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    Thread: My 04 Jetta TDI PG

    1. Junior Member don.ville's Avatar
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      07-18-2013 09:44 AM #1
      While looking for a MK1 diesel Rabbit, I came across this MK4 on Craigslist.

      A 2004 Jetta GLS TDI
      Platinum Gray
      Gray leather
      1.9 Diesel









      Bought it!
      Last edited by don.ville; 07-18-2013 at 02:12 PM.
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

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    3. Member TheTynosaur's Avatar
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      07-18-2013 09:55 AM #2
      Cool.

      Lower it.

      Sent from my HTC 3D using Tapatalk 2
      Quote Originally Posted by screwloose45 View Post
      Welcome to vwvortex, where you spend years and all of your money trying to be the epitome of what everyone thinks is cool...only to be **** on, all over, as you miss the mark by inches

    4. Member dougsvdub's Avatar
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      1989 Cabriolet, 2003 Jetta, 2008 R32
      07-18-2013 10:02 AM #3
      MKI Cabriolet
      MKIV Jetta
      MKV .:R32

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    6. Junior Member don.ville's Avatar
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      07-18-2013 11:12 AM #4
      First, get it running right....

      It had NO power, and smoked like a chimney.

      At home....




      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    7. Junior Member don.ville's Avatar
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      07-18-2013 11:15 AM #5
      Check camshaft.....



      Lobes look worn


      Follower has a hole in it.


      EGR Valve




      Mark and Pray...


      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    8. Junior Member don.ville's Avatar
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      07-18-2013 11:17 AM #6


      Bad camshaft....


      Ordered one from Metalman...
      New camshaft, and 8 followers of new design.


      Cleaned EGR, then soaked metal part in cleaner...
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    9. Junior Member don.ville's Avatar
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      07-18-2013 11:21 AM #7
      Window sticker...











      Only Service record I got.

      Last edited by don.ville; 07-18-2013 at 02:17 PM.
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    10. Junior Member don.ville's Avatar
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      07-18-2013 11:22 AM #8
      Antenna amplifier bypass mod.....

      (I soldered on the grey wire to bypass the corroded electronics)




      Reception is better, but still not that great.
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    11. Junior Member don.ville's Avatar
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      07-18-2013 11:24 AM #9
      While working on the antenna, I ended up taking out the headliner.

      I tried the trick I did on my 99 BMW 740iL where I glued the factory material back unto the board after scraping the glue off.







      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    12. Junior Member don.ville's Avatar
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      07-18-2013 11:26 AM #10
      Getting the sunroof panel out


      Washing off the glue...




      All clean
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    13. Junior Member don.ville's Avatar
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      07-18-2013 11:27 AM #11
      Broken plastic



      Reglued back on...





      Came out worse than I expected, especially around the holes and edges where the material did not stretch back correctly....

      I'll have to work on that later. It goes back in like that for now.
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    14. Member boradie sucht's Avatar
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      07-18-2013 11:27 AM #12
      solid work
      jettaaddiction #ripvwvortex

    15. Member Andrewrg's Avatar
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      07-18-2013 11:57 AM #13
      Instagram: @_andrewrg_

    16. Member Soundwave_vr6's Avatar
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      07-18-2013 12:00 PM #14


      Quote Originally Posted by don.ville View Post
      Antenna amplifier bypass mod.....

      (I soldered on the grey wire to bypass the corroded electronics)




      Reception is better, but still not that great.


    17. Member Chris Anderson's Avatar
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      07-18-2013 12:25 PM #15
      Nice
      Quote Originally Posted by automan89 View Post
      Chris is a bitch. and his car isnt even low
      Instagram: @chriss_anderson

    18. Member dieselpower04's Avatar
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      07-18-2013 12:27 PM #16
      What cam did you use? Should have gone with Frank06
      SOLD
      Diesel-Dub Club #36 TDI Build Thread Addicted to ft-lbs

      My Golf TDI

    19. Junior Member don.ville's Avatar
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      07-18-2013 01:03 PM #17
      Quote Originally Posted by dieselpower04 View Post
      What cam did you use? Should have gone with Frank06
      I used Metalman Parts Cam Kit

      http://www.metalmanparts.com/product...&categoryId=-1
      Last edited by don.ville; 07-18-2013 at 01:07 PM.
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    20. Junior Member don.ville's Avatar
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      07-18-2013 01:12 PM #18
      Driver's door would not lock.
      Micro switch to detect if it was open was not working.

      Took lock module apart looking for bad solder connections, turned out to be dirty microswitch that I could have fixed without taking door apart.







      I find that there is too much bad information on forums, and it's hard to weed through it all to find the gems.
      Driver door on MK4 not unlocking?, alarm re-arms with the driver door open? First spray the heck out of the latch with electronic parts cleaner....That would have solved my problem...
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    21. Junior Member don.ville's Avatar
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      07-18-2013 01:15 PM #19
      Posted an ad searching for GLI parts...

      got a full set of color matched Platinum Gray (PG) skirts all around within 1.5 hour drive of where I am.

      Took bumper off and saw this...



      The duct that sits over the intercooler rubbed a few holes in the cooler.
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    22. Junior Member don.ville's Avatar
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      07-18-2013 01:17 PM #20
      Started to install the front GLI lip, valance, skirt, whatever it is called...

      My bumper was a little torn up.
      I used factory fasteners to attach the lip to the bumper from above....





      Like!!!!

      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    23. Junior Member don.ville's Avatar
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      07-18-2013 01:19 PM #21
      My engine cover plastic had a crack, so I used a drywall screw in just the right place to hold the rubber grommet in ....
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    24. Member tonyb2580's Avatar
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      07-18-2013 01:20 PM #22
      Thats whats up.. good info on the door lock.. i need to do this

    25. Junior Member don.ville's Avatar
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      07-18-2013 01:23 PM #23
      Planned to buy Raceland Ultimo adjustable Coilovers, but not sure if I was ready just yet to buy.
      I wanted to see how it would look.....

      I decided to cut up my factory springs to get the look I wanted, then decide if I should get adjustable coilovers or lowering springs.

      Trick to getting front coilover out without taking other parts off.
      Factory aluminum jack is great....

      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    26. Junior Member don.ville's Avatar
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      07-18-2013 01:25 PM #24
      One and a half turns removed from the front....



      Still fits back in spring perch, and spring still is under compression when the clamps are removed
      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

    27. Junior Member don.ville's Avatar
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      07-18-2013 01:28 PM #25
      Rears were so easy....30 minutes....

      Removed 1.5 turns also, but because the base of the spring is smaller than the center, I had to secure the spring.

      I used a sheet of rubber, wrapped the end of the spring to stop noise, rattling, etc...
      Then I used large zip ties to secure the rubber wrap to the spring and to secure the spring to the spring base plate



      My MKiV TDI--> https://forums.vwvortex.com/showthrea...4-Jetta-TDI-PG
      ABC DV / Titanium muffler bearings / Xenon headlight fluid / TDI BEW PD VW MKIV / SM Intercooler / Round Steering Wheel /
      Bubba Mod / OEM Delete

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