TDI Jetta Project/DD

[wolfsburged]

Picked up this 2001 TDI Jetta GL with 114k for a song. Has an auto that is stuck in park. Will be fixing up and swapping to a manual trans for daily driver status. Very clean exterior, paint is in great condition. Needs a windshield. Interior is a little dirty, hoping to find a nice leather interior to swap.

GL model so crank windows and no sunroof. Nothing to break there.

Engine cranks over great and sounds perfect reving in neutral.

The automatic seems like it is stuck in park/neutral. You can put it in any gear, D, R, 3, 2, 1 and rev, and nothing at all, no attempts to move. Indicator on the cluster moves and indicates correct gear selection.

I can roll it forward in Neutral, but cannot roll it backwards. I would love to at least make this thing be able to roll backwards, not sure why it won't.

Looks like someone was messing with a bit of wiring under the hood. A few electrical related codes showing up. Will have to go through the wiring and fix some of that, who knows maybe the auto will start shifting?!

Pics:
http://knightcreations.com/TDI/IMG_1950.jpg

http://knightcreations.com/TDI/IMG_1951.jpg

http://knightcreations.com/TDI/IMG_1952.jpg
Elusive "TDI, Ja!" edition

http://knightcreations.com/TDI/IMG_1953.jpg

http://knightcreations.com/TDI/IMG_1955.jpg

http://knightcreations.com/TDI/IMG_1956.jpg

http://knightcreations.com/TDI/IMG_1958.jpg

http://knightcreations.com/TDI/IMG_1959.jpg

http://knightcreations.com/TDI/IMG_1960.jpg

http://knightcreations.com/TDI/IMG_1961.jpg
Suspect wiring

http://knightcreations.com/TDI/IMG_1963.jpg
Suspect wiring

Codes:
19586
http://wiki.ross-tech.com/wiki/index.php/19586/P3130/012592
19586/P3130/012592 - EGR System: Regulation Range Exceeded
Possible Symptoms



Malfunction Indicator Light (MIL) ON

Possible Causes



Exhaust Gas Recirculation (EGR) Valve (N18) faulty
Exhaust Gas Recirculation (EGR) faulty

Possible Solutions



Check/Replace Exhaust Gas Recirculation (EGR) Valve (N18)
Check Exhaust Gas Recirculation (EGR) faulty


00652
http://wiki.ross-tech.com/wiki/index.php/00652
00652 - Gear Monitoring: Implausible Signal
Possible Causes



Automatic Transmission Fluid (ATF) Level not OK
Vehicle Speed Sensor (G68) dirty/faulty

Impulse Wheel dirty or Installation faulty

Gearbox Speed Sensor (G38) dirty/faulty

Impulse Wheel dirty or Installation faulty

Multi-Function Switch (F125) faulty (but not detected)
Clutch or Valve Body faulty
Automatic Transmission Fluid (ATF) Pump faulty

Possible Solutions



Check Automatic Transmission Fluid (ATF) Level
Check/Clean/Replace Vehicle Speed Sensor (G68)
Check/Clean/Replace Gearbox Speed Sensor (G38)
Check/Replace Multi-Function Switch (F125)
Check/Replace Clutch and/or Valve Body

Special Notes



The ratio of engine speed to gearbox output speed in the currently engaged gear is implausible.
Slip rpm with torque converter lock-up clutch disengaged must be greater than stall speed.


00300
http://wiki.ross-tech.com/wiki/index.php/00300
00300 - Transmission Fluid Temp. Sensor (G93) - Implausible Signal
Possible Symptoms



MIL On
Transmission Not Shifting Properly or in Limp Mode

Possible Causes



Wiring/Connectors from/to Transmission Fluid Temp. Sensor (G93) faulty
Voltage Supply for Transmission Fluid Temp. Sensor (G93) faulty
Transmission Fluid Temp. Sensor (G93) faulty

Possible Solutions



Check Wiring/Connectors from/to Transmission Fluid Temp. Sensor (G93)
Check Voltage Supply for Transmission Fluid Temp. Sensor (G93)
Check Measuring Blocks for Transmission Fluid Temp. Sensor (G93) Readings
Check / Replace Transmission Fluid Temp. Sensor (G93)


01192
http://wiki.ross-tech.com/wiki/index.php/01192
01192 - Torque Converter Lock-Up Clutch
01192 - Torque Converter Lock-Up Clutch: Mechanical Malfunction

Possible Symptoms



Torque Converter Lock-Up Clutch slipping

Possible Causes



Torque Converter Lock-Up Clutch faulty
Valve Body faulty
Internal Failure in Transmission

Possible Solutions



Check Torque Converter Lock-Up Clutch Slip

Special Notes



When found in 4-Speed Automatic Transmission (01M) (http://wiki.ross-tech.com/wiki/index.php/4-Speed_Automatic_Transmission_%2801M%29), check Measuring Value Block (MVB) 007.


