2004-2006 mk4 FAQ list and "how to" index for pumpe duse TDI

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Volkswagen MK4 turbodiesel "how to" index
For 2004-2005 Jetta TDI and 2004-2006 New beetle and Golf
updated July 5, 2011

Volkswagen MK4 VW TDI turbodiesel "how to" index and DIY maintenance
For 2004-2005 Jetta and 2004-2006 New Beetle and Golf pumpe duse TDI

This page is for mk4 Jetta, Golf, and New Beetle TDI 2004-2006. In 2005.5 the Jetta became a mk5 so see 1000q: mk5 Jetta DIY index if you're looking for the newer body style. In North America, the mk4 pumpe duse use the "BEW" TDI engine. 2003 and earlier 4th generation cars are not pumpe duse and use the "ALH" TDI engine. Review the main index page if that's what you have. Here are some more checks to see if you have a pumpe duse or not 1000q: cosmetic differences on Jetta and 1000q: injection pump vs. PD vs. common rail. If you have a 2004-2005 Passat, see 1000q: B5 Passat "how to" index.
Did you just buy this car or are you looking to buy one? If so, see 1000q: mk4 TDI new car checklist to see a list of common service /problem areas, catch-up maintenance, and VW quirks.

Engine

Post glow plug recall hard or no starting in cold temperatures
BEW engine timing belt part 1 removal (pumpe duse engine) Inspect at 80,000 and replace no later than 100,000 miles
BEW engine timing belt part 2 installation (pumpe duse engine) (exclusive content, please join our community for free to view)
TDI EGR valve FAQ (exhaust gas recirculation valve)
How to inspect the PD TDI engine camshaft lobes for wear on the pumpe duse engine
How to fix a hard engine start or rough idle caused by camshaft timing
Water pump replacement (recommended with every timing belt change)
Thermostat replacement (check your coolant temp sensor first)
Radiator removal
Engine oil change for TDI engine (10,000 miles or as needed)
Engine oil pan replacement
Engine coolant and antifreeze flush (100,000 miles or as needed)
How to change the air filter or interior cabin air filter
Fuel filter change (20,000 miles change interval - important) (anti theft system)
Comparison between older systems, pumpe duse, and common rail direct diesel fuel injection
Starter system troubleshooting and replacement
Alternator, AC compressor, and Power Steering Pump removal

How to replace the AC coil
Tightening the AC compressor nut (this nut can come loose and cause damage)
MAF technical info (mass air flow sensor FAQ and part numbers)
MAF (mass air flow sensor) troubleshooting and replacement procedures
Immobilizer general information ,troubleshooting, procedures (anti theft system)
Keyless entry FAQ and how to program new VW keys and remote fobs
Engine runaway FAQ (rare problem where the engine races on its own due to mechanical malfunction)
Diagnosing and fixing limp mode (sudden loss of power)
Diagnosing and fixing low power(constant low power and can't rev high)
How to do a boost or vacuum leak check on your turbo VW (can cause a hissing noise or more than normal black exhaust)
Variable vane turbo (VNT) actuator removal or adjustment (not regular maintenance or tuning item)
VNT turbo vane cleaning (to free stuck vanes)
How to remove the turbo on Jetta, Golf, or New Beetle (on earlier engine but it includes some BEW engine specific notes)
ALH engine TDI turbo removal (pumpe duse engine similar, mirrored link from TDIinnovations of TX)
Turbo performance upgrade guide for TDI (comparison chart)
Fuel tank vent FAQ and removing the vent internals (this lets you add a few more gallons of fuel per tank)
Fuel door spring open modification (this lets the door open much farther when you press the button)
Metal skid plate installation (this protects the exposed oil pan, also includes a comparison of skidplates)
Stripped glow plug thread repair
How to replace the glow plug on TDI

Drivetrain

ATF (automatic transmission fluid) fluid change
Clutch/brake fluid change
Manual transmission gear oil change
TDI clutch and flywheel FAQ
DSG transmission FAQ
Manual transmission removal (for earlier ALH engine but BEW should be similar)
Manual transmission removal (external link)
How to adjust the VW shifter cables
DSG fluid change (only the New Beetle has this, shown on mk5)
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


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
Steering wheel removal on Jetta and Golf (New Beetle similar)

Steering rack replacement (external youtube video - CAUTION, do not support your car using cinder blocks as shown in the 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

General/miscellaneous

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
How to fix a fast speedometer
Tips and tricks for the mechanic
What the VW part numbers mean and how to view them in ETKA numbering system
How to compression test the engine
Making wood blocks to raise the car
OEM wheel gallery and specs


Exterior/interior

Jack points on my VW Jetta TDI
Adding soundproofing to your car and introduction to soundproofing theory
Rust on the front fenders above the wheels? See this TSB
5th gear modification to lower the rpm
-5th gear install by Audi5jim
Aspheric (blind spot), convex, and flat - mirror replacement and repair FAQ
Instrument cluster removal and high beam indicator dimmer
Ecode headlights - what are they and how do you use them
Rear bumper and taillight removal
Clearing the sunroof drains to prevent water in the interior (or repairing the broken drain line)
Center console removal
How to add an OEM iPod cable to your car and compatibility
Vinyl shifter boot replacement with leather
DIY repair of a clicking turn signal relay and replacement of the hazard switch (or turn signals not working)
How to replace the ignition key cylinder or switch
How to remove and change the headlight bulbs
Disable drl (daytime running lights)
Window regulator - making creaking or popping sounds (the window glass can fall into the door and leave the window open)
Door card (the interior panel) removal
Door lock module removal
How to remove the side marker light
Mudflap installation
How to remove the front bumper or remove the headlight hosuings
Rear shelf removal
Fender rolling
Repainting the triangular trim on the rear window that likes to rust
Glove box repair
Glove box lock cylinder replacement
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
light bulb replacement reference table
Wheel alignment specifications table
Touch up paint code reference table
To add heated seats, you need this harness, heated seats, and the heated seat buttons.
Power seat / heated seat retrofit
How to add a fuse or new circuit to the fusebox


More How tos and general TDI FAQ at 1000 answered questions: index