What did you do to your MKIV today?

dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
How does that work with the boot? I think the boot on my MKIV is attached to the knob.
Looks like you zip tie it to the ring around the bottom. Not totally unlike how vw did it, they just used that plastic ring to hold the boot to the bottom of the shifter.
 

STDOUBT

Veteran Member
Joined
Jul 30, 2007
Location
Portland, effing Oregon
TDI
dos jettas
How does that work with the boot? I think the boot on my MKIV is attached to the knob.
My OE boot was sunbaked, so I didn't re-use it, but on the installation instructions page it looks like it comes apart pretty easily!
Looks like you zip tie it to the ring around the bottom. Not totally unlike how vw did it, they just used that plastic ring to hold the boot to the bottom of the shifter.
Since my custom leather boot was thicker, I couldn't use the included o-ring thingey nor the zip tie.
I used some 12 ga copper wire like a twist-tie to attach the boot. Worked great!
 

PakProtector

Veteran Member
Joined
Jan 5, 2014
Location
AnnArbor, MI
TDI
Mk.4's and the Cummins
Should perhaps read something to do with plural Mk.4's. Am currently plotting the fettling of the latest add to the herd. TB kit, e-brake cables. Then on to an exam of 'does it need its blend doors plugged'. Right now the only thing going to happen to it is an in-place clean out of the rot pockets behind the front wheel wells, and removal of the foam should it still be there.

Douglas
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
Got the tranny back in with help from No. 1 son. Got a lot of things back together, but we were losing light before we could get to the drive axles, so I'm hoping to finish it up tomorrow.
 

KrashDH

Top Post Dawg
Joined
Dec 22, 2013
Location
Washington
TDI
2002 Golf
When I did my headlight retrofit, I custom wired the inside headlight harness for the functionality that I wanted it to have with all my extra goodies. I put led bulbs in the projector housings for the fog lights, but it was a very back burner project

Now that I wired the gauges in and ran stuff through the firewall, decided it would be a good time to run the fog light trigger wires and such too.

On the euro switch, fog position 1 will be headlight fogs, and pos 2 will be the in bumper amber/yellow fogs. I could have been done, but I decided I didn't want relays all over the place. Plus I already have some extra wiring from my morimoto harness, the under hood lights, and the addition of a BEW lift pump.

I ordered an auxiliary fuse/relay box and am going to send both sets of fog lights throught relays in there (even thought both draw such little current). Its got spots for non relay fused power as well, so I'll send my under hood lighting to there as well. Headlight ballasts im going to keep directly connected to battery power (and the ground) just for peace of mind. Fuel pump power I'm not sure if I'll keep it directly to battery or go off the new aux box, I'll make a game time decision.

Aux box is supplied by 2x 12ga wires. I'm going to install an inline 40a breaker between batter pos and the aux power since the 2x 12ga wires I'll tie together in parallel can safely handle that. The side going from the battery to the breaker will have 8ga which can also handle 40a.

So for some reason if something goes bad, the individual circuits are all protected by fuses and itlf it goes really bad, the breaker will trip (it's resettable)

I don't plan anything with massive current draw to be on this car, so 40A at the same time is plenty. I think the bumper fog light bulbs I have draw like 3A if that, and the ones in the actual headlight housing are around 1A. The under hood lighting is about 1A, the fuel pump is (?). I'm well within the parameters.

I'll post a couple pics when it's all said and done.
 
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dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
When I did my headlight retrofit, I custom wired the inside headlight harness for the functionality that I wanted it to have with all my extra goodies. I put led bulbs in the projector housings for the fog lights, but it was a very back burner project

Now that I wired the gauges in and ran stuff through the firewall, decided it would be a good time to run the fog light trigger wires and such too.

On the euro switch, fog position 1 will be headlight fogs, and pos 2 will be the in bumper amber/yellow fogs. I could have been done, but I decided I didn't want relays all over the place. Plus I already have some extra wiring from my morimoto harness, the under hood lights, and the addition of a BEW lift pump.

I ordered an auxiliary fuse/relay box and am going to send both sets of fog lights throught relays in there (even thought both draw such little current). Its got spots for non relay fused power as well, so I'll send my under hood lighting to there as well. Headlight ballasts im going to keep directly connected to battery power (and the ground) just for peace of mind. Fuel pump power I'm not sure if I'll keep it directly to battery or go off the new aux box, I'll make a game time decision.

Aux box is supplied by 2x 12ga wires. I'm going to install an inline 40a breaker between batter pos and the aux power since the 2x 12ga wires I'll tie together in parallel can safely handle that. The side going from the battery to the breaker will have 8ga which can also handle 40a.

So for some reason if something goes bad, the individual circuits are all protected by fuses and itlf it goes really bad, the breaker will trip (it's resettable)

I don't plan anything with massive current draw to be on this car, so 40A at the same time is plenty. I think the bumper fog light bulbs I have draw like 3A if that, and the ones in the actual headlight housing are around 1A. The under hood lighting is about 1A, the fuel pump is (?). I'm well within the parameters.