00668
http://wiki.ross-tech.com/wiki/index.php/00668
00668 - Supply Voltage Terminal 30: Signal Outside Specifications
00668 - Supply Voltage Terminal 30: Implausible Signal

Possible Causes



Fuse(s) faulty
Wiring/Connectors from/to Control Module faulty
Power Supply (Battery/Generator) faulty

Possible Solutions



Check Fuse(s)
Check/Repair Wiring/Connectors from/to Control Module
Check Power Supply (Battery/Generator)

Special Notes



When found in an individual control module, it's most likely a local source (e.g. wiring/connectors).
When found in multiple control modules at the same time, it's most likely a common source (e.g. ground spot, battery, generator).
Intermittent codes are often stored during low outside temperature when the battery capacity goes down and may be ignored.







00532
http://wiki.ross-tech.com/wiki/index.php/00532
00532 - Supply Voltage B+: Signal too Low
Possible Causes



Wiring/Connectors from/to Control Module faulty
Power Supply (Battery/Generator) faulty

Possible Solutions



Check/Repair Wiring/Connectors from/to Control Module
Check Power Supply (Battery/Generator)

Special Notes



When found in an individual control module, it's most likely a local source (e.g. wiring/connectors).
When found in multiple control modules at the same time, it's most likely a common source (e.g. ground spot, battery, generator).
Intermittent codes are often stored during low outside temperature when the battery capacity goes down and may be ignored.
Common with 16946/P0562/001378 - System Voltage: Too Low (http://wiki.ross-tech.com/wiki/index.php/16946/P0562/001378) stored in other control modules.


01316
http://wiki.ross-tech.com/wiki/index.php/01316
01316 - ABS Control Module: No Signal/Communication
Possible Causes



Wiring/Connector(s) from/to ABS Control Module faulty
Fault(s) stored in ABS Control Module

Possible Solutions



Check Wiring/Connector(s) from/to ABS Control Module
Check Measuring Value Blocks (MVB)

Usually Measuring Value Blocks (MVB) 125+ show the current Communication Status


01389
No Ross-Tech Wiki info.
VAG-COM info: Tailgate open switch (F124), Short to Ground intermittent.

[JessaBug]

:oddball-thatworks: Let's do this!

[veedubtek]

looks like your suspect wiring is just an overlay to the coolant sensor...with the gear monitoring code, and availability of 5speed swaps on here right now...I don't think I'd waste a whole lot of time trying to resurrect the 2 pedal. nice find though, looks like it'll clean up pretty nice.

[wolfsburged]

Put the front wheels on dollies to move around. Last night looked at the donor 5 speed car and worked out those details. Should be parting that car in about two weekends to get everything I need. Meanwhile cleaning and organizing the garage to get ready for the project and reading up on swap procedures.

[sciroccodriver]

I'm jealous... I want to do one of these someday. Actually I want to swap a tdi into a quattro B6 avant. Hmmph. Nice though. I just want a tdi. :rolleyes:

[wolfsburged]

Collecting swap parts and researching...

Decided for kicks to drain the fluid and inspect the pan on the auto.

Here's some nice metallic sludge on the pan magnet:
http://knightcreations.com/TDI/IMG_0939.JPG

Filter was disintegrated:
http://knightcreations.com/TDI/IMG_0940.JPG

And of course ATF is not supposed to look like this!
http://knightcreations.com/TDI/IMG_0944.JPG

Bought this car as the 5 speed swap donor:
http://knightcreations.com/TDI/2012-02-10%2011.55.47.jpg

215K, front end accident. Bought car minus engine for swap. Interior moldy, didn't save much else except the swap bits I needed. But I did end up with a nice selection of spares, including a VNT15 turbo w/ manifold, alternator, instrument cluster (may swap to remove extra PRNDL screen), all pedals (for the small brake pedal), brake booster & master cylinder, center stack w/ HVAC controls, power steering pump, and some misc. other stuff.

