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Sarah & Thomas 2000 Jetta GLS
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nightcrawlr
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PostPosted: Sun Oct 18, 2015 12:58 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

We will document the restoration of our 2000 Jetta GLS, goal is to make it a reliable daily driver. The car was a one owner vehicle, and has been garage kept. It is need of through cleaning and new engine. The original purchaser of the car said they took it to Wal-Mart for oil change and the oil never got installed. Needless to say the engine had a catastrophic failure.

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nightcrawlr
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PostPosted: Sun Oct 18, 2015 1:01 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

The car is equipped with the 2.0 and manual 5 speed gearbox. Only has 101,684 original miles on the clock.

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nightcrawlr
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PostPosted: Sun Oct 18, 2015 2:41 pm    Post subject: Sarah and Thomas 2000 Jetta GLS Reply with quote

Hauling it home, my dad and brothers stopped by the LKQ Pick N Pull and harvested a replacement short block.

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nightcrawlr
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PostPosted: Sun Oct 18, 2015 2:47 pm    Post subject: Sarah and Thomas 2000 Jetta GLS Reply with quote

Here are a few pictures of the teardown, having three younger brothers help is a real blessing. All are experienced VW mechanics. You can see their build threads here:

http://www.thesamba.com/vw/forum/viewtopic.php?t=439103

http://www.thesamba.com/vw/forum/viewtopic.php?t=511954

http://www.thesamba.com/vw/forum/viewtopic.php?t=610671

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Left to Right; Seth, Noah, and Micah

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Dad and me.


Last edited by nightcrawlr on Fri Oct 23, 2015 11:47 pm; edited 1 time in total
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nightcrawlr
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PostPosted: Sun Oct 18, 2015 2:49 pm    Post subject: Sarah and Thomas 2000 Jetta GLS Reply with quote

What a lack of lubrication (engine oil) looks like!

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nightcrawlr
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PostPosted: Sun Oct 18, 2015 2:54 pm    Post subject: Sarah and Thomas 2000 Jetta GLS Reply with quote

Off to LKQ Pick N Pull for more parts!

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Left to Right, Dad, Me (Sarah), Seth, and Noah

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Harvesting a passenger side mirror assembly.

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Removing 2.0 head assembly.

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Wow! It is a good head!
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nightcrawlr
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PostPosted: Sun Oct 18, 2015 2:57 pm    Post subject: Sarah and Thomas 2000 Jetta GLS Reply with quote

Engine re-installation.

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Head cleaned and ready for re-installation.

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nightcrawlr
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PostPosted: Mon Oct 19, 2015 11:03 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Dad, Seth, Micah and Noah got the head installed, next is radiator, radiator support, Oil, 5W-40, Filter PO-12, and G12 Antifreeze.

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nightcrawlr
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PostPosted: Fri Oct 23, 2015 11:53 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Thomas installing new battery and helping Seth with radiator support installation. Got the engine running, have a small leak where the metal tube seals into the block beside the thermostat housing. Will replace the o-ring and we should be done with engine installation.

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cmarino929
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PostPosted: Mon Oct 26, 2015 11:24 am    Post subject: Reply with quote

I have read all of your family's projects and you are def in good hands! Keep up the great work!
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Beetlebaum
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PostPosted: Mon Oct 26, 2015 3:28 pm    Post subject: Reply with quote

Nice! I've got a 2003 New Beetle--mechanically, pretty similar to yours, on the whole. Definitely following this thread.
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Stock Steve
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PostPosted: Tue Oct 27, 2015 10:03 am    Post subject: Reply with quote

Very cool! I'm impressed! Keep it up!
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nightcrawlr
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PostPosted: Wed Oct 28, 2015 10:31 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Thomas and Dad got a lot done on the car today. Drained and refilled with G12 coolant, installed new door pulls on all four doors, serviced the A/C system with R-134A, removed the headliner assembly and stripped and recovered it. Finally replaced a couple of bad bulbs. Took the car up the road to fill with gasoline. Thomas had the opportunity to take it on its first drive. Car ran great!

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Thomas and Dad working on the headliner.

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Headliner Installed!!!

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Thomas backing it out of the garage. Look at that Jetta grin!

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Filling the tank!
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Beetlebaum
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PostPosted: Thu Oct 29, 2015 6:12 am    Post subject: Reply with quote

Cool
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nightcrawlr
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PostPosted: Fri Oct 30, 2015 10:43 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Dad got the dash back together. Had to replace the climate control backlight bulb, took the center section of the dash apart (removed cup holder, storage pocket, radio and climate controls). When he could not figure out how the back lighting worked (typical man), he checked youtube. Simple process requiring the removal of the fan speed knob. It pays to research before removing fasteners!

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Dash back together, all back lighting now working!

Dad then vacuumed the interior and cleaned all surfaces (detailed). Turned on the heater and A/C controls to make sure everything still worked after having it apart. Instantly the interior filled with small chunks of foam particles. Past experience told him this was from the blend doors. Time to take the dash all apart again!

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Micah, my youngest brother helping Dad remove the dash.

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Dash and heater core housing removed to get access to the blend doors.

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Defective foam on the blend doors.

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Self adhesive foam used to cover the blend doors.

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Blend doors after covering with adhesive backed foam.

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Blend doors being reinstalled into heater core housing.

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Heater core assembly ready for re-installation.
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nightcrawlr
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PostPosted: Sat Oct 31, 2015 7:14 am    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

cmarino929 wrote:
I have read all of your family's projects and you are def in good hands! Keep up the great work!


Thanks! Very Happy
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nightcrawlr
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PostPosted: Sat Oct 31, 2015 7:17 am    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Beetlebaum wrote:
Nice! I've got a 2003 New Beetle--mechanically, pretty similar to yours, on the whole. Definitely following this thread.


Sarah's Dad here, yes as best I can tell, the 2003 beetle is very similar in terms of chassis and drive-train, main difference being the body and interior.
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nightcrawlr
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PostPosted: Sat Oct 31, 2015 7:18 am    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Stock Steve wrote:
Very cool! I'm impressed! Keep it up!


Thanks for the encouragement!
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Beetlebaum
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PostPosted: Tue Nov 03, 2015 7:08 pm    Post subject: Re: Sarah & Thomas 2000 Jetta GLS Reply with quote

nightcrawlr wrote:
Beetlebaum wrote:
Nice! I've got a 2003 New Beetle--mechanically, pretty similar to yours, on the whole. Definitely following this thread.


Sarah's Dad here, yes as best I can tell, the 2003 beetle is very similar in terms of chassis and drive-train, main difference being the body and interior.


I had the problem of the climate control knobs not lighting up on my New Beetle, and that fan knob proved really troublesome to pull out. Now that it's all fixed and has a new bulb in there, it's really nice to have all the dash lights working!
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nightcrawlr
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PostPosted: Tue Nov 03, 2015 10:53 pm    Post subject: Sarah & Thomas 2000 Jetta GLS Reply with quote

Started working on the seats today. Dad and Mom and my brother Noah, cleaned, repaired, and conditioned the leather seats.

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Mom and Dad cleaning and conditioning front seat.

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Mom with finished seat, ready for installation.

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Dad working on the drivers seat.

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Dad and Noah replacing the airbag. Once installed, they used VagCom to check the SRS system and clear past faults.
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