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

This index is for mk4 2004-2005 Jetta and 2004-2006 Golf and New Beetle TDI.  If you have a 2004-2005 Passat TDI, see 1000q: B5 Passat "how to" index.

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

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.


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 remove PD TDI fuel injectors (please join our forums to view)
How to remove PD TDI fuel inj #2

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

Front crankshaft seal replacement

Engine coolant and antifreeze flush (100,000 miles or as needed)

Radiator replacement

How to change the air filter or interior cabin air filter

Intake manifold removal and replacement

OEM fuel filter replacement and installation (20,000 miles change interval - important)
Fuel filter modification with 2 micron filter and replacement housing

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

Alternator troubleshooting, pulley replacement, and voltage regulator repair

Battery part number reference

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)
modified VNT actuator installation for smart sensor actuators (BEW engine shown)
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 repair broken plastic vacuum nipple

How to replace the glow plug on TDI



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



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

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, 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

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



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

Broken intercooler mounting stud repair

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

Dashboard camera (dashcam) hardwire installation

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

New Beetle broken door handle repair

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 a retrofit 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 DIY and general TDI FAQ at 1000 answered questions: index

If you can't find what you're looking for, use the search box below or ask in the VW TDI discussion forums here: bulletin board