Maintenance

Links and posts that address TDI maintenance.

Glass Headlight Lens Replacement

Finally got around to a project I have been planning for quite awhile.  A few months ago I picked up replacement glass headlight lenses from Volx Tuning, they have limited parts so just keep your eyes on their facebook site.

 

My headlights have turned into a yellowish faded smear, tried various ways of cleaning but none was ever successful.

Pulled off my bumper (far easier then I expected, took 15 mins) using this howto and worked on pulling off headlight glass.  I didn't feel like pulling the headlights out of the car so I decided to try my luck at just removing the glass without taking it out of the vehicle.

 

 

 

 

 

 

 

 

I followed the guide on how to separate the lenses from the headlight assembly from this great youtube link by RodriguezInnovations, only difference is I did this while my headlights were still mounted.

 

 

 

 

 

 

 

 

 

 

 

Once I had the headlight plastic off it was painful how nasty my lenses had become.

 

2002 Jetta TDI - Won't Start

Greetings to all:

I'm a newbie to your forum; this is my first post.  I'm also a "Cincinnati Son" of many years ago.  I lived in Springdale and went to Princeton H.S. (do they still have a strong football program?)  I have lived in the South for most of my adult life due to my career.

First of all this first post will be rather lengthy so I can explain to you in detail what my problem is; all future replies will be much more concise.

My problem is this; I have a 2002 Jetta TDI automatic that has 225,000 highway miles on it and has been impeccably serviced; synthetic oil every 8K miles, regular timing belt rplcmnt, filters, etc. etc.  It still has plenty of power, doesn't smoke, pretty much the perfect "second" vehicle.

Five months ago it simply would not start.  Just to be clear, previous to this there was no degradation in performance or for that matter any other problem; one day it just wouldn't start.  All of the dash lights come on, and all of the other electrical systems operate fine.  I will add that when I first tried to start it that morning, I noticed that the glow plug indicator light on my dash came on, then immediately went out.  It cranks fine, it just won't start.  Now, the glow plug indicator won't even come on at all; and of course, it still won't start.

Okay, here's what I have done to date.  By the way there are several things that I will list here and many of you will say "why did he replace that"?  It's just that there were several items that needed replaced so I took this opportunity to do it.  Okay, the car has a new (correct and expensive) battery, new fuel filter and new glow plugs (Beru).  Performing all of the above did not help.
 

Injection Pump Adjustment Hard No Start

I have a 1998 1.9 TDI Jetta.  I had a new timing belt and a remanufactured Injection pump put on.  The car runs great.  Plenty of power. Good fuel economy. It didn't start quickly like it should from the time I got it back from the mechanic.  He checked timing and said it is perfect.  I have VagCom.  Timing reads about 58.  It has gotten harder to start. Now it won't start.  I have been through the entire fuel system. No restrictions, no leaks.  The mechanic wants to send the IP back to be checked out.  I am thinking that the injection pump timing needs adjusted.  How should I do this the right way? Do you know a Guru in the Cincinnati area? Any suggestions.  I really want to do it myself.

Front license plate mount

Recently I had a run in with the law, not for speeding but for not having a front license plate.  I bought my car Jan 2003, its a 2002 Golf TDI.  8 years later I guess I pushed my luck on the Ohio Law 4503.21

This lead me to a dilemma, I have a pristine bumper (semi pristine I suppose, after 8 years and 190k).  I certainly do not want to drill holes in it.

After talking to a few members on the CinciTDI mailing list recommended searching the TDIClub forums for ideas, and I found a few related to mounting a bracket in the lower grill.

I poked around Walmart and came across this bracket which would squeeze into the relatively small lower grill on my Golf

After a test (and short term fix) I think this will be a good solution.  I am using wire ties for now, but will work on a solution using some nuts and bolts when the weather is a bit more forgiving.

 

Changing my 5th gear to a higher ratio for increased fuel

I recently changed the nozzles on my 02 and lost 4mpg.  Instead of changing the nozzle back because, I don't have them, I was wondering if I could just change my 5th gear?  I was wondering if anyone has any info on this either way????  thanks buck

 

Coolant Temp Sensor

My temp gauge dropped all the way down a few times during my drive home, then eventually didn't move.  My heat was working great so I am assuming its the sensor. 

It appears this is a fairly common occurance, for me it started at 167k, not bad.

I found a great writeup at http://www.inmud.co.uk/page28.htm

For reference sake I am replicating it here with my own notes.

Tools needed to change this sensor:
A small flat blade screwdriver and 10 30 minutes of your life

Parts needed:
Temperature sensor :    VW  059919501A
Rubber o-ring:                VW  N90316802
Spring clip:                     VW  032121142
Up to 1 litre of G12 coolant plus distilled water.

You can get the parts very cheap if you do a search online rather than going to the VW main dealer.  Fairfield VW total cost was about $35 at the time of this writeup, although I already had extra coolant.
Let the engine cool for as long as you dare, you can still burn yourself after a few hours but it's up to you.
Release the pressure at the expansion bottle.  I squashed a radiator hose and resealed the cap to put the system under a small amount of vacuum

Locate the temperature sensor below.

'03 jetta lacks mid-range power

need a mechanic who has dealt this before

2009 Jetta Fog Light Kit

Anyone have experience either adding the Fog Light Retrofit kit onto a 2009 Jetta TDI Sportwagen, or can recommend a place with experience?