What did you do to your MKIV today?

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
Oil change on a friend's BEW car and saw this in the new (changed 5mos. ago when we removed the EGR cooler and flushed the cooling system) coolant reservoir. :(

So...looks like head gasket, given that the EGR is out of the equation...?
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Oil change on a friend's BEW car and saw this in the new (changed 5mos. ago when we removed the EGR cooler and flushed the cooling system) coolant reservoir. :(

So...looks like head gasket, given that the EGR is out of the equation...?
Could it be residual, lots of places to hide
 

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 flushed like 15L of water through the system (in multiple fill/run/drain cycles) until I had clean water coming through. You can see how much has accumulated on the side of the reservoir in that shot, too. I wish it was just residual, but my gut says....unlikely.
 

hey_allen

Veteran Member
Joined
Nov 25, 2006
Location
Altus, OK
TDI
2000 Jetta TDI
Did you use any sort of detergent when flushing the cooling system?

The suggested methods when working on MB diesel engines had a soap flush for oily residues, a citric acid flush for scale, with water rinses between and after.
 

GlowBugTDI

Veteran Member
Joined
Jul 20, 2018
Location
Cambridge, MN
TDI
2001 Beetle GLS TDI (BIODSL). 01 original Glow Bug TDI (sold)
Well last night was an absolute disaster of a learning experience. Did I learn something new? Yes. Could it gone a lot easier? Yes.
I get a text around 2pm from my wife that once again all her coolant is gone from the bulb. I start praying because this is the 3rd time in less then 1k miles, and I just did the TB 3k ago. The last thing I want to do right now is change a headgasket. I don't have time for that. I finish work at the clinic then make the drive through stop/go traffic to her work. I look over every inch of the engine bay, all the typical leak spots and find nothing (I have done this every time). I decide I may as well check the trans fluid at this point because maybe its possible the cooler is leaking into the trans as unlikely as that is. I pull the G38 sensor on the 01m and this is where I make a critical rookie mistake. I haven't done something like this in years. Looking at the hole I notice I can only see a little bit of fluid. Hmmm, how might I get a better sample? Oh, I know I'll start the car!
Start the car, look for coolant/oil mix and nothing so I shut it down. I put the sensor back and keep searching. I look everywhere coolant goes, the subframe, and even the belly of the car looking for something. Thats when I notice the dirt accumulation in the passenger side frame rail (where the fuel lines enter the engine bay) is wet. I start trying to get a better look of the frame rail under the engine mount, ff, and coolant bulb area. Sure enough the rail is wet. I pulled the coolant bulb and the bottom tube is wet. Its been leaking from the hose clamp not doing its job. At least far as I can tell this has to be the issue. I try to get it attached better, dry it off, and put some napkins under for easy leak detection. Done! I figured it out, saved the day, my wife is happy and thankful. I make a run for the woods before dark, and soon as I get there she calls me said "I think its stuck in limp mode, or maybe 3rd gear". She's never experienced limp mode, but knows how I've explained it works. She drives to where I'm at and says ya it doesn't have any power. I get in and sure enough stuck in 3rd. Will shift from first if I manually switch it. Now I'm upset and really want to just pull this 01m out. I try shutting it off and restarting, disconnecting the battery, cleaning sensor terminals, and researching attempting to figure out what is going on. I knew it had to be something I touched but it was getting to me. I knew only thing left was to pray on the way home that my KII cable had come in the mail before the weekend. I had plenty of time for that because 65mpg was pushing 3500rpm. Sure enough it came in a nick of time. Downloaded vcds, did the update on the cable and sure enough there was a G38 sensor code in the TCM. Why the car can't tell its plugged back in is beyond me but that was dumb. What a stupid amd almost costly mistake I made. Cleared the code and amazingly it didn't come back so that was great. Also checked my timing for the TB I did which was spot on, and put the trans in sport mode. Holy crap is that more of a book than I meant to write, but yea... that's how my night went. Thankfully ended on a good note.