http://knightcreations.com/TDI/IMG_0946.JPG

http://knightcreations.com/TDI/IMG_0947.JPG

Took the power washer and some Purple Power to the engine bay, came out awesome:
http://knightcreations.com/TDI/IMG_0945.JPG

Scored this for free! Going to reglue a few small spots starting to come undone and replace the totally sagging headliner in the car:
http://knightcreations.com/TDI/IMG_0948.JPG

I think based on needing to do a timing belt on top of the swap, I will pull the core support and use an engine hoist to remove everything, then do the transmission mating out of the car for ease, and then have access to the timing belt side with ease. Also can do more cleanup. I'm planning on pulling the EGR and intake to clean really well. This way I can get in for wiring and also will probably go all the way to swap the manual brake pedal cluster in as well.

Put together my first round of parts order. Clutch/flywheel, lots of one time use bolts, maintenance bits.

More to come (but not rushing!)...

[zooyork155]

:superkewl:

[wolfsburged]

Got the front bumper and core support off.

The headlights were a bit hazy so I decided to try the 3M headlight restoration kit that uses a drill. This is the product:
Amazon.com: 3M 39008 Headlight Lens Restoration System: Automotive

All I've got to say is that wow! Major difference and not too hard either.

Before:
http://knightcreations.com/TDI/IMG_1964.JPG

First lamp done for reference:
http://knightcreations.com/TDI/IMG_1965.JPG

And final product:
http://knightcreations.com/TDI/IMG_1966.JPG

[wolfsburged]

Progress today!

http://knightcreations.com/TDI/IMG_0981.JPG
Rad support gone

http://knightcreations.com/TDI/IMG_1001.JPG
Front end out, hooking up the new engine hoist/load leveler

http://knightcreations.com/TDI/IMG_1002.JPG
Engine and auto trans is out

http://knightcreations.com/TDI/IMG_1003.JPG
Going to do a little more cleaning and then the wiring mods in here

http://knightcreations.com/TDI/IMG_1005.JPG
Good stopping point for today

Next up will be removing the auto trans from the engine, then pulling the intake and EGR to clean. I have a set of 4 new CV boots to repack the manual axles with. Then to drain and refill the manual trans, replace the seals, release bearing, etc.

[zooyork155]

Nice!
I wish I had that much usable space in my garage.

[Mr. Chan]

I'm with Rob. You're garage is huge.

[sciroccodriver]

I'm with Rob. You're garage is huge.

Me3, that lift would be up against the back wall in mine. I f'n HATE my garage. Next house will have massive work area or a barn, or both.

[JessaBug]

22' wide and 28' deep :D The GTI was moved out of the garage for ease of movement but it could have stayed in there no problem. This is one of the huge selling points on this house for us. Definitely glad to have it!

[87vr6]

Then to drain and refill the manual trans

Redline MT90, you won't regret it!!

[JessaBug]

Got some already :) In the Mk1 and GTI as well!

[91rado]

looks great! i just did a manual swap to my tdi, had the same crappy o1m that i couldn't keep on the road, i bought the 6speed manual swap and was the best thing i ever did, getting 51mpg compared to 42 with the auto

[wolfsburged]

looks great! i just did a manual swap to my tdi, had the same crappy o1m that i couldn't keep on the road, i bought the 6speed manual swap and was the best thing i ever did, getting 51mpg compared to 42 with the auto

6 speed would be sweet!

[wolfsburged]

Took the intake and EGR valve off today. Lots of crud inside! Going to go soak these in the parts cleaner at work for a day or so and then start with the scrubbing.

http://knightcreations.com/TDI/IMG_1007.JPG
EGR valve

http://knightcreations.com/TDI/IMG_1009.JPG

http://knightcreations.com/TDI/IMG_1010.JPG
Intake

Un-mated the automatic.

http://knightcreations.com/TDI/IMG_1014.JPG

Here's a look at the timing belt... I'd say it is original and needs replacing!
http://knightcreations.com/TDI/IMG_1016.JPG

And got the auto shifter out:
http://knightcreations.com/TDI/IMG_1017.JPG

Up to come this week I'll be doing the wiring changes, some more cleaning, repacking grease on the manual axles, etc etc.

[sciroccodriver]

Wow.. MINUTES away from timing belt breakage. My dad's 1.8t when it broke looked 10x better than that. On his, the teeth broke away while I was going down the highway and the block just kept spinning on the belt.
Also, my mom's TDi beetle's intake looked like that when I looked in it. I scraped away as much crud as I could and changed some setting via vagcom to let it burn that shit up a little more without being too much of a smoker. No issues with that after a couple years now.

