1998-2003 mk4 VW Jetta Golf New Beetle "how to" index

Discussion in 'VW Mk4 Jetta, Golf, New Beetle, Passat TDI forum' started by chittychittybangbang, Aug 26, 2007.

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  1. chittychittybangbang

    chittychittybangbang Administrator

    May 23, 2007
    2006 Jetta TDI
    Volkswagen MK4 turbodiesel "how to" index
    For 1999-2003 jetta and 1998-2003 new beetle and golf

    From 1000 answered questions: the diesel faq. See top of forum main page for more how to FAQ and technical info.

    updated Sept 15, 2013

    Do you have a pumpe duse? North American TDI 1998-2003 4th generation (mk4) and earlier are not pumpe duse. This page is for 1998-2003.

    North American VW TDI model year 2004-2006 are pumpe duse and use the BEW engine (except the Passat andTouareg). Here are some more checks you can do to see if you have a pumpe duse or not 1000q: cosmetic differences jetta and 1000q: injection pump vs PD vs common rail
    Also see 1000q: new car checklist to see a list of immediate service areas, common problems and VW quirks.


    Timing belt part 1: removal and accessories (non pumpe duse MY1999-2003)
    Timing belt part 2: installation and final quality control
    (exclusive content, please join our free community to view)
    Water pump replacement (recommended with every timing belt change)
    Thermostat replacement (check your coolant temp sensor first)
    Radiator removal
    Intake manifold and EGR cooler removal and cleaning of carbon buildup (non pumpe duse MY1999-2003)
    TDI injection pump removal without replacing the timing belt (part 1)
    TDI fuel injection pump replacement without replacing the timing belt
    (part 2)
    TDI EGR valve FAQ (exhaust gas recirculation valve)
    Cylinder head removal (non pumpe duse MY1999-2003)
    Engine oil change (10,000 miles or as needed)
    Rear main oil seal replacement
    Front crankshaft seal replacement
    Oil pan replacement
    Engine coolant/antifreeze flush (100,000+ miles or as needed)
    Radiator replacement
    Change air filter/cabin air filter
    Fuel filter change (drain every 10,000 miles, replace at 20,000)
    More about pumpe duse vs common rail vs direct injection
    boost or vacuum leak check (can cause a hissing noise or more than normal black exhaust)
    Fuel temp sensor and Injection Pump top cover seal replacement
    Injection pump head or middle gasket reseal
    Starter troubleshooting and replacement
    Alternator, AC compressor, and Power Steering Pump removal
    Alternator troubleshooting, pulley replacement, and voltage regulator repair
    Battery part number reference
    Immobilizer general information ,troubleshooting, procedures
    Keyless entry FAQ and programming new remote/change battery

    MAF FAQ - technical info (mass air flow sensor FAQ and part numbers)
    MAF (mass air flow sensor) troubleshooting and replacement procedures

    Diagnosing and fixing limp mode (sudden loss of power)
    Diagnosing and fixing low and no power (constant low power and can't rev high)
    Adjust fuel injection quantity or hammer mod
    VNT removal or adjustment (not regular maintenance or tuning item)
    Turbo VNT vane cleaning (to free stuck vanes)
    Fuel injector nozzle selection and info FAQ
    Fuel injector and nozzle removal and upgrade procedure

    Tightening the AC compressor nut (this nut often comes loose and causes damage)
    How to replace the AC coil
    Fuel tank venting FAQ and vent removal procedure (lets you add a few more gallons of fuel)
    Fuel door spring open modification (lets the door open much farther when you press the button)
    TDI performance turbo upgrade chart
    Turbo removal writeup #1
    ALH engine TDI turbo removal
    (mirrored link from TDIinnovations of TX)
    Engine cover fast removal pop off modification
    Metal skid plate installation (this protects the exposed oil pan, also includes a comparison of skidplate features and designs)
    Engine runaway FAQ (rare problem where the engine races on its own due to mechanical malfunction)
    Stripped glow plug thread repair
    How to repair broken plastic vacuum nipple
    How to replace the glow plug on TDI


    ATF (automatic transmission fluid) fluid change
    Clutch/brake fluid change
    Manual transmission gear oil change
    TDI clutch and flywheel FAQ
    Manual transmission removal
    Manual transmission removal
    (external link)
    Shifter cable adjustment
    Dieselgeek short shifter installation and review (mk5 shown but mk4 is similar)

