably just get a new/used knuckle next time I have to take the suspension apart.

 

[ts888]

Today I installed the Frost Heater I bought off another inmate here. I got a chuckle out of the 8 page instruction manual, since the install is all but self explanatory. Pulled the battery, pulled the battery box, dropped the heater in place. Pulled off the existing hose, slipped on the hoses from the heater. Cut the old hose loose and removed it.

This unit was stated to be for a Jetta, but the bracket on it didn't come close to anything resembling an attachment point, so I ignored the bold notice telling me "DO NOT MOVE THE BRACKET!" and moved the bracket. In fact, I took it off, smooshed it flat and drilled a new hole in it. Then I moved it to the other side of the heater. I knocked out another bracket from some scrap steel, quite a bit sturdier than the one that came with. Now it is secured on both sides and very solid.

This is step one with the existing bracket moved and modified (temporarily installed with one of the battery box bolts to hold everything while I measured for the second mount.)

frosty1.jpg

• ts888
• Sep 9, 2023

This is the end result with the added mount.

frosty2.jpg

• ts888
• Sep 9, 2023

It's not terribly cold where I live, we're often below freezing but only a few degrees, maybe we see a week in the teens or 20's. But my commute is short and I am anticipating that in winter the engine will have hard time getting up to temp in 7 miles. This will serve to get the engine warm and let me have heat when I need it.

 

[pkhoury]

*** did I do today... tried to get DSEL (unsuccessfully) on my trailer with the F-450, after something in my transmission failed (either throwout bearing, clutch or pressure plate). Went back home, AGAIN, and brought DSOL and my uhaul tow dolly. Then couldn't get it out of 5th gear initially, but eventually got it back to neutral, and the three of us rolled it onto my driveway.

Not really a TDI, but changed engine filter, oil, transmission fluid, and topped off power steering hydraulic fluid on my Ford 3400 tractor (yesterday, changed from a generator to an alternator). Need to reseal my hydraulic system, so now I get to juggle doing that (and clearing more crap off the driveway) while working on pulling my 02J to fix my other Golf. My girlfriend finally got it today WHY I have two 2002 Golf TDIs (that are almost identical mechanically). Deer is the other reason why. ;-/

 

[pkhoury]

Today I installed the Frost Heater I bought off another inmate here.

Another inmate here? Haha, this is TDIclub, not a GMC 6.5L forum. TDIclub would be like a garage; to me, anything GMC diesel <2000 would be a correctional institution.

 

[pkhoury]

Installed the Westfalia hitch on the Golf. Also replaced the stock taillights with GTI tails that I bought a while back. I think they look better on a black car than the stock lights. Finally replaced both broken springs with Lesjöfors wagon springs. Hopefully they'll last longer than the Suplex, which both broke in less than 30k miles.

Smart man. I love my Westfalia/Bosal hitches. You absolutely CANNOT go wrong with what's considered a factory hitch.

Your Suplex springs broke? I have those on the JSW now, but need to go back to my Neuspeeds when it's done at the body shop. Out of curiosity, are they Suplex towing springs, and did they break at the same time and/or same place?

 

[pkhoury]

On the turbo replacement, the oil fitting is a known PITA; any suggestion on a tool to counterhold the adapter so it will release the line instead of spinning it( and wrecking it)? Also since I acquired a Garrett VNT17 with a braided line I was not too worried, but on install the banjo bolt it came with turned out to have the wrong threads( finer ), and I used the bolt the car was built with at the oil filter end of the line. Pretty glad I did not get the first half thread engaged and then drive it in...would have ended poorly I have to bet.

Douglas

Oil fitting feeding INTO the turbo, or the return that goes back to the crankcase? I don't remember what size the return is, but remember it's a 27mm on a mk5/6. Whenever I've pulled VNT15's, I have a braided line ready and I'll just cut/destroy the hard line, rather than try to baby it. I've found it's damn near impossible to get it out alive, especially with the little space you have to work with between it and the firewall.

 

[pkhoury]

I've got some new Valeo and remanufactured Bosch ones. $145 plus core and shipping for the Bosch or $295 plus shipping for new Valeo
Both 120 amp.
Also have other options, including ceramic bearings and higher amp ones.

Any difference between the two, other than the price and core? Haven't seen recurring problems on my crappy Autozone DLG alternator, but if/when it fails again, I'll probably save myself the headache and get one of yours. I forgot - do you do alternators for other vehicles?