[Baron VonZeppelin]

More awesomeness from the Dynamic Dieselburged Duo
That new place is NICE !

Worst timing belt i've seen yet on a Diesel.
I'm with Scirocco , have seen broken ones in JYard that looked better.
Tranny died so the engine could Live ... fair game.

Think the spec on the automatics was either 60 or 80k = L U C K Y

[veedubtek]

Think the spec on the automatics was either 60 or 80k = L U C K Y


depending on the year, most of them were 40K. :eek:

[kcfoxie]

Wow, someone did clean the intake on mine. Mine looked nothing like that when I pulled it off.

As I said I'm moments away from a Race Pipe so you can have my EGR valve if you need it...

[Mitchd1283]

Liquid Draino Crystals works great for cleaning intakes. Also, stuffing a few nylon zip ties into a drill works well.

Sent from my DROIDX using Tapatalk

[wolfsburged]

A little bit of cleaning later, and viola:

http://knightcreations.com/TDI/IMG_1020.JPG

http://knightcreations.com/TDI/IMG_1021.JPG

Not perfect but much much better!

Also had the machinist at work make these up for me. Won't have to deal with this crud again!

http://knightcreations.com/TDI/IMG_1022.JPG

Put in some more parts orders today...

[wolfsburged]

Got a lot done this weekend.

Installed the new flywheel, clutch, and pressure plate. Then mated the transmission:
http://knightcreations.com/TDI/IMG_1023.JPG

Timing belt and waterpump, all rollers and tensioner replaced.

Here's the old belt and stuff:
http://knightcreations.com/TDI/IMG_1024.JPG

http://knightcreations.com/TDI/IMG_1031.JPG

New stuff on:
http://knightcreations.com/TDI/IMG_1033.JPG

And all wrapped up:
http://knightcreations.com/TDI/IMG_1035.JPG

I drilled and tapped the intake manifold and exhaust manifold for a boost fitting and EGT probe respectively. Went with the same Aircraft Spruce pyrometer probe as I did on the '84 Jetta. Ran the EGT leads through some fire sleeving. Installed and also installed the new blockoff plates on the EGR.
http://knightcreations.com/TDI/IMG_1030.JPG

Wrestled the automatic gas/brake pedal cluster out. I decided to run the proper manual pedal cluster to avoid having to cut the pedal down. Now I also have a donor drive by wire gas pedal for possible future projects.
http://knightcreations.com/TDI/IMG_1025.JPG

Getting this ball from the socket on the pedal was fun. Thanks a ton to Evan to lend me the proper tool to get it off without breaking it.
http://knightcreations.com/TDI/IMG_1026.JPG

New pedals in:
http://knightcreations.com/TDI/IMG_1028.JPG

Manual shift box installed:
http://knightcreations.com/TDI/IMG_1037.JPG

Then finally cleaned and repacked the outer CVs with new grease.
http://knightcreations.com/TDI/IMG_1036.JPG

So now all that is left to do is the wiring changes, hang the clutch pedal, reinstall engine and transmission, hook everything back up, fill with oil, coolant, and power steering fluid, recode ECU with VAG-COM, check timing with VAG-COM, and try it out!

Also just for kicks, went out on a little photoshoot on Sunday. Here are the other two VWs:
http://knightcreations.com/ghetto/images/ncdubs/mar2012/IMG_2031.jpg

[wolfsburged]

Wiring is done. New thermostat in. New serpentine belt tensioner installed. Clutch pedal hung.

Picking up the EGR bypass coolant hose tomorrow. Took the cooler back off the motor. Have some new silicon vacuum line to replace the fraying old lines with, and some Viton injector return lines to install.

Otherwise need to do a little cleaning, then ready to reinstall everything.

Picked up a New South 0-35 PSI boost gauge.

Just found out that the New South EGT gauge I bought is apparently incompatible with the Aircraft Spruce EGT probe I have installed. Not sure what I'm going to do there. Need to find out more info on what type of thermocouple the New South takes, and if the probe is a decently slim one. If not, I will keep the known Aircraft Spruce probe and get a different gauge.

[wolfsburged]

Put it all back together yesterday. Got it started today and drove it around the block!

Need to advance timing a bit after the manual coding to increase IQ to fix idle stutter.

[wolfsburged]

Saturday progress was to install the engine and trans, hook everything up, fill with fluids, put bumper back on.

