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Discussion Starter #1
Just bought this 02 Jetta. Lady put intake valve through number 3 piston.
Purchased used motor with only 120000 miles. Want to freshen it up before install. New clutch. Timing kit. Any other suggestions? ASE mastertech, but new to TDIs and diesels in general. This looks like a great site with tons of info, so I joined. Thanks!!
 

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Hi, welcometomyturbodies.

It might be worth having a look at the intake manifold as they tend to get pretty clogged up so you could maybe give it a clean and also worth checking the turbo for soot build up and making sure the vanes aren't sticky. If you look in the faq at the top of the page for your car and have a look at fixing limp mode there's a bit in there that shows the turbo and how it's supposed to work and there's stuff in there about low power etc that should have more on the manifold.:)
 

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Ohh.....single mass flywheel to replace the dual mass flywheel (more reliable and better clutch engagement), larger injection pump from an automatic, larger fuel injection nozzles, chip tuning, heavier clutch kit :) It will be a very nice car :)

Bare minimum: replace all the vacuum lines while you're in there, check turbo rod position (take a look in the FAQ at VNT actuator checks) and movement since there's lots of room. And clean the intake while you're in there.

FYI, there's a writeup contest for new original articles, there's currently no article on pulling and replacing the engine. If you do a step by step pictorial with tips and cautions, it would help many others and qualify for the contest. Current prize is $50 e-gift certificate to and from the sponsor kermatdi.com, full details and guidelines in general forum. This writeup would be very competitive due to difficulty and complexity. Pictures of things like what plugs to pull, where to hook up the engine support, etc. Some pictures would be more clear with the engine out of the car as well. If you do it, please take more pics instead of less pictures.

There are currently writeups on how to pull the transmission, how to remove the intake, and how to remove the dogbone mount (pendulum mount) that should help you as well.
 

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Discussion Starter #4
2002 Jetta Engine Install

Hey guys. Took a while to get this thing going. Couldn't do the picture/writeup on the removal and install cause I took the head off first to see what what wrong with it. Anyways, everything went back in, every piece spotless clean, Gripforce Clutch(very,very stiff), new timing kit, all filters etc. Ran fine when I started it up, then after about a minute running, ran very very rough. Played around a bit. Bought VAG-COM. Diagnosis was injector pump faulty. PERFORMED The HAMMER MOD. Fixed it!!!!! Unbelievable. Car runs and drives awesome. Definitely sold on this whole TDI stuff. Thanks.
 
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