 

[Mozambiquer]

Any difference between the two, other than the price and core? Haven't seen recurring problems on my crappy Autozone DLG alternator, but if/when it fails again, I'll probably save myself the headache and get one of yours. I forgot - do you do alternators for other vehicles?

The design is slightly different, but both are good. The Valeo is harder to rebuild, the Bosch is really easy to rebuild.

 

[PakProtector]

Another inmate here? Haha, this is TDIclub, not a GMC 6.5L forum. TDIclub would be like a garage; to me, anything GMC diesel <2000 would be a correctional institution.

There is actually a set of audio forums called Audio Asylum.... LOL

Douglas

 

[SoKYTDi]

__Yesterday__ Completed the removal of the 02M from my Golf so I can begin fixing the R-1-2 shift fork at a later date. I'm paying for it today -- I'm sore as hell -- and after 5 years of sitting, it can wait. Besides, I have to mow today.

 

[J_dude]

Another inmate here? Haha, this is TDIclub, not a GMC 6.5L forum. TDIclub would be like a garage; to me, anything GMC diesel <2000 would be a correctional institution.

I saw that too
Sounds like you’ve been to thetruckstop.us in the past... lol

 

[ts888]

There is actually a set of audio forums called Audio Asylum.... LOL

Douglas

I think I am a member there. But the 'inmate' thing probably arises from my many years on ADVRider.

 

[Mozambiquer]

Another inmate here? Haha, this is TDIclub, not a GMC 6.5L forum. TDIclub would be like a garage; to me, anything GMC diesel <2000 would be a correctional institution.

I've got a 6.5 diesel... 450k miles before the engine failed, not too bad lol. Building an engine for it now.

 

[pkhoury]

I've got a 6.5 diesel... 450k miles before the engine failed, not too bad lol. Building an engine for it now.

I used to own one, and sold that POS in February. Haha, I beg to differ on "not too bad." It's bad when you have both a blown head gasket on the original block, and a blown head gasket on the rebuilt block/new head.

 

[Mozambiquer]

I used to own one, and sold that POS in February. Haha, I beg to differ on "not too bad." It's bad when you have both a blown head gasket on the original block, and a blown head gasket on the rebuilt block/new head.

I've never blown a head gasket on any of them. (Fingers crossed)
I've owned four of them, and the only major failure I had was this one which broke the crank at 450k miles. I'm building an 6500 optimizer for it, studs, hx-35 turbo, air to water intercooler and a fluidampr. Also going with the military multi-fuel pump and new oem injectors

 

[Mozambiquer]

20230901_151116.jpg

• Mozambiquer
• Sep 10, 2023

Did a 6.5 swap... umm sticker... on my passat lol.

 

[J_dude]

I've never blown a head gasket on any of them. (Fingers crossed)
I've owned four of them, and the only major failure I had was this one which broke the crank at 450k miles. I'm building an 6500 optimizer for it, studs, hx-35 turbo, air to water intercooler and a fluidampr. Also going with the military multi-fuel pump and new oem injectors

Are you on TheTruckStop?

 

[pkhoury]

I've never blown a head gasket on any of them. (Fingers crossed)
I've owned four of them, and the only major failure I had was this one which broke the crank at 450k miles. I'm building an 6500 optimizer for it, studs, hx-35 turbo, air to water intercooler and a fluidampr. Also going with the military multi-fuel pump and new oem injectors

I'll never make that mistake again. I will say it sounded impressive, but didn't come close to my 1995 F-Super 7.3. Supposedly, the guy who sold me the block said it was an optimzer block based on the casting code, but I think he was full of crap. Head studs, hx-35 as well, a tune way crappier than Malone, fluidampr, the dual t-stat deal, aftermarket intake, downpipe, new billet torque converter, and some crap that stopped working from a guy called LeroyDiesel. I needed some tech support from him years ago and he made comments that really steered me away from his company, all because I've had arthritis in both thumbs since I was a child, so it makes using hand tools interesting sometimes. When I'm doing a lot of gripping, the pain is extraordinary. Sometimes I can suck it up, and other times, it's unbearable.

It was NOT a good rig I found for using as a farm truck; some people seem to swear by them, but trying to tow 7000+ pounds and it really struggled compared to the 7.3, which is also lightly modified/tuned.

