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.


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

OEM Fuel filter replacement and removal (drain every 10,000 miles, replace at 20,000)
Fuel filter modification with 2 micron filter and replacement housing

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 to" and general FAQ at 1000 answered questions: index

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