2003 MK4 Jetta TDI - Daily Driver

[kevin286]

Quality work!

Whats the in the Red square?

Just highlighting an area where I've scrapped off some of the build-up VS area that still gunky. Maybe 4 thou of buildup in some areas.

[kevin286]

Vanes cleaned


Housing cleaned


Torquing it. 4mm bolts don't take much. 20 inch lbs


Looking minty fresh


Clean this side too. Why not.


Clean the outer ring that sits down inside the hot side and put anti seize on.


Anti seize bolts. Pretty much anti seize everything


Adjust the new actuator as per VW TSB to 0.002" free at 17 in hg, rubbing at 17.5 in hg and stung/stuck at 18" hg


Ready to go in


I love using parts I ordered close to a year ago. Maybe this box can get the heck off the top of my tool box now.


New turbo oil supply line. Cause internet said to. Old one is just fine but whatever.


Torquey them new copper nuts on. 18 ft lbs.


Waste time and post this sh** to the internet. In a few minutes it'll be 5 and booze can commence which will productivity++

[SweaterVest]

Sweet man looks like some good work! Few things I love more than cleaning oils dirty parts

[MT-Getto]

Damn fine work

[kevin286]

So after or so yesterday I didn't get much more done.

On the intake manifold there's this broken off bolt that's been taunting me every time I look under the hood. Not sure what it's for, maybe for the engine cover that I don't have... Anyways, dremel that flat, drill and extract. Suck it stupid broken bolt




This morning back at it. Rev my motor with some Redbird coffee.


And intake in, and all the top side work is done.


That is all

[MT-Getto]

That coffee makes me wanna poo

[kevin286]

So... I fukd up and forgot a piece.

When I was taking the exhaust manifold off a small tin bracket fell off. I didn't really know where it came from, just that it fell off when I pulled the manifold off the studs. Well I re-discovered this tin piece laying there under the car after all the manifolds and such were installed.

TL;DR Since I didn't know for sure where it went I first needed to figure that out. Has two bolt holes. Bolt holes fit distance between exhaust manifold studs. Ok. Piece of of such shape that it wouldn't fit on the upper row of bolt holes. Ok. Would fit on driver side two... but wouldn't make any sense to go there. Ok. Would maybe fit on passenger side two bolts. Lots of crap in way, cannot confirm. Look through bentley manual to see if I could find diagram. No. Ok. Look through VW OEM parts catalog to see if can find diagram. No. Ok. Go to eBay. You can always find good pictures on eBay. Search ALH engine and find long block. Zooming shows bracket on passenger side two bolts. Fack fack fack. This means piping has to come off. Oil supply line off. Other heat shield off. Two manifold nuts off. Much cursing.

This POS


Highlighted bracket. Looks like a penis because it is. grrrrr.

[kevin286]

So while down there I noticed my intercooler scoop was cracked and so was my radiator support.
Newman! Well the intercooler scoop is plastic so that was easy to fix with a little solder iron welding.
The radiator support is fiberglass. Not wanting to spend all the time and effort to get a new one (70 bucks) and rip out everything to install, I just patched re-inforced the cracked area with some fiberglass mat. Meh, not the best in the world but it stiffened it up really nice.

[kevin286]

I thought I could do it. Just repair the radiator support. But I couldn't. It's fine. Fixed. Whatever, but... I'll know it's not perfect and it'll eat away at me. Ordered a new one. So... Sigh. Time to put the tools up and start on the headliner maybe.

[kevin286]

Ok. Bolted on the exhaust down pipe and put on the two lower in & out pipes on the turbo. That's all buttoned up.
With that done I cleaned up the mess and put away tools.
Then pimped it out with new wiper blades. Tough times.

Finally, the boot lid has always been stiff to open and close. I'd attempted to grease it but without much affect.
Took the hinges off and worked them back and forth a gazillion times with penetrating oil. Once freed up, lubed them with white lithium grease. Then reinstalled with new struts. Bam! Pop it and it opens a little, tug it up a little, and then it opens the rest all by itself. Mission fukn accomplished.
Cleaned up garage


Pimping new wiper blades. All slick style


Crusty


After working it a bit, the rusty color junk works it's way out



Foam it up good with the white lithium grease and work it back and forth a million times to get it into the pivots


Clean up when done. Tada


I'm pretty happy how the trunk opens now in 120 FPS slow mo. It's dark, it's lame, but these little things bug me, esp. when I've got a huge costco box in my arms and I'm trying to get the darn trunk open.