 

[pkhoury]

As for what I did today - pulled the battery, airbox and most of the top bolts/shifter cables. Sadly, I had to come in because I was soaked (damn hyperhidrosis). Need to jack up the car, pull the CV's, dogbone, rest of the bolts and start to pull the 02J. Still hoping it's just a throwout bearing, but I see some dust near the viewing port on top of the transmission.

 

[gmenounos]

Smart man. I love my Westfalia/Bosal hitches. You absolutely CANNOT go wrong with what's considered a factory hitch.

Your Suplex springs broke? I have those on the JSW now, but need to go back to my Neuspeeds when it's done at the body shop. Out of curiosity, are they Suplex towing springs, and did they break at the same time and/or same place?

They were wagon springs, not towing springs. I have not had good luck with Suplex rear springs. I've had several break at the same spot at the bottom of the spring. 2 different cars:

https://forums.tdiclub.com/index.ph...-your-mkiv-today.452221/page-229#post-5661134

https://forums.tdiclub.com/index.ph...-your-mkiv-today.452221/page-336#post-5774330

 

[pkhoury]

They were wagon springs, not towing springs. I have not had good luck with Suplex rear springs. I've had several break at the same spot at the bottom of the spring. 2 different cars:

https://forums.tdiclub.com/index.ph...-your-mkiv-today.452221/page-229#post-5661134

https://forums.tdiclub.com/index.ph...-your-mkiv-today.452221/page-336#post-5774330

I saw the photos, and "oh f**k" was my reaction. Seems like a manufacturing defect, if they're that $hitty and both broke in the same spot.

 

[Gvr]

Replaced the steering rack bushing with a Strongflex poly one, did the job in less than 30 minutes. Might be placebo, but I find the steering "tighter". Well worth for the time and money..

IMG_20230912_163711.jpg

• Gvr
• Sep 12, 2023

 

[pkhoury]

Pulled my oil pan, cleaned it as best as I could, especially where it mates to the block. I might've screwed up my RMS, but I have another one that arrives tomorrow. Found my flywheel has a timing mark (unlike two other new flywheels that don't), so I need to find out if a shop locally can resurface it for me. Then, I can get started reinstalling my clutch. Only thing I'd be missing is a new mounting bracket. Without any vertical force applied to it, one of the bolts didn't want to come out so easy and took some aluminum threads with it. Figured I'd order another one and might timesert the bad one to keep as a spare.

 

[IndigoBlueWagon]

After a long drive a couple Sundays ago I noticed that my transmission would whine at neutral power delivery (not accelerating, not decellerating) when it got hot. I was concerned about bearing wear. So before I went too far in sourcing a replacement I changed the gear oil with the old school G050 along with 100 ml of Liqui-Moly Ceratec. Now it's quiet. Not sure how long it will last, but I'm happy, for now.

 

[ts888]

Took a few minutes after work today and renewed the transmission oil. The new oil -- some GL4 from Redline -- has been sitting on my bench for a few months. Oil in the trans was dark but not really nasty, still smelled like gear oil and not dead moose.

It's been about 3,000 miles since I brought this one back to life with a new head, timing parts, rod bearings, etc. Engine oil level is still sitting at the full mark, pretty happy with that for a 290k-ish engine with no history. One of the techs at the shop came over while I was working and said "Holy sh**, that's the cleanest old VW engine I've ever seen!" To which I replied "... and it's a diesel."

 

[pkhoury]

I'm pretty f**king tired. So I had an adventure today. Found that the throwout bearing I just got recently doesn't stay adhered to the clutch fork (yet another one from the same order does). Then a bolt sheared off on me, that connects the flywheel to the crank. Thankfully I had just barely enough of a high spot to use a dead blow and a screwdriver to get it started and unscrew it by hand (got the idea from one of @oilhammer 's posts). Pinched my damn braided oil line, so I gotta replace that, and had to take out both flanges to get the transmission stabbed in. After I got the transmission stabbed, the rest of the job was fairly easy. If I get my parts on time, hopefully I'll be back to driving by Wednesday or Thursday.

Don't have pictures of it, but showered three times from today's work alone. Did something new, and when I went to sit down and raise the transmission jack, I sat in a plastic tub of used motor oil. Yes, my boxers and shorts have a BIG black spot on them. Took me 15-20 minutes for my third shower to get all the nastiness off. In my other thread, someone mentioned gloves. I don't think gloves protect someone from R&Ring a transmission, when other parts of your body get filthy.

 

[jmodge]

Sounds like you need to wear plastic pants as well as gloves