I'll post a couple pics when it's all said and done.
Interested to see finished pictures too.
 

The Cream Dolphin

Veteran Member
Joined
Feb 22, 2021
Location
Fernie, B.C. originally Dwight, ON
TDI
02 VW Golf TDI ALH 245k
Got code P1563 QA lower limit stop value, with a slight shudder at idle and 170̷0̷RPM. Got it the first time ever after changing my fuel filter, and noticed some air in the clear line, It seems from other reading that may be the cause? Brought the adaptation for qa back to stock at 5mg/st from 3. It stopped it for now
 

ts888

Veteran Member
Joined
Feb 18, 2023
Location
PNW US
TDI
03 ALH
Today I installed some new headlamp bulbs, and discovered the wiring inside the housings is shedding insulation like a 90's Mercedes. I patched it up with electrical tape. I'm eventually going to shell out for some new headlamps, for now disaster is averted.

*EDIT* I should add that this project also revealed why the driver headlamp was dimmer and had a wonky pattern -- the bulb was not locked in, and it had slipped back so only about half the bulb was inside the reflector. In hindsight I should have realized this sooner, but I wasn't motivated to pull the battery for access.
 
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KrashDH

Top Post Dawg
Joined
Dec 22, 2013
Location
Washington
TDI
2002 Golf
Today I installed some new headlamp bulbs, and discovered the wiring inside the housings is shedding insulation like a 90's Mercedes. I patched it up with electrical tape. I'm eventually going to shell out for some new headlamps, for now disaster is averted.
Honestly, most of the aftermarket headlight wiring these days uses the flexible silicone sheath wiring harnesses. Won't crack on you again and much greater flexibility than the PVC coated crap. If your headlights are in good shape, I would just rob a wiring kit from one of those if you end up purchasing aftermarket ones.

I also think AArodriguez sells just the pre made harnesses with the upgraded wiring as well.

Edit: After being shown an "interesting" news article to say the least, maybe just skip him and steal the harnesses out of an aftermarket light setup...

I do have a couple of new headlight harnesses that have the standard PVC coating that were pulled from an aftermarket setup (new)that have the wiring for the projector bulb. If you don't have projector in the housing you could just omit using that wire
 
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ts888

Veteran Member
Joined
Feb 18, 2023
Location
PNW US
TDI
03 ALH
Honestly, most of the aftermarket headlight wiring these days uses the flexible silicone sheath wiring harnesses. Won't crack on you again and much greater flexibility than the PVC coated crap. If your headlights are in good shape, I would just rob a wiring kit from one of those if you end up purchasing aftermarket ones.

I also think AArodriguez sells just the pre made harnesses with the upgraded wiring as well.

Edit: After being shown an "interesting" news article to say the least, maybe just skip him and steal the harnesses out of an aftermarket light setup...

I do have a couple of new headlight harnesses that have the standard PVC coating that were pulled from an aftermarket setup (new)that have the wiring for the projector bulb. If you don't have projector in the housing you could just omit using that wire
My headlights are junk. The reflectors are flaking, the DS is missing the cover over the turn signal bulb, and of course the insulation is coming off the wires. I would have replaced them all ready, but I keep fishing for a dead Golf close enough to be practical to buy for front end parts. That fixes multiple issues -- denty left fender, beat up bumper cover and junk lights. Plus it makes the car more attractive, at least to my eyes.
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
Not specifically only mk4 related, but I signed a lease on a shop close to me where I will be working on these and other tdis. I may be a bit excited lol.
Obviously still doing the starters and alternators, but adding in diagnostics, repairs and all on small diesels.
 

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,gluten for punishment got another tdi 2001NB,another yellow tdi NB
Congratulations ! Good luck with the shop !
 

TornadoRed

Top Post Dawg
Joined
Aug 3, 2003
Location
West Des Moines (formerly St Paul)
TDI
2003 Jetta TDI wagon, silver; 2003 Jetta TDI wagon, indigo blue; 2003 Golf GL 5-spd, red (PARTED); 2003 Golf GLS 5-spd, indigo blue (SOLD); 2003 Jetta TDI wagon, Candy White (SOLD)
Not specifically only mk4 related, but I signed a lease on a shop close to me where I will be working on these and other tdis. I may be a bit excited.
I hope there are enough TDIs in the area to keep you busy. Though I suppose you'll branch out to work on other diesels as well, and maybe gas-engine VWs?
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
I hope there are enough TDIs in the area to keep you busy. Though I suppose you'll branch out to work on other diesels as well, and maybe gas-engine VWs?
There are a lot of them locally, and I also do the starters and alternators as well plus work on other small diesels that some people won't touch, like some of the old mechanical VW, Ford, Mazda, Chevrolet, Mitsubishi and etc.
 