Also a big thanks to @LibertyHead for the super fast shipping on that KII cable. He got that thing sent out to me soon as he got payment and it was perfect timing.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
I flushed like 15L of water through the system (in multiple fill/run/drain cycles) until I had clean water coming through. You can see how much has accumulated on the side of the reservoir in that shot, too. I wish it was just residual, but my gut says....unlikely.
There’s still hope, oil coolers crush real easy, oil pressure is higher than coolant pressure. unless it’s definitely from combustion and not oil, combustion pressure is higher than coolant. Hopefully it’s a small can of worms
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Well last night was an absolute disaster of a learning experience. Did I learn something new? Yes. Could it gone a lot easier? Yes.
I get a text around 2pm from my wife that once again all her coolant is gone from the bulb. I start praying because this is the 3rd time in less then 1k miles, and I just did the TB 3k ago. The last thing I want to do right now is change a headgasket. I don't have time for that. I finish work at the clinic then make the drive through stop/go traffic to her work. I look over every inch of the engine bay, all the typical leak spots and find nothing (I have done this every time). I decide I may as well check the trans fluid at this point because maybe its possible the cooler is leaking into the trans as unlikely as that is. I pull the G38 sensor on the 01m and this is where I make a critical rookie mistake. I haven't done something like this in years. Looking at the hole I notice I can only see a little bit of fluid. Hmmm, how might I get a better sample? Oh, I know I'll start the car!
Start the car, look for coolant/oil mix and nothing so I shut it down. I put the sensor back and keep searching. I look everywhere coolant goes, the subframe, and even the belly of the car looking for something. Thats when I notice the dirt accumulation in the passenger side frame rail (where the fuel lines enter the engine bay) is wet. I start trying to get a better look of the frame rail under the engine mount, ff, and coolant bulb area. Sure enough the rail is wet. I pulled the coolant bulb and the bottom tube is wet. Its been leaking from the hose clamp not doing its job. At least far as I can tell this has to be the issue. I try to get it attached better, dry it off, and put some napkins under for easy leak detection. Done! I figured it out, saved the day, my wife is happy and thankful. I make a run for the woods before dark, and soon as I get there she calls me said "I think its stuck in limp mode, or maybe 3rd gear". She's never experienced limp mode, but knows how I've explained it works. She drives to where I'm at and says ya it doesn't have any power. I get in and sure enough stuck in 3rd. Will shift from first if I manually switch it. Now I'm upset and really want to just pull this 01m out. I try shutting it off and restarting, disconnecting the battery, cleaning sensor terminals, and researching attempting to figure out what is going on. I knew it had to be something I touched but it was getting to me. I knew only thing left was to pray on the way home that my KII cable had come in the mail before the weekend. I had plenty of time for that because 65mpg was pushing 3500rpm. Sure enough it came in a nick of time. Downloaded vcds, did the update on the cable and sure enough there was a G38 sensor code in the TCM. Why the car can't tell its plugged back in is beyond me but that was dumb. What a stupid amd almost costly mistake I made. Cleared the code and amazingly it didn't come back so that was great. Also checked my timing for the TB I did which was spot on, and put the trans in sport mode. Holy crap is that more of a book than I meant to write, but yea... that's how my night went. Thankfully ended on a good note.
Also a big thanks to @LibertyHead for the super fast shipping on that KII cable. He got that thing sent out to me soon as he got payment and it was perfect timing.
As long as your wife keeps faith in you all is good
 