    Wheel / tire / gearing calculator

    Wheel tire calculator - also shows wheel/tire clearance, offset, and final drive calculator


    Front and rear brake pad and rotor job
    Rear wheel bearing replacement
    Brake fluid and clutch fluid service
    Parking brake cable service and adjustment
    Strut, spring, and mount replacement first writeup
    Strut, spring, and mount replacement second writeup
    Sway bar bushing and endlink installation
    LCA, ball joint, and bushing replacement
    Dogbone/pendulum mount replacement
    Brake tips and busting big brake myths
    TDI specific big brake upgrade FAQ and spec table/links
    Installing larger brake carriers (must have 1.8T/VR6 or other spindle to use)
    Audi TT/VW golf R32 spindle and /or lower control arm conversion (also lets you use larger brakes)
    DIY pressure brake/clutch bleeder
    Brake booster removal and replacement
    How to remove the steering wheel
    Steering rack removal (external youtube video - CAUTION, do not support your car using cinder blocks as seen in the video, it's a 3rd party video!)

    Car Detailing

    Car detailing index: wash and wax the proper way, polishing paint, using rubbing compound, clay bar treatment
    Washing/waxing your car - yes, there is a right way
    Polishing your paint/swirl mark removal - enhance paint shine and remove paint spiderwebbing
    Clay bar treatment - make the paint feel like glass
    Sticker removal - safely remove that sticker from the paint
    Headlight polishing - restore the headlight plastic to clear
    Wax stain removal - remove white stains on the trim
    Paint chip repair
    Small scratch removal


    VCDS (ross tech vagcom) mods, tricks, and settings - These can disable auto-unlock of the doors above 10 mph, unlock all doors with one press of the remote, or adjust the horn/light blinking when locking/unlocking the car.
    How to use a torque wrench, buyer's guide, and FAQ
    Jack points on my VW Jetta TDI
    How to swap in power and/or heated seats
    To add heated seats, you need a retrofit harness, heated seats, and the heated seat buttons.
    Adding soundproofing to your car and introduction to soundproofing theory
    Broken intercooler mounting stud repair
    VW ipod, aux in, and mp3 cable adapter compatibility
    Tips and tricks for the mechanic
    5th gear modification to lower the rpm
    -5th gear install by Audi5jim

    Aspheric (blind spot), convex, and flat - mirror replacement and repair FAQ
    Rust on the front fenders above the wheels? See this TSB
    How to read the VW part numbering system (and make sense of them)
    Coolant migration symptoms and solutions
    Instrument cluster removal and high beam indicator dimming
    and How to fix a fast speedometer

    How to fix a clicking turn signal or replace the hazard switch relay (turn signals not working)
    How to remove the ignition switch or lock cylinder
    Ecode headlights - what are they and how do you use them
    Headlight switch repair and cleaning
    Dashboard camera (dashcam) hardwire installation
    Mudflap installation
    Change headlight bulbs
    Disable drl (daytime running lights)
    Rear bumper and taillight removal
    Headlight / front fascia (front bumper) removal
    Clearing the sunroof drains to prevent water in the interior (or repairing the broken drain line)
    Door card (the interior panel) removal, both front and rear
    New Beetle broken door handle repair
    Door lock module removal
    Window regulator - making creaking or popping sounds (the window glass can fall into the door and leave the window open)
    Glove box repair
    Glove box lock cylinder replacement
    Center console removal
    Vinyl shifter boot replacement with leather
    How to add a fuse or new circuit to the fusebox
    Rear shelf removal
    Fender rolling to fit larger wheels
    Repainting the triangular trim on the rear window that always rusts
    How to remove the side marker light bulb (or remove the light)
    where is it: the location of random stuff that is useful to know.
    MK3 vs MK4 differences - 3rd vs. 4th generation differences
    MK4 vs MK5 differences - 4th vs. 5th gen differences
    How to compression test the engine
    Making wood blocks to raise the car
    OEM wheel gallery and specs
    light bulb replacement reference table
    Wheel alignment specifications table
    Renault 1.6L injection pump rebuild part 1
    Renault 1.6L injection pump rebuild part 2
    Touch up paint code reference table

    More How tos and general FAQ at 1000 answered questions: index
    ant1981 and cblake like this.
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