Only pic mid-progress:
http://knightcreations.com/TDI/IMG_1066.JPG

Sunday hooked up the VAG COM and switched coding to manual transmission. Checked new functions - reverse light switch works, and was able to start the car, so starter interlock wiring is good.

First impression on the clutch is that it is extremely light! If I had not read that people thought this combo was almost strangely light I would maybe have been concerned. Regardless, was able to move the car and drive it around the block fine, found all gears.

First drive had a stutter at idle, which I expected based on the swap documentation. Checked timing once warm, and it was right near the red line on the TDI Timing graph in VAG COM, i.e. within spec but retarded. Also checked IQ and at idle it was fluctuating 0.6-1.0, which explained the stutter.

Advanced the timing, now it is sitting advanced, but within spec. Was able to adapt the IQ via software to max out at 3.0. Stutter is now gone. The general knowledge is that this should be 3-5 at idle. Not sure if I should increase this, but any further will have to be accomplished via the "hammer mod". Otherwise seems to drive fine as set.

First two passes around the blocks, had no power assist on the brakes. Realized there was a slit in the hard vacuum line to the booster. Covered with electrical tape and hose clamped, now I have brakes!

http://knightcreations.com/TDI/IMG_2038.JPG

http://knightcreations.com/TDI/IMG_2039.JPG

Washed the car for the first time and vacuumed. Still need to go back with the steam cleaner and hit the seats again, but they did come much cleaner than the first time.

http://knightcreations.com/TDI/IMG_2035.JPG

http://knightcreations.com/TDI/IMG_2036.JPG

http://knightcreations.com/TDI/IMG_2037.JPG

Still need to reinstall interior trim around the shifter and lower dash. Also have to install the gauges and install my MP3 CD player.

[Das Newb]

Sweet!

[87vr6]

Freaking rocking!!

[IN-FLT]

good stuff!

[wolfsburged]

Drove to the inlaws this weekend. 299.5 miles / 5.665 gallons diesel = 52.86 MPG! Pretty happy with the first highway tank of 52.86 MPG beating my best mileage out of the '84 (51.2 on that same drive).

A few minor things still to do:
Need a light bulb behind the HVAC controls, burnt out
Boost and EGT gauges installed. Having issues getting EGT probe to read. New South claims their gauge is a K type thermocouple, however it is not working with my probe.
Need a new spare tire/wheel. There is another stock alloy in the trunk but has a horrible bend and busted tire.
Want to find a leather wrapped wheel, or buy a wheelskin wrap. Foam is falling apart in my hands.
Need to install new headliner to stop the flapping in the breeze!
Got the Sony stereo installed out of the Honda, however now the front passenger speaker has blown
Have a new cut switchblade key. Need to get it programmed to immobilizer
Need to get EGR function removed from software (hopefully later this week).

[kcfoxie]

Windows down or AC? That's really good. What was your average speed?

I got 48.6 (49.1 had I not added that extra .10 gallons) going to/from GSO (180mi trip) in mine... very happy with the swap, tires and tune. Still haven't had a chance to do a good 300+ mile drive yet. My sunroof was open, as were my windows (possible to see 51-52 if the AC was on and those were closed). I ordered a sunroof wind deflector to see if that aids in the economy (I recall it did on my Jetta but my memory can be faulty).

Curious to see your in-town economy. I've always heard nonsunroof is more efficient than sunroof.

[wolfsburged]

Windows cracked. 70 MPH cruise control on the highway, then 60ish on windy country back roads.

[Baron VonZeppelin]

2 coats of Klasse Glaze on body
1 coat on all glass
Remove mirrors and antenna
Tires @ 35 cold

55 MPG ?
lol

Great results on this project Bill & Jess
Super Congrats and ^5 's

[wolfsburged]

Old headliner:
http://knightcreations.com/TDI/IMG_2074.JPG

New headliner:
http://knightcreations.com/TDI/IMG_2077.JPG

Wheelskin wrap installed, radio swapped over:
http://knightcreations.com/TDI/IMG_2078.JPG

Got a new windshield, thanks Nate & Apex Tuning.

Replaced that HVAC control bulb.

Have a leather knob & shift boot, need to install.

Picked up another Avus alloy and had a new tire mounted as a spare.

I've tried twice now to get a decent cut key for the car, both times have failed to work (sidewinderkey.com). So I need to find someone local who can cut one of these...

Just ordered some new speakers as the stock units have blown out shortly after installing the new headunit.