Boosty

Well-known member
Joined
May 20, 2024
Location
Indiana
TDI
04 Golf GL
Well last night was an absolute disaster of a learning experience. Did I learn something new? Yes. Could it gone a lot easier? Yes.
I get a text around 2pm from my wife that once again all her coolant is gone from the bulb. I start praying because this is the 3rd time in less then 1k miles, and I just did the TB 3k ago. The last thing I want to do right now is change a headgasket. I don't have time for that. I finish work at the clinic then make the drive through stop/go traffic to her work. I look over every inch of the engine bay, all the typical leak spots and find nothing (I have done this every time). I decide I may as well check the trans fluid at this point because maybe its possible the cooler is leaking into the trans as unlikely as that is. I pull the G38 sensor on the 01m and this is where I make a critical rookie mistake. I haven't done something like this in years. Looking at the hole I notice I can only see a little bit of fluid. Hmmm, how might I get a better sample? Oh, I know I'll start the car!
Start the car, look for coolant/oil mix and nothing so I shut it down. I put the sensor back and keep searching. I look everywhere coolant goes, the subframe, and even the belly of the car looking for something. Thats when I notice the dirt accumulation in the passenger side frame rail (where the fuel lines enter the engine bay) is wet. I start trying to get a better look of the frame rail under the engine mount, ff, and coolant bulb area. Sure enough the rail is wet. I pulled the coolant bulb and the bottom tube is wet. Its been leaking from the hose clamp not doing its job. At least far as I can tell this has to be the issue. I try to get it attached better, dry it off, and put some napkins under for easy leak detection. Done! I figured it out, saved the day, my wife is happy and thankful. I make a run for the woods before dark, and soon as I get there she calls me said "I think its stuck in limp mode, or maybe 3rd gear". She's never experienced limp mode, but knows how I've explained it works. She drives to where I'm at and says ya it doesn't have any power. I get in and sure enough stuck in 3rd. Will shift from first if I manually switch it. Now I'm upset and really want to just pull this 01m out. I try shutting it off and restarting, disconnecting the battery, cleaning sensor terminals, and researching attempting to figure out what is going on. I knew it had to be something I touched but it was getting to me. I knew only thing left was to pray on the way home that my KII cable had come in the mail before the weekend. I had plenty of time for that because 65mpg was pushing 3500rpm. Sure enough it came in a nick of time. Downloaded vcds, did the update on the cable and sure enough there was a G38 sensor code in the TCM. Why the car can't tell its plugged back in is beyond me but that was dumb. What a stupid amd almost costly mistake I made. Cleared the code and amazingly it didn't come back so that was great. Also checked my timing for the TB I did which was spot on, and put the trans in sport mode. Holy crap is that more of a book than I meant to write, but yea... that's how my night went. Thankfully ended on a good note.
Also a big thanks to @LibertyHead for the super fast shipping on that KII cable. He got that thing sent out to me soon as he got payment and it was perfect timing.

Lol I just had a g12 leak from the exact same spot! I was thinking as always worst case scenario as the coolant kept leaking out somewhere then noted it was running down the track under the fish bowl, all wet there. So my nephew, who first noted it, pulled the fish bowl and noted the connection to the hose directly under the bowl was wet as was the hose. I'd made certain to not spill a drop when adding last time so this might be the perp! I was thinking no way it's this easy! My nephew noted the hose wasn't all the way seated on the connector to begin with, pulled the hose, rotated it and also rotated the spring clamp on the hose itself slightly. No way it could be this easy. Filled the bowl and went for several 70mph plus drives on I69 and the level hasn't changed at all. It was that easy. Now if only crank/cam sensors and wiring was that easy. I'd love to be able to just get a new loom but that will likely be as costly as the car was.
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
Did you use any sort of detergent when flushing the cooling system?
No, I didn't. But I did have the car here to install a short-shifter (whole different shift mechanism - this kinda thing) this summer (roughly halfway between EGR cooler delete and now - 5000km in each of those intervals) and it didn't jump out at me like it did the other day. So, it certainly looks like it's getting worse over time, which I wouldn't expect if it had just "cleaned out" the residue.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
finally put in a new t-stat and coolant temp sensor in wifes BEW golf... been putting that off for too long. should be much happier now with both working correctly. also finished getting rid of the hard coolant/fuel on the head. forgot to take a pic of the results, but i like much better. less connections and hoses less "in the way" lol. retuned it again for the millionth time.

edit - oh and also finally fixed the leaky dieselgeek oil bypass fitting thats' been leaking for years :s no more oil leaks!
 
Last edited:

JonA

Veteran Member
Joined
Feb 25, 2015
Location
Rhode Island
TDI
2002 Golf TDI M/T
finally put in a new t-stat and coolant temp sensor in wifes BEW golf... been putting that off for too long. should be much happier now with both working correctly. also finished getting rid of the hard coolant/fuel on the head. forgot to take a pic of the results, but i like much better. less connections and hoses less "in the way" lol. retuned it again for the millionth time.

edit - oh and also finally fixed the leaky dieselgeek oil bypass fitting thats' been leaking for years :s no more oil leaks!
Would love to see a pic of your cleaned up engine bay, or if you wouldn't mind popping the hood for me when I swing by 😄
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
Would love to see a pic of your cleaned up engine bay, or if you wouldn't mind popping the hood for me when I swing by 😄
we can even go for a test drive :) drives pretty good for an automatic. but 1-2nd gear doesn't like too much torque...
 

