2003 Jetta Tdi Wagon first impressions, Fun Car!

[Jon_slider]

I just bought the car with 142k miles. 5 speed manual tranny. It only came with a Valet Key. I bought a pair of Flip keys off Ebay, for $30.. paid the dealer to cut and program them.

then I added the KVW100 Window control module.. Now one click to lock rolls up the windows and closes the sunroof.. Love it!

Replaced worn out shocks with Koni Orange, awesome handling improvement, added 1" lift, and Panzer skid plate. Now I dont live in fear of cracked oil pan when pulling up to a parking spot.

the car had a 3000rpm power loss, with CEL and Overboost code. It would go into limp mode when merging onto the freeway. Frustrating!

5 go backs to try and solve the problem… replaced Maf, N75, and G-31 valves.. no luck, lighter wallet.

I figured cleaning the intake manifold would be next. One shop wanted to sell me a new turbo!

then my friend and fantastic mechanic vwhead of German MotorWerks researched online and found this

http://www.askatech.com/AskATechLive/forums/ResourceHandler.ashx?a=10929

step One, cleaning the grounds under the battery tray, solved the Overboost problem!

Now the car is really fun to drive, and I expect to see an increase, above the 36mpg it was getting

The Jetta is a small car, I can not fit lying down in the back, and flipping the back seat flat means the driver seat needs to move further forward than I like. 2wd and low clearance means it is not suitable for car camping on Big Sur dirt roads, but makes a fantastic freeway commuter.
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My Soapboxes: Inflation; Handling; Gearing; Decoupling; Swepco

[TeamSpatula]

They are fun cars to drive, but as you mentioned kinda hurt in the wallet area...I had a 2004 TDI GLS 5 speed, and averaged about 45 mpg...although it was a sedan, and not a wagon...
but definitely a fun car.
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[kamzcab86]

My grandma has an '01 just like yours, but it's a GLX with a VR6. Nice cars... had I known they were coming out with a wagon version, I would've waited and gotten one instead of the sedan. The VR6 is quite the opposite of the TDI mpg-wise, but it's a blast to drive with.

Grandma lost her driving ability several years ago and has willed her car to me. Quite nice of her, but I no longer want the car because my uncle, come to find to out, has been using it as his daily driver despite owning 4 cars of his own... and he's been beating the hell out of it because to him "it's just a VW". :2gunfire:

Anyway, in case you haven't stumbled upon it, here's an FAQ for that generation: http://forums.vwvortex.com/showthread.php?5187132-MK4Forum-Essentials-DIY-FAQ-amp-Resources-Guide .
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~Kamz
1986 Cabriolet: www.Cabby-Info.com
1990 Vanagon Westfalia: Old Blue's Blog
2016 Golf GTI S
"Real knowledge is to know the extent of one's ignorance." - 孔子

[Jon_slider]

[Jon_slider]

Help request

This Jetta is stranded in Carlsbad, California for Thanksgiving.

Any suggestions on a reputable shop welcome. The car wont start. We have AAA.

Any mobile mechanics able to check on it would be even handier.
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My Soapboxes: Inflation; Handling; Gearing; Decoupling; Swepco

[TDCTDI]

What do you mean "won't start"?
Does the starter turn the engine over?

If so, does it sound like it's rotating faster than usual? (Broken timing belt)

Does the engine bay smell of diesel fuel & is the injection pump wet? (Pump lost prime due to leak)

Check the "anti-shudder" valve portion of the EGR valve, this devise shuts off air to the engine to prevent run-on or runaway engine conditions. On the passenger side of the engine, follow the large black intake hose as it goes into the intake manifold, it goes into the EGR valve. On the back side there is a lever actuated by a solenoid, if you push on the lever & it suddenly snaps free, then you should be able to start the car. You will need to (or have someone) remove the EGR valve & clean it (& probably the intake manifold too).
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[Jon_slider]

thanks for the troubleshooting tips
timing belt was serviced 30k miles ago, when we bought the car w 140k miles.

The possibility of carbon buildup in the intake clogging the EGR valve is more likely possible.

I am 500 miles away from the car. One of my adult children drove it to see family out of town.

Im hoping someone, not me, can look at the car for us. I dont have detailed info on what kind of "the car wont start" situation, my kid is dealing with.

Our text messages were focused on, Where should I tell AAA to tow the car to? We had it towed to a family members house, while deciding what shop to tow it to next.

I have contacted rubbachicken, who lists mobile mechanic services in San Diego Area, and I have emailed BRU Automotive, a mechanic Ive used in the past, for a TDI install in a syncro, also in San Diego Area.