The Cream Dolphin

Veteran Member
Joined
Feb 22, 2021
Location
Fernie, B.C. originally Dwight, ON
TDI
02 VW Golf TDI ALH 245k
Finally got around to rewiring my golf hatch (got it right @Rrusse11 ) properly. I realized it did not work last time because the hatch lock happened to be gumming up as I was testing it, what a waste of an afternoon. But anyway, I fixed the latch, but the wire has been sitting there over a month fed through the door wire feed. pulled the card, spliced the wire, pulled the under steering column panels, spliced that end, and voila! Free entry into the hatch when the driver door is unlocked, locked when the driver door is. What a relief. But then putting the under column panels back on, I realized the wire was fed below the obd port support. There was no way it would live there without me eventually catching a toe on it. Sigh. Pulled the splices off, fed it the right way, spliced it again, put everything together, taped excess line out of the way, done. Success.

Also found a problem with RR caliper where the e brake cable attaches, I will read up on it and probably make another post for it.
 

Rob Mayercik

Veteran Member
Joined
Dec 19, 2001
Location
NJ, U.S.A.
TDI
2002 Jetta GLS, Baltic Green/Beige
Back on this past Saturday (12/30/23, 491,35x miles):

- diesel purge injector cleaning
- oil and filter change
- new fuel filter
- new air filter (Mann, with foam pre-filter)
- blew out/cleaned snowscreen (yes, I still have it. No, I'm not planning to delete it).

Checked the tire tread a couple days prior, a little shy of 80,000 on them and they still measure 4/32". Probably going to squeeze a bit more out of them before replacing, so long as things don't get too snowy in the next couple months...
 

KrashDH

Top Post Dawg
Joined
Dec 22, 2013
Location
Washington
TDI
2002 Golf
My Golf horn has sounded like a whiny 10 year old for the last few years because one of the trumpets failed. Finally pulled the trigger on some "OEM" Hella replacements. Only thing OEM about them was the connector. The studs and nuts were not the same size. Had to use a fender washer (that was almost too thick) on each of the OEM brackets so the Hella nut had something to put pressure on. The OD of the nut faces were only a tad larger than the holes in the brackets on the car.

Figured while I was doing my fog light upgrade I'd swap them. They sound great, but advertised as an "OEM" replacement is kind of misleading. Really wish some of these companies could sort this stuff out so we don't have to go through the pain of trying to jerry-rig something to make them work.
Car might actually get noticed now if I need to be from all the people pay attention to their phones instead of driving.
 

PakProtector

Veteran Member
Joined
Jan 5, 2014
Location
AnnArbor, MI
TDI
Mk.4's and the Cummins
Made a slow start on a timing belt replacement for the newest herd member( an '05 Golf ). Its age was giving me the shivers every time I had it running( it was original to the car ). Kit from IDP should arrive today. Conti upgrade was made. Next to track down some high-bolster seats, and maybe a Mk5 GTI steering wheel( no multi-function to worry about losing ).

Douglas
 

wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagon,2003 Jetta 261K Sold but not forgotten
My Golf horn has sounded like a whiny 10 year old for the last few years because one of the trumpets failed. Finally pulled the trigger on some "OEM" Hella replacements. Only thing OEM about them was the connector. The studs and nuts were not the same size. Had to use a fender washer (that was almost too thick) on each of the OEM brackets so the Hella nut had something to put pressure on. The OD of the nut faces were only a tad larger than the holes in the brackets on the car.

Figured while I was doing my fog light upgrade I'd swap them. They sound great, but advertised as an "OEM" replacement is kind of misleading. Really wish some of these companies could sort this stuff out so we don't have to go through the pain of trying to jerry-rig something to make them work.
Car might actually get noticed now if I need to be from all the people pay attention to their phones instead of driving.
If you want to get attention jury rig an old 6 volt Beatle horn with a relay and horn button to the dash.
I did it years ago. EAR PIERCING :D
It did last for years of low usage.
 

Zak99b5

Veteran Member
Joined
Apr 30, 2021
Location
Albany NY
TDI
2003 Jetta TDI
Realized how bad the valve cover was leaking when I did the clutch, so today I swapped in a new one. Aftermarket with replaceable gasket.

I put a little dab of black silicone on the head where the cam caps rise up.

Had to make a tool for the bolt under the egr valve. Took a short 5mm 1/4” drive socket, and cut a small piece off a 5mm Allen key. Wrapped a little electrical tape to the bit so it stayed in the socket. Worked like a charm with a universal joint.

Torqued it to 7 ft lbs. seems way too light a spec, but it is correct. I’ll be checking to make sure it’s sealing properly.

Snapped a few pics of the cam while I had the cover off. Looks really good in there.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
Had to make a tool for the bolt under the egr valve. Took a short 5mm 1/4” drive socket, and cut a small piece off a 5mm Allen key. Wrapped a little electrical tape to the bit so it stayed in the socket. Worked like a charm with a universal joint.
Nice!!
 
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