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
Oil change on a friend's BEW car and saw this in the new (changed 5mos. ago when we removed the EGR cooler and flushed the cooling system) coolant reservoir. :(

So...looks like head gasket, given that the EGR is out of the equation...?
It is a BEW - don't rule out injector o-rings. I have heard of those leaking nastiness into cooling system (I'm guessing a coolant passage runs along next to oil passage at/near injectors)

Jason
 

Rob Mayercik

Veteran Member
Joined
Dec 19, 2001
Location
NJ, U.S.A.
TDI
2002 Jetta GLS, Baltic Green/Beige
Any cheap scan tool can clear the codes and check readiness. So the only issue is the perma-MIL. Which could "hide" another issue popping up because it's already lit.

I know NY stops testing emissions on cars at 25 years. Does NJ also exempt old cars?

But the real solution is get a Burpod tune and leave the deactivated EGR stuff in place.
I do have VCDS, so clearing codes isn't an issue (though I agree with the point of a "perma-MIL" masking other issues).

I'm thinking strongly about doing the Burpod tune thing, now that I know it's running more or less optimally. I had the EGR stuff left in place (new valve, though, mine was coked up and done) because I didn't want to sacrifice the Anti-Shudder valve.
 

mk3

Veteran Member
Joined
Sep 13, 2005
Location
Wisconsin, USA
TDI
03 Jetta GLS 5-speed
new Turbo assembly at 360k miles because on rare occasions it would pop into limp mode. also intake cleaning, new RH axle due to the inner boot being heat damaged (I assume). The clutch is still original.

this was the literal first time I have touched anything on the turbo system in 21 years. The vacuum line was even the original one.

I _love_ this car. I'm fairly certain the mpgs are up now and I wasn't expecting that because the old turbo really didn't seem in bad condition.

also, refreshed all 3 sound shield plastic parts and one fender liner. running out of preventive maintenance to do. : )
 

Sting

Veteran Member
Joined
Jan 20, 2004
So, I saw on FB Marketplace a GT1749V turbo, brand new, never used. $400 CDN. I definitely want to upgrade performance, but nothing too extreme or expensive. I've been thinking turbo, injectors, tune... possibly upgraded SMIC. If I could get anywhere between 150-180 hp, I'd be quite happy with that. Would this turbo potentially be a good option for what I'm aiming for?
 

joe00golf

Well-known member
Joined
Feb 5, 2024
Location
Connecticut
TDI
2000 Golf
Cleaned it a bit. Need to get my but in gear before the real cold starts to come in. Gotta get my seat heaters wired in and see why the front end is shaking when I hit the brakes when going faster than 70mph.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
So, I saw on FB Marketplace a GT1749V turbo, brand new, never used. $400 CDN. I definitely want to upgrade performance, but nothing too extreme or expensive. I've been thinking turbo, injectors, tune... possibly upgraded SMIC. If I could get anywhere between 150-180 hp, I'd be quite happy with that. Would this turbo potentially be a good option for what I'm aiming for?
That’s a stock turbo, you won’t get your power goals out of it. I have one on my Jetta and my Taco. It’s pretty much the same as a vnt15.
 

JonA

Veteran Member
Joined
Feb 25, 2015
Location
Rhode Island
TDI
2002 Golf TDI M/T
Finally threw a new axle in, sometime before this one goes bad I'll rebuild the one that was on there, I'm thinking it's probably OEM.
 

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 , added an 06 NB DSG
Any ideas where it’s stamped ?
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
It is a BEW - don't rule out injector o-rings. I have heard of those leaking nastiness into cooling system (I'm guessing a coolant passage runs along next to oil passage at/near injectors)
Any idea on how one rules that out (or in, hopefully) as the cause? Change the o-rings, do a flush and hope for the best?
 

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've been thinking turbo, injectors, tune... possibly upgraded SMIC
Unless it's been done already, you're probably going to need an upgraded clutch to hold that - so plan on adding that to the list.
And I'd skip the upgraded SMIC - people who've tested have found placebo-level "improvement" from what I recall.
 

dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
Unless it's been done already, you're probably going to need an upgraded clutch to hold that - so plan on adding that to the list.
And I'd skip the upgraded SMIC - people who've tested have found placebo-level "improvement" from what I recall.
Takes longer to heat soak, then it's about the same level of effectiveness as a stock unit. + you're not getting any better airflow through the thicker core. Ie not worth it imo.
 
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