Hopefully one of those two will find time to help by the weekend

Happy Turkey day!

update 1

I sent my kid an EGR video showing how to wiggle the actuator. They did it, but the car is still crank with NoStart

The problem started when the car lost power going uphill and went into limp mode, then died completely. The fuel tank is 3/4 full.


Update 2.. kinda GOOD News
AAA says they will pay for meals, lodging AND the mechanical repair, up to $1500, thanks to their Trip Interruption Insurance, included in our Premier policy.

Wow!

I LOVE AAA Today!
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My Soapboxes: Inflation; Handling; Gearing; Decoupling; Swepco

[TDCTDI]

Yeah... that's much more sinister than a simple won't start. At best a charging system fault, at worst it could be catastrophic failure of the engine due to cooling/oiling issues.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[Jon_slider]

[oprn]

We had a very similar problem with our '04 sedan TDI. It turned out to be a bad electric fuel pump located in the fuel tank. Take the bottom of the right rear seat out and there is an access panel to get at it if I recall correctly.
Nice car by the way! We lost our '04 TDI wagon to a roll over last summer and can't find a replacement. People just don't want to let them go!

[Jon_slider]

[TDCTDI]

There isn't an electric transfer pump in 03 & older TDIs.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[Jon_slider]

[Jon_slider]

update
Dealership says the timing was off, that the belt slipped. They say they were able to tighten it back and reset the timing, and that there was no valve to piston contact.

My local service mechanic disagrees with the dealership's repair, and says I should have the timing belt replaced, along with the tensioner and water pump.

Now for the bad news. None of it is covered by AAA Trip Interruption. Apparently mechanical repairs are Excluded from Trip Interruption, it actually only covers food, lodging, and transportation..

darn.. too good to be true

not only that, but we also have Vehicle Return coverage, that does not apply either. They will only return the vehicle home IF the driver got sick, NOT if the vehicle broke down and the driver had to end the trip and go home.

oh, and, even though we have enough tows remaining, we are not allowed to string tows together, unless we are present with the vehicle when it gets picked up..

soooo, no free repair, no free return of the vehicle, and no unattended tows, nor tows chained together

the bottom line is, the car is running again, Im not sure I trust the repair, and we now get to figure out how to do a 900 mile round trip to get the car back

Im loving AAA a little less now… aaargh!
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My Soapboxes: Inflation; Handling; Gearing; Decoupling; Swepco

[oprn]

I didn't know the 03 don't have the boost pump, make sense though, they have a different injection system.

Yes there were a couple of minor injuries. Just temporary set backs and all good now.

I too would be very suspicious of that timing belt unless it was just recently done and the tensioner slipped.

[Jon_slider]

minor injuries from a roll over is fortunate, glad you're all well now.

best info Ive been able to glean from the service writer is that the dealers mechanic says there were no missing teeth on the belt

the timing belt was done 20k miles ago, by a mechanic that works for the used car dealership we got the car from. Not a lot of confidence in them. Still, I decided not to add $1500 to the bill, for timing belt replacement along w tensioner and water pump, at dealer prices, 450 miles away from home.

The ongoing fine print saga of AAA is that they told us, incorrectly, that we cannot have the car towed out of the dealership unless we are there at the time of pickup. The correct info turned out to be that we are allowed to be there at the drop off, instead. So were having the car towed 192 miles closer, to shorten the pick up drive. (our premier coverage gives us one 200 mile tow)

Im feeling lucky, so we are going to gamble and drive the car the remaining 250 miles to get home. If it does not grenade, Im hoping to wait until the next oil change, when I will ask one of our local mechanics, either Van-Cafe or Freds Garage, to inspect the timing belt and advise me on the adviseability of timing belt replacement, and cost. Im hoping to hear a slightly smaller number, as they tend to have very good prices.

Next oil change is in 2k miles, assuming the motor keeps running, my confidence in the health of the timing belt may increase, and it delays having to face the timing belt expense for a couple more months..

I will let you know if I was penny wise and pound foolish this time.. fingers crossed.

thanks for the brainstorming help
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My Soapboxes: Inflation; Handling; Gearing; Decoupling; Swepco

[oprn]

I confess to be quite jealous of that car! My understanding is that the '99 to '03 are the "best of the best" TDIs from a mileage and maintenance free driving stand point. Down 10 Hp from the '04s though but to me that is not an issue. I drive ours for it's superior fuel economy, reasonable long range comfort and great handling(for a family car that is). If I feel like snorting around I take the Porsche!

As I said earlier we had no luck finding another wagon so take good care of that one please. Meanwhile we are very happy with this '02 sedan that we found but my daughter is driving it while I fix her '92 Jetta... and now... she doesn't want to give it back!

[Jon_slider]

[oprn]

[Jon_slider]