Volkswagen MK4 VW TDI DIY "how to" index
For 1999-2003 Jetta, Golf, and 1998-2003 New beetle
Do you have a pumpe duse? North American TDI 1998-2003 4th generation (mk4) and earlier are not pumpe duse. North American VW TDI model year 2004-2006 are pumpe duse and use the BEW engine (except the Passat and Touareg). 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.
Engine
Timing belt part 1: removal and accessories
(non pumpe duse MY1999-2003)
Timing belt part 2: installation and final
quality control (non pumpe duse MY1999-2003)
Water pump replacement (recommended with every timing belt change)
Thermostat replacement (check your coolant temp sensor first)
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
Engine coolant/antifreeze flush (100,000+ miles or as needed)
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
Starter troubleshooting and replacement
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)
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)
Drivetrain
ATF (automatic transmission fluid) fluid change
Manual transmission gear oil change
Manual transmission removal
Manual
transmission removal (external link)
Wheel / tire / gearing calculator
Wheel tire calculator - also shows
wheel/tire clearance, offset, and final drive calculator
Brakes/Suspension
Front and rear brake pad and rotor job
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
How to remove the steering wheel
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
Miscellaneous/body/interior
How to use a torque wrench, buyer's guide, and FAQ
How to swap in power and/or heated seats
To add heated seats, you need this harness, heated seats, and the heated seat buttons.
Adding soundproofing to your car and introduction to soundproofing theory
Tips and tricks for the mechanic
5th gear modification to
lower the rpm
-5th gear install by Audi5jim - Audi5jim's
installation pics
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
Ecode headlights - what are they and how do you use them
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
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
Vinyl shifter boot replacement with leather
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
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 to" and general FAQ at 1000 answered questions: index
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